FLEXIBLE FOOTWEAR

Abstract

A footwear product includes a sole assembly and an upper and has an at least partially flexible construction. The sole assembly includes a number of sole sections with one or more connecting members disposed between adjacent sole sections.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/641,766, filed on May 2, 2012, and of U.S. Provisional Patent Application Ser. No. 61/755,880, filed on Jan. 23, 2013, and of U.S. Provisional Patent Application Ser. No. 61/763,868, filed on Feb. 12, 2013, all of which are incorporated by reference herein in their entireties for all purposes.

TECHNICAL FIELD

Embodiments of the present invention relate generally to footwear, and more specifically to segmented flexible footwear.

SUMMARY

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used, in isolation, as an aid in determining the scope of the claimed subject matter. At a high level, embodiments of the invention relate to a footwear product having an at least partially flexible construction.

An outsole according to embodiments of the present invention includes a plurality of independent segments each formed of an injection moldable material, wherein each of the plurality of independent segments includes a top surface and a bottom surface, wherein each of the plurality of independent segments includes at least one hole formed entirely through the segment and positioned between the top and bottom surfaces; and at least one band extending through the at least one hole of each of the plurality of independent segments, wherein the at least one band is elastic and permits stretching apart of each of the plurality of independent segments with respect to each other, and wherein the at least one band applies a compression force to the plurality of independent segments causing the plurality of independent segments to align in an overall shape of a foot absent external forces, and wherein nothing spans adjacent segments of the plurality of independent segments except for the at least one band.

The outsole of paragraph [0004], wherein an edge of the top surface of each of the plurality of independent segments is beveled.

The outsole of any of paragraphs [0004] to [0005], wherein the plurality of independent segments is four or more independent segments.

The outsole of any of paragraphs [0004] to [0006], wherein the plurality of independent segments is five or more independent segments.

The outsole of any of paragraphs [0004] to [0007], wherein the plurality of independent segments is six or more independent segments.

The outsole of any of paragraphs [0004] to [0008], wherein each of the plurality of independent segments includes a portion of a medial perimeter and a portion of a lateral perimeter of the outsole.

The outsole of any of paragraphs [0004] to [0009], further comprising a toe bar attached to a forward-most segment of the six or more independent segments, and a foot strap connected to the toe bar at one end and to an other segment of the six or more independent segments at another end, wherein the other segment of the six or more independent segments is separated from the forward-most segment by at least three segments of the six or more independent segments.

The outsole of any of paragraphs [0004] to [0010], wherein the plurality of independent segments is thirteen or more independent segments.

The outsole of any of paragraphs [0004] to [0011], wherein each of the plurality of independent segments includes a portion of a medial perimeter and a portion of a lateral perimeter of the outsole.

The outsole of any of paragraphs [0004] to [0012], further comprising one or more spacers between each adjacent pair of the plurality of independent segments.

A sole assembly for a footwear product according to embodiments of the present invention includes a first outsole section including a first surface and a second surface; a second outsole section adjacent to the first outsole section, the second outsole section having a first surface and a second surface; a connection member having a top surface and a bottom surface, wherein a first portion of the bottom surface of the connection member is disposed on at least a first portion of the first surface of the first outsole section, a second portion of the bottom surface of the connection member is disposed on at least a first portion of the first surface of the second outsole section, and a third portion of the connection member extends between the first and second outsole sections; and at least one footbed section disposed on at least a portion of the top surface of the connection member.

The sole assembly of paragraph [0014], further comprising a third outsole section.

The sole assembly of any of paragraphs [0014] to [0015], further comprising a fourth outsole section.

The sole assembly of any of paragraphs [0014] to [0016], wherein the first surface of the first outsole section includes a lip extending along at least a portion of a periphery of the first surface of the outsole section.

A method of constructing a sole assembly for a footwear product according to embodiments of the present invention includes: injection molding a plurality of independent outsole sections; injection molding a connecting member; arranging at least a first and second of the plurality of independent outsole sections such that the first outsole section is adjacent to the second outsole section; adhering a first portion of a bottom surface of the connecting member to at least a portion of a first surface of the first outsole section; and adhering a second portion of the bottom surface of the connecting member to at least a portion of a first surface of the second outsole section, such that a third portion of the connecting member extends between the first and second outsole sections; wherein the connecting member holds together the first and second outsole sections while permitting the first and second outsole sections to flex about the connecting member and to flex with respect to each other.

The method of paragraph [0018], wherein each of the plurality of outsole sections is molded from a foam material.

The method of any of paragraphs [0018] to [0019], wherein the foam material comprises ethylene vinyl acetate (EVA).

The method of any of paragraphs [0018] to [0020], wherein the connecting member is created using an elastomeric material.

The method of any of paragraphs [0018] to [0021], wherein the first surface of the first outsole section is a top surface of the first outsole section, and wherein the first surface of the second outsole section is a top surface of the second outsole section.

The method of any of paragraphs [0018] to [0022], further comprising: forming a first hole from a front surface of the first outsole section to a rear surface of the first outsole section; forming a second hole from a front surface of the second outsole section to a rear surface of the second outsole section; inserting an elastically deformable band through the first and second holes, without otherwise connecting the elastically deformable band to the first and second outsole sections.

The method of any of paragraphs [0018] to [0023], further comprising: forming a third hole from the front surface of the first outsole section to the rear surface of the first outsole section; and forming a fourth hole from the front surface of the second outsole section to the rear surface of the second outsole section.

The method of any of paragraphs [0018] to [0024], wherein the elastically deformable band is a first elastically deformable band, the method further comprising inserting a second elastically deformable band through the third and fourth holes, without otherwise connecting the second elastically deformable band to the first and second outsole sections.

The method of any of paragraphs [0018] to [0025], further comprising inserting the elastically deformable band through the third and fourth holes, without otherwise connecting the elastically deformable band to the first and second outsole sections.

While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in detail below with reference to the attached drawing figures, wherein:

FIG. 1A is a perspective view of a sandal in accordance with embodiments of the invention;

FIG. 1B is a side view of a sandal in accordance with embodiments of the invention;

FIG. 2 is a perspective exploded view of a sandal in accordance with embodiments of the invention;

FIG. 3A is a side view of a shoe in accordance with embodiments of the invention;

FIG. 3B is a side view of the shoe of FIG. 3A, showing internal features, in accordance with embodiments of the invention;

FIG. 4A is a perspective view of a sandal in accordance with embodiments of the invention;

FIG. 4B is a side view of a foot wearing a sandal in accordance with embodiments of the invention;

FIG. 5A is a perspective view of a shoe in accordance with embodiments of the invention;

FIG. 5B is a side view of a shoe in accordance with embodiments of the invention;

FIG. 5C is a bottom view of a shoe in accordance with embodiments of the invention; and

FIG. 5D is a side view of a shoe being flexed in accordance with embodiments of the invention.

FIG. 6 illustrates a top view of a sandal according to embodiments of the present invention.

FIG. 7 illustrates a top view of the sandal of FIG. 6 in a twisted configuration, according to embodiments of the present invention.

FIG. 8 illustrates the sandal of FIGS. 6 and 7 being bent over itself, according to embodiments of the present invention.

FIG. 9 illustrates a top view of a shoe outsole, according to embodiments of the present invention.

FIG. 10 illustrates the shoe outsole of FIG. 9 in a twisted configuration, according to embodiments of the present invention.

FIG. 11 illustrates a bottom view of a shoe and insole, according to embodiments of the present invention.

FIG. 12 illustrates a top view of the shoe and insole of FIG. 11, according to embodiments of the present invention.

FIG. 13 illustrates a bottom view of an alternative outsole, according to embodiments of the present invention.

FIG. 14 illustrates a cross sectional view of the alternative outsole of FIG. 13 taken along line A-A of FIG. 13, according to embodiments of the present invention.

DETAILED DESCRIPTION

The subject matter of embodiments of the invention is described with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different steps or features or combinations of steps or features similar to the ones described in this document, in conjunction with other technologies. Moreover, although aspects of methods of constructing products according to embodiments of the invention are described with reference to “blocks,” the term “block” should not be interpreted as implying any particular order among or between various aspects unless the order of individual aspects is explicitly described.

Embodiments of the invention include a footwear product having an at least partially flexible construction. The footwear product can be a shoe, a boot, a sandal, a clog, or any other type of footwear product having at least a partially-flexible construction in accordance with embodiments of the invention. Embodiments of the invention can include different combinations of the features and components described herein, additional features or components that are not described herein, and components made from different materials or combinations of materials than those described herein. All such implementations are considered to be within the ambit of the invention.

FIG. 1A depicts a sandal 1 having a partially-flexible construction in accordance with embodiments of the invention. As illustrated in FIG. 1A, the sandal 1 includes a sole assembly 10 and an upper 12 disposed on top of the sole assembly 10. The sole assembly 10 includes a number of sole sections 14, 16, 18, and 20. According to embodiments, the sole assembly can include two sections, three sections, four sections, five sections, or the like. In embodiments, the upper 12 can be coupled to the sole assembly 10.

FIG. 1B shows a sandal 30 that includes a sole assembly 32 and an upper 34, which is coupled to the sole assembly 32. The sole assembly 32 includes four sole sections: a forefoot section 36, two mid sections 38 and 40, and a heel section 42. In embodiments, a sole assembly 32 can include fewer than four sections or more than four sections. For example, as shown in FIGS. 4A and 4B, a sandal 400, in accordance with embodiments of the invention, may include a sole assembly 410 having five sole sections 414, 416, 418, 420, and 422. An upper 412 is coupled to the first sole section 414 and the fourth sole section 420. As shown in FIG. 4B, various constructions of a footwear product in accordance with embodiments of the invention facilitate an at least partially flexible construction that can flex with the movement of the wearer's foot 430.

In FIG. 1B, each sole section includes an outsole section 44 and a footbed section 46. In embodiments, an outsole section 44 can include a tread feature 47. A connecting member 48 extends between adjacent sole sections 40 and 42. As illustrated, the sole assembly 32 can include a connecting member 48, 50, and 52 that extends between each pair of adjacent sole sections 36 and 38, 38 and 40, and 40 and 42. In embodiments, the connecting members 48, 50, and 52 can be a single piece, extending between each of the adjacent sole sections, while, in other embodiments, the connecting members 48, 50, and 52 can be individual pieces.

As shown in FIG. 1B, a first portion 52 of the upper 34 can be coupled to a first sole section 36 and a second portion 54 of the upper 34 can be coupled to a third sole section 40. In other embodiments, various portions of the upper 34 can be coupled to any number of different sole sections. For example, as shown in FIG. 3A, a portion of the upper can be coupled to each sole section. In embodiments, portions of the upper can be coupled to a footbed portion, an outsole portion, a connecting member, or a combination of these.

FIG. 2 shows an exploded view of a footwear product 200 (a sandal, in the illustrated embodiments) according to embodiments of the invention. As shown in FIG. 2, the footwear product 200 includes a sole assembly 210 and an upper 212. The sole assembly 210 includes outsole sections 214, 216, 218, and 220; footbed sections 222, 224, 226, and 228; and a connecting member 230. The upper 212 can be coupled to any number or combination of outsole sections, footbed sections, the connecting member 230, or a combination thereof. Although four outsole sections and four footbed sections are illustrated in FIG. 2; in embodiments, the footwear product 200 may include fewer than, or more than, four of each of these sections. In some embodiments, each outsole section may correspond to a footbed section, while in other embodiments, there may be a different number of footbed sections compared to outsole sections. For example, in embodiments, a sole assembly may include a number of outsole sections and one footbed section.

According to embodiments of the invention, as illustrated in FIG. 2, a first portion 232 of the bottom surface 233 of the connecting member 230 is disposed on at least a first portion 234 of a first surface 235 of a first outsole section 214; a second portion 236 of the bottom surface 233 of the connecting member 230 is disposed on at least a first portion 238 of a first surface 239 of a second outsole section 216; a third portion 240 of the connecting member 230 extends between the first and second outsole sections 214 and 216. Similar arrangements, as shown, can be constructed with respect to the other outsole sections.

As is further illustrated in FIG. 2, a first footbed section 222 is disposed on a first portion 242 of the top surface 243 of the connecting member 230 such that a bottom surface 245 of the first footbed section 222 interfaces with the first portion 242 of the top surface 243 of the connecting member 230; a second footbed section 224 is disposed on a second portion 244 of the top surface 243 of the connecting member 230 such that a bottom surface 247 interfaces with the second portion 244 of the top surface 243 of the connecting member 230. In embodiments, a wearer's foot (not shown) rests on a top surface 249 of each footbed portion.

In embodiments, as shown in FIG. 2, an outsole portion 218 can include one or more lips 250. For example, outsole section 250 includes a pair of opposed lips 250 that are substantially parallel to one another. Each lip 250 includes an inner surface 252 oriented at an angle with respect to a first surface 253; an outer surface 254 that is opposed to the inner surface 252; a top surface 256, a forward surface 258, and a rear surface 260. In embodiments, any one or more of the surfaces of a lip 250 can be integral with one or more other surfaces of the outsole portion 218. Additionally, in embodiments, a lip 250 may have continuous, rounded surfaces, angled interfaces between surfaces, beveled edges, or the like. As shown in FIG. 2, in some embodiments, a forefoot outsole section 214 and a heel outsole section 220 may include a continuous lip 262 extending around a portion of the periphery of the section, including the front of the section and the rear of the section, respectively. In embodiments, a connecting member and/or a footbed portion can be configured to be disposed between lips 250 of an outsole section. In other embodiments, a footbed portion may not include lips and a connecting member and/or a footbed portion may be configured to be disposed on top of the outsole section.

In embodiments, the outsole-interfacing portions 232, 236, 282, and 285 of the connecting member 230 can be joined with the connecting-member interfacing portions 234, 238, 283, and 286 of the outsole portions 214, 216, 218, and 220, in any number of manners. For example, in embodiments, the interfacing portions can be adhered to each other using an adhesive (e.g., glue, tape), integrated with one another, fastened to one another (e.g., using a hook-and-loop fastening mechanism, stitches), or the like. Additionally, in embodiments, portions of the connecting member 230 can be coupled (e.g., adhered, fastened) to one or more of the lips 250 disposed on the outsole portions.

In embodiments of a method of constructing the footwear product 200, the first footbed section 222 can be disposed on a first portion 242 of the top surface 243 of the connecting member; the second footbed section 224 can be disposed on a second portion 244 of the top surface 243 of the connecting member 230; the third footbed section 226 can be disposed on a third portion 290 of the top surface 243 of the connecting member 230; and the fourth footbed portion 228 can be disposed on a fourth portion 292 of the top surface 243 of the connecting member 230. In embodiments, the footbed portions can be adhered to the connecting member, fastened to the connecting member, or the like. According to embodiments, various portions of the footwear product 200 can be adhered to other portions using techniques such as, for example, welding, fusing, taping, clipping, and the like.

In embodiments of the illustrative method, the upper 212 is coupled to the sole assembly 210 by passing the toepost 280 through the set of apertures 270, 272, and 274 such that the anchor 294 of the toepost 280 engages at least a portion of the bottom surface 278 of the first outsole section 214. Each strap 296 of the upper 212 can be coupled, for example, to the third footbed portion 226, the third outsole portion 218, the connecting member 230, or a combination of the above. In embodiments, an end 298 of each strap 296 can be disposed between a lip 250 of the third outsole section 218 and an outside edge 299 of the third footbed portion 226. Any number of other manners of coupling the upper 212 to the sole assembly 210 can be implemented.

In the embodiment illustrated in FIG. 2, the footwear product 200 can be assembled by performing any number of different steps, in any number of different orders. One illustrative method of assembling the footwear product 200 includes creating a number of outsole sections 214, 216, 218, and 220. The illustrative method also includes creating a number of footbed sections 222, 224, 226, and 228. In embodiments, the outsole sections and/or the footbed sections may be molded from a foam material such as ethylene vinyl acetate (EVA). For instance, in embodiments, to form sections of a sole assembly, liquid EVA may be injected into two pieces of a clamshell-type mold. An example of such a molding process is described in U.S. Pat. No. 6,439,536 to Piccolo, which is incorporated herein by reference. In other embodiments, various sections of the sole assembly may be molded from rubber, while, in other embodiments, different portions of the sole assembly may be constructed using different materials.

A connecting member 230 is also created. In embodiments, the connecting member 230 can be constructed using an elastomeric or nonelastomeric textile material, a thermoplastic elastomer (TPE) material (e.g., thermoplastic polyurethanes (TPUs), styrenic block copolymers), a rubber material, or the like. The illustrative method also includes creating an upper 212. In embodiments, the upper 212 is molded from a foam material such as EVA. In other embodiments, the upper 212 is constructed using a TPE material, nylon, or other textile material.

To assemble the sandal illustrated in FIG. 2, corresponding apertures 270, 272, and 274 are formed through the first outsole portion 214, the first footbed portion 222, and the connecting member 230, respectively. The apertures 270, 272, and 274 are formed such that, when the sandal 200 is assembled, the apertures 270, 272, and 274 line up to form a continuous passage through from the top surface 276 of the first footbed section 222 to the bottom surface 278 of the first outsole section 214 for receiving the toepost 280 of the upper 212. In embodiments in which the footwear product is not a sandal such as, for example, where the footwear product is a shoe, a boot, a clog, or the like, an aperture may not be necessary as the upper may include a larger foot-covering that can be coupled to the sole assembly 210 without using a toepost.

In embodiments of the illustrative method, the outsole sections 214, 216, 218, and 220 are arranged such that the first outsole section 214 is adjacent to the second outsole section 216, the second outsole section 216 is adjacent to the third outsole section 218, and the third outsole section 218 is adjacent to the fourth outsole section 220. The connecting member 230 is positioned such that a first portion 232 of the bottom surface 233 of the connecting member 230 is disposed on at least a first portion 234 of a first surface 235 of a first outsole section 214; a second portion 236 of the bottom surface 233 of the connecting member 230 is disposed on at least a first portion 238 of a first surface 239 of a second outsole section 216; a third portion 240 of the connecting member 230 extends between the first and second outsole sections 214 and 216; a fourth portion 282 of the bottom surface 233 of the connecting member 230 is disposed on at least a first portion 283 of the first surface 253 of the third outsole section 218; a fifth portion 284 of the connecting member 230 extends between the second outsole section 216 and the third outsole section 218; a sixth portion 285 of the bottom surface 233 of the connecting member 230 is disposed on at least a first portion 286 of a first surface 287 of the fourth outsole section 220; and a seventh portion 288 of the connecting member 230 extends between the third outsole section 218 and the fourth outsole section 220.

FIGS. 3A and 3B show a shoe 300 having an at least partially flexible construction in accordance with embodiments of the invention. As illustrated, the shoe 300 includes a sole assembly 310 and an upper 312 that is coupled to the sole assembly 310. In embodiments, the upper 312 can be coupled to the sole assembly 310 using stitching, adhesive, or the like. In embodiments, for example, the sole assembly 310 may be constructed similar to the sole assembly 210 described in relation to FIG. 2. The sole assembly 310 includes sole sections 314, 316, 318, and 320. Each sole section may include an outsole section 322 and a footbed section 324. A connecting member 326 extends between each adjacent sole section. In embodiments, the shoe 300 can include a single footbed section 324 or a number of footbed sections 324. In embodiments, an insole (not shown) can be disposed on or over the footbed sections 324. Additionally, in embodiments, the upper 310 can be constructed using an elastic canvas, leather, or any number of other different types of material and can be configured to cover a portion of a wearer's foot (not shown) or the entire foot.

FIGS. 5A-5D show a shoe 500 having an at least partially flexible construction in accordance with embodiments of the invention. The shoe 500 includes a sole assembly 510 and an upper 512, which is coupled to the sole assembly 510. The upper 512 includes an elastic member 514 that can enhance the stretchability of the upper 512. The elastic member 514 may stretch across the entire upper 512 or a portion of the upper 512. In embodiments, the upper 512 may include a number of elastic members 514. In embodiments, the upper 512 can be connected to the sole assembly 510 using any number of different techniques. In embodiments, for example, the upper 512 is coupled to a number of outsole sections 516, 518, 520, and 522 using a stitch and turn elastic.

In embodiments, the shoe 500 can be configured to be flexible and/or stretchable along any number of different axes, in any number of different directions, and in any number of different amounts. For example, in embodiments, an elastomeric connecting member can be used to connect the sole sections 516, 518, 520, and 522 such that the sole assembly 510 (and thus, in embodiments, the shoe 500) is stretchable longitudinally along a first axis 520. Additionally, the shoe 500 can be flexible along the first axis 520, as shown in FIG. 5D. In embodiments, elastic members 514 can be used to facilitate flexibility and/or stretchability of the shoe 500 along or about a second axis 522. Additionally, in embodiments, the shoe 500 can be stretchable and/or flexible along any number of different axes. According to some embodiments of the present invention, all of the materials of the upper 512 and lining (in addition to elastic member 514) are flexible and/or stretchable in order to improve stretchability of the overall shoe.

FIGS. 6-8 illustrate footwear 60 which includes multiple outsole segments 61, 62, 63, 64, 65, and 66. The segments 61-66, which may also be referred to as sections, are completely independent of each other (e.g. are separate, distinct pieces), except for one or more bands 67, 68 which run through one or more holes 670 formed longitudinally through each segment, according to embodiments of the present invention. The bands 67, 68 provide enough compression to keep the segments 61-66 together in a manner resembling a normal outsole during use by a wearer, while also permitting the segments to bend and flex with respect to each other during use. For example, FIG. 7 illustrates the footwear 60 being twisted about its longitudinal axis, whereas FIG. 8 illustrates the footwear 60 being bent along a transverse axis, according to embodiments of the present invention.

The footwear 60 may also include one or more separators 690 between two or more adjacent segments 61, 62. Separators 690 may be placed over or around bands 67, 68 in order to keep them in place, and may further enhance the range of motion in flexibility of adjacent segments by providing a small degree of separation as well as a natural pivot location, according to embodiments of the present invention. As shown in FIGS. 6-8, various vamp or footwear upper features may be attached to one or more of the segments 61-66, in order to permit the outsole formed by the segments 61-66 to serve as the outsole of a piece of footwear. For example, a toe bar 610 may be attached to segment 61, and one or more straps attached to segment 65, which permits the footwear 60 to be worn as a flip flop type sandal, according to embodiments of the present invention.

FIGS. 9 and 10 illustrate an alternative outsole 90, according to embodiments of the present invention. Outsole 90 includes two or more segments 94, which are completely independent of each other except for one or more cords or bands 91, 92 extending through longitudinal holes formed in the segments 94. While FIGS. 6-10 illustrate two bands extending through each segment, with one band on each side of a longitudinal centerline of the outsoles 60, 90, one of ordinary skill in the art will appreciate that fewer than two or more than two bands or cords may be used to connect the segments. For example, a single band may be used to connect the segments, and may extend at or to either side of a longitudinal centerline of the outsole, according to embodiments of the present invention. A single band may also be inserted through each of the segments in one direction, and then looped back around and extended through each of the segments along the other direction. Such a band assembly may be tied with knots or other connectors at one end to prevent the ends of the bands (e.g. ends 910, 920 of FIG. 9) from slipping back through the holes in end segment, and may be looped at the other end of the outsole to prevent the band from slipping back through the holes in such other end. According to other embodiments of the present invention, the band or cord may be a loop, for example a continuous loop like a rubber band, around which the sole segments have been molded or otherwise attached.

The band 67, 68, or 91, 92, may be an elastic band which permits the outsole segments to flex or move with respect to each other in three different modes: pulling apart (e.g. FIG. 10), twisting longitudinally (e.g. FIG. 7), and bending/curling/rolling (e.g. FIG. 8). When such flexional positions are released, the elasticity of the connecting band 67, 68 or 91, 92 as well as the compression force imparted by its elasticity, may cause the segments to be pulled back together in the configuration of a traditional outsole, as shown in FIG. 6. According to some embodiments of the present invention, the bands 67, 68 extend through holes in each segment 61-66, or 94, but are not otherwise attached to each segment, such that the entire outsole may be pulled apart as shown in FIG. 10. According to other embodiments (not shown), the bands 67, 68 or 91, 92 are connected or attached to segments at locations other than the end segments (e.g. 61 and 66 in FIG. 6); for example, being knotted between every two or every three or four or five segments. FIGS. 9 and 10 illustrate thirteen segments 94, each with a first hole through which band 91 extends and each with a second hole through which band 92 extends, and the only point of connection of the bands 91, 92 to the outsole 90 is at loop 95 and knots 960, 961. Otherwise, the segments 94 are each capable of sliding along the bands 91, 92. This arrangement permits a wide range of flexibility that more closely reflects natural flexibility of a user's foot. The edges 96 formed by the transverse gaps between the segments 94 may be beveled or otherwise shaped with a lower profile in order to increase the range of flexibility between adjacent segments 94, and/or to minimize potential pinching of the foot between adjacent segments 94 during use, according to embodiments of the present invention.

As shown in FIGS. 6-8, two or more adjacent segments may have top surfaces that include a footbed pattern which aligns when the segments (e.g. 61 and 62) are in their resting position (e.g. FIG. 6). Two or more adjacent segments may also have bottom surface that include a tread pattern (see FIG. 8) which aligns when the segments (e.g. 61 and 62) are in their resting position (e.g. FIG. 6). As seen in FIG. 6, the footbed pattern of raised bumps is visually continuous across multiple segments 61-66 when the segments 61-66 are brought together via the default compression of the bands 67, 68, according to embodiments of the present invention. Also, as shown in FIG. 6 and FIG. 9, in the resting position (unflexed or “flat” position), the lateral (right side of FIG. 6) and medial (left side of FIG. 6) outer perimeter of the overall outsole is substantially continuously curved, such that the outer perimeter(s) of each segment 61-66 and 94 add up to form the overall continuous curvature in the shape of a foot, according to embodiments of the present invention.

Although some embodiments of the present invention are described as outsoles, such embodiments may alternatively be used as insoles, and/or used in combination with corresponding outsoles. For example, the outsole 90 of FIG. 9 may form the outsole 90 of a shoe, and one or more layers of fabric or other material may separate the user's foot from the outsole 90. Above such layer or layers, an insole similar to outsole 90 may be placed for contact with or in proximity with a user's foot. The shape and positioning of each segment of such insole may correspond with the shape and positioning of each segment of the outsole 90, such that each segment of both outsole and insole above and below the middle layers operate in unison to permit flexing of the entire sole at the breaks between adjacent segments, with such breaks being substantially vertically aligned. Embodiments of the present invention may also be used as an insole only, in some situations.

Although the break lines between adjacent segments 61-66, 94 are shown in FIGS. 6 and 9 as being substantially lateral, in other words substantially perpendicular to a longitudinal centerline of the outsole, one of ordinary skill in the art will appreciate, based on the present disclosure, that such break lines may be formed at an angle with respect to the longitudinal centerline. Break lines between different sets of segments 61-66, 94 may also be formed at different angles with respect to each other. Also, instead of being substantially linear, such break lines may be formed in non-linear or curved shapes or patterns, thus permitting flexibility of the outsole 60, 90 about varying and differing directions, according to embodiments of the present invention.

FIG. 11 illustrates a bottom view of a shoe 70 and insole 80, according to embodiments of the present invention. FIG. 12 illustrates a top view of the shoe 70 and insole 80 of FIG. 11, according to embodiments of the present invention. Shoe 70 is similar to shoe 500, according to embodiments of the present invention. Shoe 70 includes various sole segments 71 which are independent segments having breaks or gaps 72 between them. The segments 71 may be adhered or otherwise attached to the upper 74, but may be otherwise free to flex at the breaks 72 or boundaries between each segment 71. In addition, a cord, such as an elastic cord or band as described with respect to FIGS. 6-10, may be placed longitudinally along or between two or more adjacent segments, according to embodiments of the present invention. Such a band may be placed in channels 130 in the top side of each segment 71 or 120, as shown in FIG. 14. The band may provide additional compression force to resist bending of the outsole 70, and/or to customize the bending resistance among the segments 71, according to embodiments of the present invention. The insole 80 may be made of a similar material as the outsole 70, or may be made of a softer material for greater footbed comfort, according to embodiments of the present invention. According to some embodiments of the present invention, the insole 80 is loose (e.g. not adhered) with respect to the shoe 70, and may simply be inserted into opening 73 such that it becomes the footbed of the shoe 70 to receive the user's foot. The insole 80 may include flexure lines 82 (e.g. grooves or gaps) that correspond in location to one or more of the breaks 72 when the insole 80 is placed into the shoe 70. For example, one or more of the breaks 82 in the outsole 80 may each be configured to be located directly above a corresponding break 72 in the outsole of shoe 70, according to embodiments of the present invention.

FIG. 13 illustrates a bottom view of an alternative outsole 77, according to embodiments of the present invention. FIG. 14 illustrates a cross sectional view of the alternative outsole 77 taken along line A-A of FIG. 13, according to embodiments of the present invention. The outsole 77 includes one or more segments 120 (for example, the two adjacent segments 120 located in a foot arch or midfoot location) that each have a groove 121 which extends from the bottom surface upwardly into the outsole 77, for example halfway or just over halfway between the bottom and top surfaces of the outsole 77, according to embodiments of the present invention. According to some embodiments, groove 121 extends substantially longitudinally along the two segments 120, but not to additional adjacent segments.

The present invention has been described in relation to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. Alternative embodiments will become apparent to those of ordinary skill in the art to which the present invention pertains without departing from its scope. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

Claims

1. An outsole comprising:

a plurality of independent segments each formed of an injection moldable material, wherein each of the plurality of independent segments includes a top surface and a bottom surface, wherein each of the plurality of independent segments includes at least one hole formed entirely through the segment and positioned between the top and bottom surfaces; and

at least one band extending through the at least one hole of each of the plurality of independent segments, wherein the at least one band is elastic and permits stretching apart of each of the plurality of independent segments with respect to each other, and wherein the at least one band applies a compression force to the plurality of independent segments causing the plurality of independent segments to align in an overall shape of a foot absent external forces, and wherein nothing spans adjacent segments of the plurality of independent segments except for the at least one band.

2. The outsole of claim 1, wherein an edge of the top surface of each of the plurality of independent segments is beveled.

3. The outsole of claim 1, wherein the plurality of independent segments is four or more independent segments.

4. The outsole of claim 1, wherein the plurality of independent segments is five or more independent segments.

5. The outsole of claim 1, wherein the plurality of independent segments is six or more independent segments.

6. The outsole of claim 5, wherein each of the plurality of independent segments includes a portion of a medial perimeter and a portion of a lateral perimeter of the outsole.

7. The outsole of claim 6, further comprising a toe bar attached to a forward-most segment of the six or more independent segments, and a foot strap connected to the toe bar at one end and to an other segment of the six or more independent segments at another end, wherein the other segment of the six or more independent segments is separated from the forward-most segment by at least three segments of the six or more independent segments.

8. The outsole of claim 1, wherein the plurality of independent segments is thirteen or more independent segments.

9. The outsole of claim 1, wherein each of the plurality of independent segments includes a portion of a medial perimeter and a portion of a lateral perimeter of the outsole.

10. The outsole of claim 1, further comprising one or more spacers between each adjacent pair of the plurality of independent segments.

11. A sole assembly for a footwear product, the sole assembly comprising:

a first outsole section including a first surface and a second surface;

a second outsole section adjacent to the first outsole section, the second outsole section having a first surface and a second surface;

a connection member having a top surface and a bottom surface, wherein a first portion of the bottom surface of the connection member is disposed on at least a first portion of the first surface of the first outsole section, a second portion of the bottom surface of the connection member is disposed on at least a first portion of the first surface of the second outsole section, and a third portion of the connection member extends between the first and second outsole sections; and

at least one footbed section disposed on at least a portion of the top surface of the connection member.

12. The sole assembly of claim 11, further comprising a third outsole section.

13. The sole assembly of claim 12, further comprising a fourth outsole section.

14. The sole assembly of claim 11, wherein the first surface of the first outsole section includes a lip extending along at least a portion of a periphery of the first surface of the outsole section.

15. A method of constructing a sole assembly for a footwear product, the method comprising:

injection molding a plurality of independent outsole sections;

injection molding a connecting member;

arranging at least a first and second of the plurality of independent outsole sections such that the first outsole section is adjacent to the second outsole section;

adhering a first portion of a bottom surface of the connecting member to at least a portion of a first surface of the first outsole section; and

adhering a second portion of the bottom surface of the connecting member to at least a portion of a first surface of the second outsole section, such that a third portion of the connecting member extends between the first and second outsole sections;

wherein the connecting member holds together the first and second outsole sections while permitting the first and second outsole sections to flex about the connecting member and to flex with respect to each other.

16. The method of claim 15, wherein each of the plurality of outsole sections is molded from a foam material.

17. The method of claim 16, wherein the foam material comprises ethylene vinyl acetate (EVA).

18. The method of claim 15, wherein the connecting member is created using an elastomeric material.

19. The method of claim 15, wherein the first surface of the first outsole section is a top surface of the first outsole section, and wherein the first surface of the second outsole section is a top surface of the second outsole section.

20. The method of claim 19, further comprising:

forming a first hole from a front surface of the first outsole section to a rear surface of the first outsole section;

forming a second hole from a front surface of the second outsole section to a rear surface of the second outsole section;

inserting an elastically deformable band through the first and second holes, without otherwise connecting the elastically deformable band to the first and second outsole sections.

21. The method of claim 20, further comprising:

forming a third hole from the front surface of the first outsole section to the rear surface of the first outsole section; and

forming a fourth hole from the front surface of the second outsole section to the rear surface of the second outsole section.

22. The method of claim 21, wherein the elastically deformable band is a first elastically deformable band, the method further comprising inserting a second elastically deformable band through the third and fourth holes, without otherwise connecting the second elastically deformable band to the first and second outsole sections.

23. The method of claim 21, further comprising inserting the elastically deformable band through the third and fourth holes, without otherwise connecting the elastically deformable band to the first and second outsole sections.