Shoe Tuning System and Method

Abstract

A replaceable tuning wedge-shaped piece of a variety of hardnesses, is inserted in the midsole of shoes for enhancing the rate of compression. As the shoe breaks down or compresses, the tuning wedges will help the midsole rate of compression in each individual's gait. Such wedges can be made of elastomers, rubbers, plastics, wood, air bladders, Skydex brand thermoplastic polyurethane (TPU) material, D3O® Set Foam, or the like. A method of adjusting the density and compression of the midsoles or platforms of footwear includes using these wedges in shoes. An athletic or casual or dress shoe can include an upper component, a midsole, an outsole, and a void or voids along the midsole borders for housing wedges of different durometers for controlling compression rates of each foot of the individual wearer.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

Priority of our U.S. provisional patent application No. 62/085,800, filed 1 Dec. 2014, incorporated herein by reference, is hereby claimed.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

REFERENCE TO A “MICROFICHE APPENDIX”

Not applicable

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to shoes with midsoles or platforms. More particularly, the present invention relates to shoes with midsoles of compressible materials, including midsoles with pronation plugs for over pronation.

IMPROVEMENTS TO PRIOR ART

Shoes manufactured today are basic athletic shoes, using an upper, a midsole, with cushioning characteristics, and control hardnesses, such as pronation plugs, to help control excessive pronation. Wave plates, gels, air and different combinations of rubbers and plastic can be combined to help control these abnormalities. There have been plugs used in the 1980s for rearfoot cushioning, such as in the Adidas 1980 model used in a very hard plastic midsole, so the wearer could add some cushioning.

General Background of the Invention

According to a podiatrist journal, 44% of humans have a different gait in each foot. Shoes typically do not adapt to both feet.

A typical running shoe has a hardness 50-55 durometers shore A. Conventional shoe construction involves an upper mounted on a midsole, which has an outsole for wear from hitting the ground.

The prior art discloses midsoles that are made of ethylene-vinyl acetate (EVA) of different durometers. The prior art discloses different hardnesses within the midsole, such as pronation plugs, supination plugs, plastic wave plates, gels, air and other foot controlling devices, that are manufactured into the midsole or platform.

The following US Patent Numbers are incorporated herein by reference:

U.S. Pat. No. 873,775; U.S. Pat. No. 3,159,928; U.S. Pat. No. 3,783,373; U.S. Pat. No. 4,223,457; U.S. Pat. No. 4,237,626; U.S. Pat. No. 4,322,895; U.S. Pat. No. 4,429,474; U.S. Pat. No. 4,430,810; U.S. Pat. No. 4,573,279; U.S. Pat. No. 4,624,061; U.S. Pat. No. 4,882,856; U.S. Pat. No. 4,897,936; U.S. Pat. No. 4,942,677; U.S. Pat. No. 5,077,915; U.S. Pat. No. 5,212,878; U.S. Pat. No. 5,533,280; U.S. Pat. No. 5,692,322; U.S. Pat. No. 5,875,568; U.S. Pat. No. 6,023,859; U.S. Pat. No. 6,604,301.

Shimano at one time (late 1990's or early 2000's) sold shoes which include voids for receiving rectangular blocks for adjusting hardnesses of the shoes. However, these blocks created lumps in the shoes, and these shoes may no longer be sold.

Adidas at one time (around 1980) sold shoes with cylindrical voids for receiving cylinders around 25 mm in diameter and around 40 mm long for adjusting the hardness of the heel.

BRIEF SUMMARY OF THE INVENTION

A goal of the present invention is to achieve footwear that can adapt to each foot of the individual.

The present invention relates generally to footwear and more particularly, to shoes with shock absorbing midsoles or platforms.

Manufacturing footwear with a replaceable tuning wedge allows the user to take out the tuning wedge and replace it with a softer or harder durometer tuning wedge to control or alter the densities of each individual's shoes. In altering the density of the midsole at specific locations, the magnitude and rate of compression resulting from the foot striking the ground is altered. The position or location of the tuning wedges within the midsole or platform adjusts the shoe to control over pronation or supination of the individual's feet.

In accordance with the illustrated preferred embodiments of the present invention, replaceable tuning wedges having different durometers can be inserted into a void manufactured within the midsole. Tunable wedges can also be inserted into all shoes with midsoles or platforms without a pre-manufactured void. For example, a plastic wedge can be inserted by cutting a slice in the midsole and inserting the plastic wedge.

The apparatus of the present invention includes an athletic or casual or dress shoe comprising an upper component, a midsole, an outsole, and wedges of preferably different durometers for controlling compression rates of each foot of the individual wearer. Preferably, there is a void or voids along the midsole borders for housing the wedges.

The apparatus of the present invention further includes a shoe for controlling compression rates of a wearer's foot, the shoe comprising an upper, a midsole, an outsole, and one or more wedges of preferably varying durometers. Preferably, there are one or more voids along the midsole, wherein the one or more voids are sized and shaped to accept the one or more wedges.

The apparatus of the present invention further include apparatus for controlling the compression rate of an individual's foot, the apparatus having a size and a shape so that one or more can be placed in the individual's shoes, wherein the apparatus has various durometers.

A. Shoe and associated Control Devices

The present invention provides an improved article of footwear including an upper component, a midsole component attached to the upper component, wherein the midsole component is made of a foam material that includes one or more different durometers, and an outsole for wear characteristics. Pre-manufactured midsoles with voids on the sides of said midsole in which different durometer tuning wedges may be inserted to help control or enhance compression and breakdown of the midsole in various areas of the shoe. Voids may be placed in areas such as lateral and medial rear foot and fore foot, along with the arch area, for example.

Tunable wedges will help an individual who has a different gait pattern in his or her right and left feet. Tunable wedges can be used to help reduce motion created by the breakdown of the midsole, such as the lateral heel breakdown and the medial forefoot breakdown that can lead to iliotibial band issues. It is believed that almost all shoe-related soft tissue injuries can be helped by the tunable wedges of the present invention.

Inserting the tuning wedges into the void of the midsole or platform can help create a more natural curvature of the heel within the shoe by creating a U shape underneath the wearer's heel.

The tuning wedges can also help with the rate of midsole breakdown, thus giving the wearer longer wear with added control.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:

FIG. 1 is a perspective view of a shoe upper in current athletic shoes, including a heel section, a midfoot section, a fore foot section, an outsole for durability and wear, and tuning wedges, in accordance with a preferred embodiment of the present invention.

FIG. 2 shows a method of locking the tuning wedge in accordance with a preferred embodiment of the present invention.

FIG. 3 shows a method of locking the tuning wedge in accordance with a preferred embodiment of the present invention.

FIG. 4 shows a method of locking the tuning wedge in accordance with a preferred embodiment of the present invention.

FIG. 5 shows a method of locking the tuning wedge in a preferred embodiment of the present invention.

FIG. 6 shows tuning wedges inserted into a midsole, showing the U shape it creates around wearer's heel in accordance with a preferred embodiment of the present invention.

FIG. 7 shows tuning wedges inserted into a midsole, showing the U shape it creates around wearer's heel, and a sensor contained within a wedge, in accordance with a preferred embodiment of the present invention.

FIG. 8 shows tuning wedges inserted into a midsole, showing the U shape it creates around wearer's forefoot, and a sensor contained within a wedge, in accordance with a preferred embodiment of the present invention.

FIG. 9 shows an outer side of a shoe with tuning wedges inserted into a midsole in accordance with a preferred embodiment of the present invention.

FIG. 10 shows an inner side of a shoe with tuning wedges being inserted into a midsole in accordance with a preferred embodiment of the present invention.

FIG. 11 shows an outer side of a shoe with voids in a midsole for receiving tuning wedges in accordance with a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a shoe 20 having an upper 10 that is preferably made of a suitable material such as nylon, leather, or synthetic leather, for example, in accordance with the present invention. A midsole or platform 11 is attached to the upper 10 and preferably made of ethylene-vinyl acetate or EVA foam, plastics, leather or types of rubber, for example, for cushioning and controlling the individual's gait. An outsole 12 is preferably attached to the midsole 11 for wear and traction according to the individual's needs. A void 13 and/or a void 24 may be within the midsole 11, manufactured or created, preferably in a wedge shape to house wedges 14, 114, 214, 314 of the proper durometers of the individual wearer's right and left feet. The wedges 14, 114, 214, 314 of different durometers preferably get seated into the void 13 and/or void 24 of the midsole for compression control and gait control.

Shoe 20 includes an upper 10, a heel section 34, a midfoot section 35, a forefoot section 36, an outsole 12 for durability and wear, and voids 13 and 24 for receiving tuning wedges, in accordance with a preferred embodiment of the present invention. See FIGS. 1 and 10.

As shown in FIGS. 6 and 7, there is a void 13 on each side of shoe 20. Likewise, there is a void 24 on each side of shoe 20 (the one on the left is the mirror image of the one on the right).

Materials, hardnesses, dimensions, and angles for the wedges can be for example as follows. Wedges 14, 15, 16, 17, 18, 40, 114, 140, 214, 240, 314, 340, 414, 440 can be made of the following materials: Elastomers, rubbers, plastics, wood, air wedge, air bladders, Skydex brand thermoplastic polyurethane (TPU) material, D3O® material used in motorcycle jackets or equivalent material which gets harder on impact, or plastic/rubber. The air wedges could be made of TPU. Wedges 14, 114, 214, 314, and 440 can for example have the following hardnesses:

Wedges 14, 40:

30-60 Durometer Shore A, more preferably 35-55 Durometer Shore A, and most preferably 40-50 Durometer Shore A—for example, about 45 Durometer Shore A;

Wedge 114, 140:

40-70 Durometer Shore A, more preferably 45-65 Durometer Shore A, and most preferably 50-60 Durometer Shore A—for example, about 55 Durometer Shore A;

Wedge 214, 240:

50-80, 55-75, 60-70, for example 65

50-80 Durometer Shore A, more preferably 55-75 Durometer Shore A, and most preferably 60-70 Durometer Shore A—for example, about 65 Durometer Shore A; and

Wedge 314, 340:

60-90 Durometer Shore A, more preferably 65-85 Durometer Shore A, and most preferably 70-80 Durometer Shore A—for example, about 75 Durometer Shore A;

Wedge 414:

Any of the hardnesses of any of the above wedges.

Wedge 440:

Any of the hardnesses of any of the above wedges.

Wedge 18:

Any of the hardnesses of any of the above wedges.

A typical set of wedges for use by store owners to adjust shoes of the present invention might be as follows:

multiple wedges having a hardness of 45 durometer;
multiple wedges having a hardness of 55 durometer
multiple wedges having a hardness of 65 durometer;
multiple wedges having a hardness of 75 durometer
Wedges 14, 15, 16, 17, 40, 114, 140, 214, 240, 314, 340, 414, 440 can have the following dimensions, for example:
Width W: preferably from 10 mm to 60 mm, more preferably from 15 mm to 55 mm, most preferably from 20 mm to 50 mm, for example around 35 mm for men's sizes 10-16 and for women's size 11-13, around 25-30 mm for men's sizes 7-9 and women's sizes 6-10. The width of the forefoot wedges can be the same as the rearfoot wedges, or the two widths can be different. The forefoot wedge width is preferably 40%-100% of the rearfoot wedge width, more preferably 45-90%, and most preferably 55-80% of the rearfoot wedge width. Height H: preferably from 3 mm to 23 mm, more preferably from 4 mm to 22 mm, most preferably from 5 mm-21 mm, for example around 6 mm-10 mm for the forefoot wedge (14, 114, 214, 314, 414) for men's sizes 7-9 and women's sizes 6-10 and for example around 10 mm-15 mm for the rearfoot wedge (40, 140, 240, 340, 440) for men's sizes 7-9 and women's sizes 6-10; for example around 10 mm-15 mm for the forefoot wedge (14, 114, 214, 314, 414) for men's sizes 10-16 and women's sizes 11-13 and for example around 15 mm-20 mm for the rearfoot wedge (40, 140, 240, 340, 440) for men's sizes 10-16 and women's sizes 11-13;
Depth D: preferably from 10 mm to 50 mm, more preferably from 15 mm to 45 mm, most preferably from 20 mm to 40 mm, for example around 25 mm-30 mm for men's sizes 7-9 and women's sizes 6-10, for example around 30-35 mm for men's sizes 10-16 and for women's size 11-13. The depth can be the same for forefoot and rearfoot wedges, or they can vary. It is expected that they will normally be the same.

It is possible to have more than 4 wedges per shoe and to have the wedges have a total area approximately equal to that of the midsole 11; however, typically, four wedges are used in each shoe 20 and together they may typically have a total area (width W×depth D×4 wedges) of from 5% to 30% of the surface area of midsole 11, more preferably from 10% to 25% of surface area of midsole 11, and most preferably from 15-20% to for example, 16% of surface area of midsole 11.

Angle A may be from 5 degrees to 30 degrees, more preferably from 8 degrees to 25 degrees, most preferably from 10 degrees to 20 degrees, for example around 15 degrees.

Referring to FIG. 5, wedge 18 may have dimensions as follows: depth D; height H; a first width, W1; a second width, W2; an angle of wedge, A; and an angle of flare, A2. The wedges may substantially rectangular in vertical cross section. In some embodiments, there may be four wedges per shoe. Angle A, depth D and height H of wedge 18 can be the same as for any of wedges 14, 15, 16, 17, 18, 40, 114, 140, 214, 240, 314, 340, 414, 440. First width W1 of wedge 18 can be the same as width W for any of wedges 14, 15, 16, 17, 18, 40, 114, 140, 214, 240, 314, 340, 440. Second width W2 of wedge 18 can be for example 105-140%, more preferably 110-125%, and most preferably 110-120% of first width W1 of wedge 18. Angle of flare A2 of wedge 18 is determined by the W1 and W2 and preferably both angles A2 on a wedge are the same. In some applications, some or all wedges 14, 15, 16, 17, 18, 40, 114, 140, 214, 240, 314, 340, 414, 440 may be made of D3O® material (such as D3O® Set Foam 001 ST.1, density range 400-500, standard density 450, hardness range Shore 00 60-75) that will get harder upon impact, or other materials that react to impact, such as UA Speedform by Dow Chemical.

Preferably, in many cases, wedges used in the forefoot will be thinner than wedges in the rearfoot. For example, if wedges in the forefoot are around 7 mm high, the wedges in the rearfoot can be around 13 mm high.

The shoes will preferably be made with voids for the wedges, and sold with wedges having the same material (including hardness) as the midsole. A store would then test the shoes on the user and replace none, one, some, or all of the wedges with wedges of other hardnesses, based on observations by the shoe store operator or based on readings from sensors.

In a preferred embodiment, there is preferably an attachment characteristic for seating said wedges. Exemplary attachment characteristics for use in some embodiments are shown in FIGS. 2-4. In FIG. 2, the attachment characteristic includes mating projection device 26 configured to couple with a receiving groove 27. Referring to FIG. 3, the attachment characteristic includes mating serrations 28 configured to couple with receiving mating serrations 29. The exemplary attachment characteristics in FIG. 3 also include a mating projection device 30 configured to couple with a receiving groove 31. Referring to FIG. 4, the attachment characteristic may include a mating projection device 32 configured to mate with a receiving groove 33. One having ordinary skill in the art will recognize that FIG. 1 shows an exemplary embodiment having four voids (one at each end as shown in FIG. 1 and one on each side as shown in FIGS. 6 and 7) for use with four wedges. However, alternative embodiments may have greater or fewer than four voids.

The midsole 11 may be configured for gait control and cushioning for the wearer. One or more voids 13 or seats in the midsole 11 may be wedge shaped, for example, for controlling the compression rate in that section of the midsole. A wedge b 14 of a harder durometer that may control the forefoot section of the midsole, for example. Wedges 14 with different durometers may be seated into the voids creating the right gait control for each individual wearer, as shown in FIG. 1. Exemplary attachment characteristics to seat each wedge and to secure the wedge from falling out are show in FIGS. 2-5. The wedges used in a single shoe or in a pair of shoes may all be of the same hardness, or perhaps in some cases each will be of a different hardness from all others used in the pair of shoes, or anything in between.

FIGS. 2-5 show preferred methods of seating the tuning wedges 15, 16, 17 and 18 within the void. The tuning wedges 14, 40, 114, 140, 214, 240, 314, and 340 in FIG. 1 show another preferred method of seating the tuning wedges within the void 13, 24. As shown in FIGS. 2-4, the wedges 15, 16, and 17 may be configured to mate with mating surfaces 21, 22, and 23 of the midsole 11, respectively. Alternatively, the shoes without a void may be tuned by placing different durometer materials in desired locations of the midsole. In such a case, the wedges could look like wedge 18. Wedge 18 is wider at the thin part so it can be pinched and it stays in a slit which can be cut with a knife. A wedge can have the shape of wedge 18 and include a sensor 19 therein.

FIGS. 6 and 7 show tuning wedges 14 seated within the midsole 11, preferably creating a U shaped compression pattern 25 from the weight of the wearer. Referring to FIG. 7, a pressure sensor 19, such as a piezo electronic sensor or strain gauge, may be placed in the wedge 440 and configured to measure compression rate or other inputs. This will alert the user as to whether the compression rate is too low to be effective in preventing pronation or supination. The sensor 19 may be configured to give feedback on a display or to connect with a computing device, such as a mobile phone, via Bluetooth or other wired or wireless networking connection. One having ordinary skill in the art would recognize that the sensor may be placed in a part of the shoe other than the wedge in an alternative embodiment. The sensor could be, for example, an Omega brand LCKD or LCMKD load cell commercially available from Omega corporation at www.omega.com. In shoe 20 shown in FIG. 7, there is a wedge 440 having a sensor 19 and a wedge 240 not having a sensor. In FIG. 8, there is a wedge 414 having a sensor 19 and a wedge 14 not having a sensor. Each wedge used in a pair of shoes may have a sensor, and each wedge may not, or any combination of wedges with sensors and without sensors can be used.

Having multiple sensors gives additional information that one sensor does not give. For example, with an outside and inside sensor, when and how much pressure is applied during the foot strike can be measured. Generally, one sensor is better than no sensors, but multiple sensors (including one on each wedge used in each shoe) are sometimes preferred.

The tuning wedges of the present invention can be modified as the midsole breaks down, which allows shoe stores to continue to tune the individual's gait throughout the life of the shoe.

While it is preferred to use a unitary wedge in each void, one could fill the void with multiple wedges that together approximate the shape of the void.

Though not preferred, one could glue the wedges in place.

This wedge system can be used with virtually any type of shoe or boot or sandal.

PARTS LIST

The following is a list of parts and materials suitable for use in the present invention:

Parts
Number Description
10     upper
11     midsole or platform
12     outsole
13     void
14     wedge
15     wedge
16     wedge
17     wedge
18     wedge
19     sensor
20     shoe
21     mating surface
22     mating surface
23     mating surface
24     void
25     weight of the wearer
26     mating projection device
27     receiving groove
28     mating serrations
29     receiving mating serrations
30     mating projection device
31     receiving groove
32     mating projection device
33     receiving groove
34     heel section
35     midfoot section
36     forefoot section
40     wedge
114    wedge
140    wedge
214    wedge
240    wedge
314    wedge
340    wedge
414    wedge including sensor 19
440    wedge including sensor 19
W      width
D      depth
H      height
A      angle
W1     width
W2     width
A2     angle of flare

All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.

The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.

Claims

1. A shoe comprising:

a) an upper component;

b) a midsole having borders;

c) an outsole;

d) a void or voids along the midsole borders for housing wedges of different durometers for controlling compression rates of each foot of an individual wearer; and

e) wedges which fit in the void or voids.

2. A shoe as in claim 1, wherein the wedges are made of plastic, EVA, rubber, air bladders, wood, and/or D3O® Set Foam or like materials.

3. A shoe as in claim 1 where the wedges have attachment characteristics for seating said wedge into the midsole without voids.

4. A shoe for controlling compression rates of a wearer's foot, the shoe comprising:

a) an upper;

b) a midsole;

c) an outsole;

d) one or more voids along the midsole; and

e) one or more wedges of varying durometers, wherein the one or more voids are sized and shaped to accept the one or more wedges.

5-9. (canceled)

10. A method of using the shoe of claim 4 wherein the wearer chooses the one or more wedges to place in the one or more voids based on the durometer of the wedge that will most effectively control the compression rate of the wearer's foot.

11. Apparatuses for controlling the compression rate of an individual's foot, the apparatuses having a size and a shape so one or more can be placed in the individual's shoes, wherein the apparatuses have various durometers, and wherein the apparatuses are substantially wedge-shaped.

12. The apparatuses of claim 11, wherein the apparatuses are wedge-shaped.

13. A method of using the apparatuses of claim 11 comprising the steps of:

(a) choosing one or more apparatuses of the appropriate durometer for each different shoe of the individual to most effectively control the compression rate of each of the individual's feet; and

(b) placing the apparatuses chosen in step (a) in the individual's shoes.

14-16. (canceled)

17. The method of claim 13 wherein the one or more apparatuses are different for each of the individual's shoes.

18. The method of claim 13 further comprising the following step:

(c) repeating steps (a) and (b) as the shoe breaks down to continue to most effectively control the compression rate of each of the individual's feet.

19-21. (canceled)

22. The shoe of claim 1, wherein the wedges include a sensor or sensors.

23. The shoes of claim 4, wherein the wedges include a sensor or sensors.

24. The apparatus of claim 11, wherein the apparatuses of various durometers include a sensor.

25. The method of claim 13, wherein choosing the apparatus is based on input collected from a sensor contained within the shoe.

26. The shoe of claim 1, wherein the wedges are rectangular in vertical cross section and taper toward a point.

27. The shoe of claim 1, wherein the wedges are rectangular in vertical cross section and taper to a point.

28. The shoe of claim 1, wherein there are four voids in the shoe for receiving wedges.

29. The shoe of claim 1, wherein the wedges are inserted from the side.

30. (canceled)

31. A shoe as in claim 1 where the wedges have attachment characteristics for seating said wedge into the midsole.

32. A method of using the shoe of claim 4 wherein a user chooses the one or more wedges to place in the one or more voids based on the durometer of the wedge that will most effectively control the compression rate of the wearer's foot.

33-34. (canceled)