SHOE SOLE AND METHOD OF MANUFACTURING SAME

A shoe including a shoe sole and a method of manufacturing a shoe sole are disclosed. The sole includes a sole body possessing a rear section, a midsection, and a front section. The sole further includes a rear cavity at the rear section, an arched portion at the midsection, and a front cavity at the front section. A first cushion is located at or inside the rear cavity and possesses a first hardness. A rigid member is located at the arched portion of the midsection. A second cushion is located at or inside the front cavity and possesses a second hardness greater than the first hardness. The sole optionally includes flex grooves along a bottom portion of the front section.

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Description
TECHNICAL FIELD

The present disclosure relates to a shoe including a shoe sole, and more particularly, to a shoe sole configured to maximize comfort, stability and energy return during the stages of foot movement during walking, trail hiking, running, and the like, and further to a method of manufacturing the shoe and sole.

BACKGROUND INFORMATION

A typical walking movement includes a landing phase, a neutral/transitional phase, and a lift-off phase. The user's heel impacts the ground during the landing phase. The user's weight is then shifted forward at the neutral/transitional phase as the user prepares for the lift-off phase, during which the user's weight is concentrated at the midfoot/arch region. Finally, the forefoot area is activated during the lift-off state. Shoes typically contain foam materials and the like to absorb the impact of the user's foot on the ground. Conventional shoe designs however do not adequately account for the role played by the three core stages of the user's foot during the natural walking gate. The present disclosure is directed in part to assisting in the perambulatory processes by providing for cushioning, stabilizing, and energy return (propelling) during the various stages of walking, trail hiking, running, and the like.

SUMMARY

A shoe and shoe sole are disclosed. The sole comprises a sole body possessing a rear section, a midsection, and a front section. The sole possesses a top portion and a bottom portion. In certain embodiments, the sole further includes a rear cavity at the rear section, an optionally arched portion at the midsection formed such that a bottom surface of the sole body is substantially concave at the midsection, and a front cavity at the front section. A first cushion is located inside the rear cavity and possesses a first hardness. A rigid member is located at the midsection. A second cushion is located inside the front cavity and possesses a second hardness that may in preferred embodiments be greater than the first hardness. The shoe comprises the aforementioned sole and an upper attached directly or indirectly thereto. As used herein, the term shoe may generically refer to any article of footwear that has a sole.

A method of manufacturing a shoe and sole is disclosed. The method comprises forming a sole body possessing a rear section, a midsection, and a front section. The sole body includes a rear cavity at the rear section, an arched portion at the midsection shaped such that a bottom surface of the sole body is substantially concave at the midsection, and a front cavity at the front section. The method further comprises placing a first cushion inside the rear cavity, the first cushion possessing a first hardness, placing a rigid member at the arched portion of the midsection, and placing a second cushion inside the front cavity. The second cushion possesses a second hardness that in preferred embodiments may be greater than the first hardness.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features and advantages disclosed herein will become more apparent from the following detailed description of exemplary embodiments when read in conjunction with the attached drawings, wherein:

FIG. 1 is a schematic illustration of an exemplary embodiment of a sole;

FIG. 2 is a schematic cross section of the heel area of an exemplary embodiment of a sole coupled to a shoe upper;

FIG. 3 is a schematic illustration of another exemplary embodiment of a sole;

FIG. 4 is a schematic illustration of another exemplary embodiment of a sole;

FIG. 5 is a schematic illustration of an exemplary embodiment of a shoe including a sole; and

FIG. 6 is a schematic illustration of another exemplary embodiment of a shoe including a sole.

 DETAILED DESCRIPTION

FIGS. 1, 3 and 4 show an exemplary embodiments of a sole 100, which includes a sole body 110 possessing a rear section 112, a midsection 114, and a front section 116. The sole 100 further includes a rear cavity 122 at the rear section 112, an arched portion at the midsection formed such that the top surface of the sole body 110 is convex and/or the bottom surface S of the sole body 110 is substantially concave at the midsection 114, and a front cavity 126 at the front section 116. The sole further includes a top portion 1101 and a bottom portion 1102. A first cushion 132 is located at or inside the rear cavity 122 and possesses a first hardness. A rigid member 134 is located at the arched portion of the midsection 114. A second cushion 136 is located at or inside the front cavity 126 and possesses a second hardness. In exemplary embodiments, the second hardness is greater than the first hardness. In exemplary embodiments, the second cushion 136 is bouncier than the first cushion 132. In exemplary embodiments, the rigid member 134 is substantially harder than the first and second cushions 132, 136. In exemplary embodiments, the rigid member 134 is substantially rigid or semi-rigid and in preferred embodiments may have a hardness greater than that of the first cushion 132 and the second cushion 136, individually or combined. In exemplary embodiments, the rigid member 134 is located within or upon a middle cavity 124, which may be located on the top portion 1101 (see FIG. 3) or the bottom portion 1102 (FIGS. 1 and 4) of the midsection 114. In exemplary embodiments, plural rigid members are placed at the midsection 114 in or on the top or bottom portions.

In exemplary embodiments, the rear section 112 supports the heel area of the foot of the user, and is configured to absorb the impact made during walking, hiking, running, or the like, when the heel strikes the ground. The first cushion 132 located at the rear section 112 allows for a softer heel landing, thereby potentially reducing stress on the joints, knees and back of the user.

In exemplary embodiments, as the foot of the user transitions from heel impact to a more neutral state, the rigid member 134 provides arch support, promotes stability, and prepares and supports the foot of the user for the next phase in the walking, hiking, or running motion. The midsection with its rigid member 134 allows for stable and smooth transition between the immediate heel strike and the forefoot lift-off phase of the walking, hiking, or running motion. The rigid member 134 is proportioned and configured so as to reduce rolling and prevent collapsing of the foot, thus reducing pain and the amount of work needed to move forward. In exemplary embodiments, the rigid member 134 is manufactured in a very dense compound for desirable arch support, for example nylon or thermoplastic polyurethane. In FIGS. 1 and 4, the rigid member 134 is inserted from the bottom, and in FIG. 3, the rigid member 134 is inserted from the top. The rigid member 134 supports the foot and prevents the arch from collapsing, therefore stabilizing the foot as it transitions forward to the final portion of the walking gate.

In exemplary embodiments, the front section 116 supports the forefoot area, and is configured to propel the foot forward. The hardness and positioning of the second cushion 136 promotes energy return, thus potentially producing a bounce or propel sensation, which may or may not be perceptible to the user, during the thrust phase of the walking, hiking, or running motion.

In exemplary embodiments (see FIGS. 1 and 3), the rear cavity 122 and the front cavity 126 are open to a top surface of the sole body 110. In certain embodiments, an insole may cover the top surface of the sole, and be considered as part of the sole disclosed herein. The insole may be configured with section to further aid in the absorption, stabilizing and energy return (propel) advantages of the sole 100.

In various exemplary embodiments (see FIGS. 1, 3 and 4), the rear cavity 122 and/or the front cavity 126 can be open or closed to various sides of the sole body 110, including the upper, bottom, front, rear, and lateral surfaces of the sole body 110. The first cushion 132, second cushion 136 and/or rigid member 134 may optionally be accessible or removable through any of the upper, bottom, front, rear, and lateral surfaces of the sole body 110, such feature being informed by whether a corresponding cavity is open or closed to any one of those surfaces. In FIGS. 1 and 3, both the rear cavity 122 and the front cavity 126 are open to the top surface of the sole body 110, and are closed to all other sides of the sole body 110. In FIG. 4, the rear cavity 122 is open to the top surface of the sole body 110 and is closed to all other sides of the sole body 110, and the front cavity 126 is open to the bottom surface of the sole body 110 and is closed to all other sides of the sole body 110. In such these embodiments, an insole may optionally be placed substantially abutting (directly or indirectly) the top portion of the sole body 110.

In exemplary embodiments, the rigid member 134 includes an elongated portion possessing a longer extent along a rear section-to-front section direction (i.e., the major axis) of the sole body 110. The rigid member 134 may further comprise a shorter extent along a transverse direction perpendicular to the rear section-to-front section direction of the sole body 110.

In exemplary embodiments, the elongated portion is located against the bottom surface S of the sole body 110 at the midsection 114.

In exemplary embodiments, the sole includes a middle cavity 124 located at the midsection 114 and optionally closed to the upper surface and/or to the bottom surface S of the sole body 110, to promote stabilization of the arch of the foot, and to reduce the risk of collapsing of the arch of the foot. The middle cavity 124 may optionally be located along the top portion of the midsection 114. The rigid member 134 is located at or inside the middle cavity 124, as illustrated by the dotted line in FIG. 5. In an exemplary embodiment, the rigid member 134 includes injected nylon, thermoplastic polyurethane, and/or steel. In FIGS. 1 and 4, the middle cavity 124 is open to the bottom, and in FIG. 3, the middle cavity 124 is open to the top.

In exemplary embodiments, the rear section 112 includes a suspended middle portion 1121 (shown in FIG. 2) between two lateral portions 1122. The lateral portions 1122 extend further than the suspended middle portion 1121 in a top-to-bottom direction of the sole body 110.

In exemplary embodiments, the suspended middle portion 1121 further allows for a softer heel landing, thereby further reducing stress on the joints, knees and back of the user. This structure may also provide a softer sensation at the user's heel area. In an exemplary embodiment, the two lateral portions 1122 touch the ground during the process of walking. Alternatively, the two lateral portions 1122 may be separated from the ground by outsole portions 1123, as shown in FIG. 2.

In exemplary embodiments, an air pocket 1124 is located above or inside the suspended middle portion 1121 of the rear section 112. In exemplary embodiments, the air pocket 1124 further allows for a softer heel landing, thereby further reducing stress on the joints, knees and back of the user. For example, the air pocket 1124, along with the suspended middle portion 1121 of the rear section 112, creates a comfortable landing area wherein the air pocket 1124 allows for freedom of movement down for the heel, and cantilevered heel portions on either sides of the suspended middle portion 1121 can splay/flares out, as illustrated for example by the white arrows in the sectional X-X view in FIG. 3. This allows for a softer heel landing, thereby further reducing stress on the joints, knees and back of the user, for example during the initial heel strike of the walking gate. For example, the first cushion 132 located at the rear section 112, the air pocket 1124 and the cantilevered heel portion design, can together allow for a softer heel landing, thereby potentially reducing stress on the joints, knees and back of the user.

In exemplary embodiments, the suspended middle portion 1121 is substantially oval in shape when viewed from the bottom. In other embodiments, the suspended middle portion 1121 may be circular or substantially rectangular in shape without deviating from the disclosure.

In exemplary embodiments, the front section 116 may have flex grooves 1161 along the bottom portion of the sole body 110. In preferred embodiments these flex grooves 1161 are disposed along the bottom portion of the front section 116 in a substantially lateral direction, perpendicular to the major axis of the shoe sole. The flex grooves 1161 may additionally or alternatively be present on the bottom portion of the front section 116 in a direction parallel to the major axis of the shoe sole, and/or may be further disposed in such directions as may facilitate or enhance the deformation of the shoe sole in directions that would complement contemplated foot movements encountered during exercise, hiking, cross training, running, climbing, etc. Flex grooves 1161 can be formed on the sole body 110 and/or on the second cushion 136. The combination of the flex grooves 1161 and the second cushion 136 creates desirable propulsion effects during walking and other exercise activities.

In exemplary embodiments, the bottom surface of the shoe sole may include striations 1125 that are positioned so as to complement the functions (absorb, stabilize, propel) of the various portions of the shoe sole. In certain embodiments, such striations 1125 in the front section 116 may be substantially perpendicular to the major axis of the shoe; in the midsection 114 may be substantially radially disposed in relation to the midpoint(s) of the lateral edges of the midsection 114; and/or in the read section 112 may be disposed substantially radially to the midpoint of the rear section 112 or center of curvature of the suspended middle portion 1121.

In exemplary embodiments, the rigid member 134 includes nylon. In an exemplary embodiment, a nylon rigid member 134 at the midsection 114 further promotes stability.

In exemplary embodiments, the first cushion 132 includes compression molded ethylene vinyl acetate (EVA). In exemplary embodiments, the compression molded EVA cushion at the rear section 112 further allows for a softer heel landing, thereby further reducing stress on the joints, knees and back of the user.

In exemplary embodiments, the first cushion 132 includes 55-60 degree EVA. In an exemplary embodiment, the 55-60 degree EVA cushion at the rear section 112 further allows for a softer heel landing, thereby further reducing stress on the joints, knees and back of the user. In exemplary embodiments, the first cushion 132 is formed of the same material as the sole body 110. In exemplary embodiments in which the sole body 110 is injection molded, the first cushion 132 is integrally formed with the sole body 110 and does not exist as a separate component (see FIG. 6). In exemplary embodiments, one purpose of the first cushion 132 is to close, and thereby form, the air pocket 1124 at the rear section 112.

In exemplary embodiments, the sole body 110 is made of EVA, ethylene propylene (EPR), polyurethane, and/or rubber, or any suitable materials known in the art.

In exemplary embodiments, the second cushion 136 includes elastic EVA foam. In an exemplary embodiment, the elastic EVA foam cushion at the front section 116 of the sole body 110 includes 55-60 degree EVA. In an exemplary embodiment, the elastic EVA foam cushion at the front section 116 of the sole body 110 includes EPR. In an exemplary embodiment, the elastic EVA or EPR foam cushion at the front section 116 of the sole body 110 further promotes energy return during the thrust phase of the walking motion. In exemplary embodiments, the second cushion 136 is arranged and configured to align with the user's metatarsal bones.

In exemplary embodiments, the first cushion 132 and second cushion 136 maybe be substantially rectangular or trapezoidal when viewed from the top or bottom, with the sides and/or edges of the rectangular shapes being optionally rounded. In exemplary embodiments, the top and bottom surfaces of the first cushion 132 and second cushion 136 may be substantially flat, or may be curved so as to allow for their top surfaces to receive the curvature of the foot and/or insole. In certain embodiments, the bottom surface of the second cushion 136 may optionally include lateral projections disposed in a direction perpendicular to the major axis of the sole, as shown in FIG. 1. The first cushion 132 and second cushion 136 may be shaped and/or proportioned so as to maximize energy return with design constraints and materials cost considerations.

In exemplary embodiments, the second cushion 136 includes 45 degree EVA. In an exemplary embodiment, the 45 degree EVA cushion at the front section 116 of the sole body 110 further promotes energy return during the thrust phase of the walking motion.

FIG. 5 shows an exemplary embodiment of a shoe 300 including a sole 100 and an upper 200. The upper 200 is configured to receive the foot of a user. The sole 100 is coupled directly or indirectly to the upper 200 such that a heel portion of the foot is supported by the rear section 112 of the sole body 110 and a forefoot portion of the foot is supported by the front section 116 of the sole body 110.

In exemplary embodiments, the shoe 300 includes an outsole 250 coupled to the sole 100 such that the sole 100 is located between the outsole 250 and the upper 200. The shoe 300 may optionally further comprise an insole. It will be appreciated that the sole 100 disclosed herein may be a midsole between an outsole and an insole, or may include one or more of an outsole or insole, integrally or via attachment, without deviating from the present disclosure. An exemplary embodiment of an insole includes a 360 degree EVA insock. The combination of the sole and the insock creates desirable propulsion effects during walking and other exercise activities.

An exemplary method of manufacturing a shoe and sole comprises forming a sole body 110 possessing a rear section 112, a midsection 114, and a front section 116. The sole body 110 includes a rear cavity 122 at the rear section 112, an arched portion at the midsection 114 shaped such that a bottom surface S of the sole body 110 is substantially concave at the midsection 114 and/or a top surface of the sole body 110 is substantially convex at the midsection 114, and a front cavity 126 at the front section 116. The method further comprises placing a first cushion 132 at or inside the rear cavity 122, the first cushion 122 possessing a first hardness, placing a rigid member 134 at the arched portion of the midsection 114, and placing a second cushion 136 at or inside the front cavity 126. In exemplary embodiments, the second cushion 136 possesses a second hardness greater than the first hardness. In exemplary embodiments, the second cushion 136 is bouncier than the first cushion 132.

It will be appreciated by those skilled in the art that the disclosure herein can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restricted. The scope of the invention is indicated by the appended claims rather than the foregoing description and all changes that come within the meaning and range and equivalence thereof are intended to be embraced therein.

Claims

1. A shoe comprising a shoe sole comprising:

a sole body possessing a rear section, a midsection, and a front section;
a rear cavity at the rear section;
an arched portion at the midsection.
a front cavity at the front section;
a first cushion located at or inside the rear cavity and possessing a first hardness;
a rigid member located at the arched portion of the midsection; and
a second cushion located at or inside the front cavity and possessing a second hardness, the second hardness being greater than the first hardness.

2. The sole of claim 1, wherein the rear cavity and the front cavity are open to a top surface of the sole body.

3. The sole of claim 1, wherein the rigid member comprises an elongated portion possessing a longer extent along a rear section-to-front section direction of the sole body.

4. The sole of claim 3, wherein the elongated portion is located against a bottom surface of the sole body at the midsection.

5. The sole of claim 3, wherein the sole includes a middle cavity located at the midsection and closed to a bottom surface of the sole body, and the rigid member is located at or inside the middle cavity.

6. The sole of claim 1, wherein the rear section includes a suspended middle portion between two lateral portions, the lateral portions extending further than the suspended middle portion in a top-to-bottom direction of the sole body.

7. The sole of claim 6, further comprising an air pocket located above or inside the suspended middle portion of the rear section.

8. The sole of claim 1, wherein the rigid member includes nylon.

9. The sole of claim 1, wherein the first cushion includes compression molded ethylene vinyl acetate.

10. The sole of claim 1, wherein the first cushion includes 55-60 degree ethylene vinyl acetate.

11. The sole of claim 1, wherein the second cushion includes elastic ethylene vinyl acetate foam.

12. The sole of claim 1, wherein the second cushion includes 45 degree ethylene vinyl acetate.

13. The sole of claim 1, wherein the front section further includes flex grooves along a bottom portion of the sole body.

14. The sole of claim 1, wherein the sole body includes ethylene vinyl acetate.

15. The sole of claim 1, wherein the sole body includes polyurethane.

16. The sole of claim 1, wherein the sole body includes ethylene propylene.

17. The sole of claim 1, wherein the sole body includes rubber.

18. A shoe comprising:

an upper configured to receive a foot of a user; and
the sole of claim 1 coupled to the upper such that, when the foot of the user is received in the upper, a heel portion of the foot is supported by the rear section of the sole body and a forefoot portion of the foot is supported by the front section of the sole body.

19. A method of manufacturing a shoe and shoe sole comprising:

forming a sole body possessing a rear section, a midsection, and a front section, the sole body including a rear cavity at the rear section, an arched portion at the midsection shaped, and a front cavity at the front section;
placing a first cushion at or inside the rear cavity, the first cushion possessing a first hardness;
placing a rigid member at the arched portion of the midsection; and
placing a second cushion at or inside the front cavity, the second cushion possessing a second hardness greater than the first hardness.
Patent History
Publication number: 20180153253
Type: Application
Filed: Dec 2, 2016
Publication Date: Jun 7, 2018
Applicant: G-III Apparel Group, Ltd. (New York, NY)
Inventors: Shane Henry WARD (New York, NY), Cory HABERMAN (Ridgewood, NJ)
Application Number: 15/367,395
Classifications
International Classification: A43B 13/18 (20060101); A43B 13/14 (20060101); A43B 13/20 (20060101); A43B 13/04 (20060101); A43B 7/14 (20060101);