FOOTWEAR WITH UNITARY INSOLE AND STRAP
Unitary insole/strap layers for articles of footwear and methods for making such unitary insole/strap layers are provided. The insole/strap layers are transformed from a two-dimensional patterned base into a three-dimensional insole/strap layer, which simplifies the manufacturing process. The insole/strap layer is then secured to an outsole structure to form an article of footwear, such as a flip flop or sandal.
The present disclosure relates generally to footwear, and more particularly to footwear with a unitary insole and strap layer.
Description of the Related ArtConventional articles of footwear known as flip flops and/or sandals include two primary elements, a sole structure and one or more straps that are independent of the sole structure and then secured to the sole structure to hold a foot relative to the sole structure. The one or more straps form one or more arches that receive and position a foot relative to the sole structure. In configurations with two straps, each of the two straps have one end joined together at a center post or thong in the forefoot region of the article of footwear, and the other end secured to the sole structure in the heel region of the article of footwear typically on opposite sides of the article of footwear. The center post or thong is then inserted into an aperture in the sole structure to secure the front of the straps to the sole structure.
SUMMARYThe present disclosure provides unitary insole/strap layers for articles of footwear, such as flip flops and sandals, and methods for making such unitary insole/strap layers. In one exemplary embodiment, the method for making a unitary insole/strap layer of an article of footwear comprises forming a patterned base having an insole portion and a strap portion. The insole portion includes an aperture in a toe region and the strap portion comprises at least two straps each extending from either a midfoot region or a heel region of the insole portion. Each strap also includes a distal end. The at least two straps are then folded relative to the insole portion and the distal end of each strap is passed through the aperture in the insole portion. The distal end of each strap passed through the aperture is then folded in opposite directions relative to the insole portion and secured to the insole portion.
In another exemplary embodiment, the method for making a unitary insole/strap layer of an article of footwear comprises forming a patterned base having an insole portion and a strap portion. The insole portion comprises a heel portion and a toe portion and the strap portion extends between the heel portion and the toe portion. The toe portion is then wrapped over and around the heel portion until a heel facing edge of the toe portion is aligned with a toe facing edge of the heel portion such that the toe portion and heel portion form the insole portion and the strap portion is arched over the insole portion.
The present disclosure also provides articles of footwear that include the insole/strap layers described above secured to an outsole structure.
The figures depict embodiments for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles described herein, wherein:
Referring to
Continuing to refer to
Referring to
The article 10 also comprises a unitary insole/strap layer 100 made in accordance with the methods disclosed herein. The insole/strap layer 100 is used to provide an additional layer of padding for the foot and/or to hold the foot relative to the sole structure 50. The insole/strap layer 100 includes an insole portion 102 in the general outline of a foot, and a strap portion, e.g., one or more straps. The strap portion is integrally formed into the insole portion 102 and then wrapped around the insole portion 102 to form one or more arches that are sufficient to receive a foot. In the embodiment of
In some embodiments, the insole portion 102 and the strap portion, e.g., the first strap 110 and the second strap 120, may comprise one or more layers of a flexible material sufficient to cushion a foot and fold from a two-dimensional patterned base to the three-dimensional insole/strap layer 100. Examples of such flexible material include, but are not limited to, neoprene, T-Foam, Poron, Flat Knit, Leather, Synthetic Leather, HM Millon LQ, Woven, Circular Knit, OGRS-006, BRS-1000, BASF-9339 TPU RUBBER, RP Printed TPU, Flat Knit TPU yarns, Circular Knit TPU yarns, & Woven TPU yarns. In the exemplary embodiment shown, the insole portion 102 and the strap portion comprise a single layer of neoprene. The shape of the straps 110 and 120 may vary. For example, the straps may be rectangular in shape as shown. Examples of other shapes include, but are not limited to, rounded shapes, square shapes, polygonal shapes, regular shapes, irregular shapes as well as any other shapes.
In addition, while two straps are illustrated in the embodiment of
Referring now to
It is noted that in some embodiments, the thong 130 can be configured to insert between two adjacent toes of a foot. For example, in one embodiment, the aperture 104 in the insole portion 102 can be positioned so that the thong 130 is inserted between the hallux (big toe) and the index toe of a foot. In another embodiment, the aperture 104 in the insole portion 102 can be positioned so that the thong 130 could be inserted between other adjacent toes of a foot. For example, the aperture 104 in the insole portion 102 can be positioned so that the thong 130 could be inserted between the index toe and the middle toe. In still other embodiments, the aperture 104 in the insole portion 102 can be positioned so that the thong 130 could be inserted between the middle toe and the fourth toe, or the aperture 104 in the insole portion 102 can be positioned so that the thong 130 could be inserted between the fourth toe and the little toe.
To secure the thong 130 to the insole portion 102, the distal ends 114 and 124 of the straps 110 and 120 forming the thong 130 that have passed through the aperture 104 are folded back in opposite directions so that top surfaces 110a and 120a of the straps 110 and 120 respectively move towards the bottom surface 102b of the insole portion 102, as shown in
Referring now to
In some embodiments, the insole portion 212 and the strap portion 230 may comprise one or more layers of a flexible material sufficient to cushion a foot and fold from a two-dimensional patterned insole to the three-dimensional insole/strap layer 210. Examples of such flexible material include, but are not limited to, neoprene, T-Foam, Poron, Flat Knit, Leather, Synthetic Leather, HM Millon LQ, Woven, Circular Knit, OGRS-006, BRS-1000, BASF-9339 TPU RUBBER, RP Printed TPU, Flat Knit TPU yarns, Circular Knit TPU yarns, & Woven TPU yarns. In the exemplary embodiment shown, the insole portion 212 and the strap portion 230 comprise a single layer of neoprene. The shape of the strap portion 230 may vary. For example, the strap portion may be rectangular in shape as shown. Examples of other shapes include, but are not limited to, rounded shapes, square shapes, polygonal shapes, regular shapes, irregular shapes as well as any other shapes.
Referring to
While the illustrated embodiments show straps that are rectangular in shape, the straps can come in a number of different shapes, including but not limited to rounded shapes, rectangular shapes, polygonal shapes, regular shapes, irregular shapes as well as any other shapes. It will be understood that while the foregoing description is for a single shoe for one foot, the same features can be provided in a mirror image shoe for the wearer's other foot. Moreover, while the present disclosure describes various embodiments of an insole/strap layer, it will be understood that various modifications can be made to the embodiments of the present disclosure herein without departing from the spirit and scope thereof. Therefore, the above description should not be construed as limiting the disclosure, but merely as embodiments thereof. Those skilled in the art will envision other modifications within the scope and spirit of the disclosure as defined by the claims appended hereto.
Claims
1. A method for making a unitary insole/strap layer of an article of footwear, the method comprising:
- forming a patterned base having an insole portion and a strap portion, wherein the insole portion includes an aperture in a toe region and the strap portion comprises at least two straps each extending from either a midfoot region or a heel region of the insole portion and having a distal end;
- folding the at least two straps relative to the insole portion and passing the distal end of each strap through the aperture;
- folding the distal end of each strap passed through the aperture in opposite directions relative to the insole portion; and
- securing the folded distal end of each strap to the insole portion.
2. The method according to claim 1, wherein the at least two straps comprise a first strap and a second strap, wherein the first strap has a first side and a second side and the second strap has a first side and a second side, and wherein folding the two straps relative to the insole portion comprises:
- folding the first strap to form a first arch;
- folding the second strap to form a second arch; and
- aligning the distal end of each strap so that the second side of the first strap is adjacent to the second side of the second strap to form a thong.
3. The method according to claim 2, wherein folding the distal end of each strap in opposite directions relative to the insole portion comprises:
- folding the distal end of the first strap passed through the aperture toward the insole portion; and
- folding the distal end of the second strap passed through the aperture toward the insole portion.
4. The method according to claim 3, wherein securing the folded distal end of each strap to the insole portion comprises;
- applying an adhesive to the first side of the folded distal end of the first strap adjacent the insole portion and applying pressure to the distal end of the first strap and the insole portion; and
- applying an adhesive to the first side of the folded distal end of the second strap adjacent the insole portion and applying pressure to the distal end of the second strap and the insole portion.
5. The method according to claim 1, wherein securing the folded distal end of each strap to the insole portion comprises applying an adhesive to the distal end of each strap adjacent the insole portion and applying pressure to the distal end of each strap and the insole portion.
6. The method according to claim 1, wherein the at least two straps are formed as substantially rectangular shapes.
7. The method according to claim 1, wherein the patterned base is made from a flexible material.
8. The method according to claim 7, wherein the flexible material comprises neoprene.
9. An article of footwear comprising:
- an outsole structure; and
- a unitary insole/strap layer secured to the outsole structure, wherein the insole/strap layer comprises an insole portion and a strap portion, wherein the insole portion includes an aperture in a toe region, wherein the strap portion comprises at least two straps each extending from either a midfoot region or a heel region of the insole portion and having a distal end, wherein the at least two straps are folded relative to the insole portion and the distal end of each strap is passed through the aperture and the distal end of each strap passed through the aperture is folded in opposite directions relative to the insole portion and secured to the insole portion.
10. The article of footwear according to claim 9, wherein the insole/strap layer is made from a flexible material.
11. The article of footwear according to claim 10, wherein the flexible material comprises neoprene.
12. A method for making a unitary insole/strap layer of an article of footwear, the method comprising:
- forming a patterned base having an insole portion and a strap portion, wherein the insole portion comprises a heel portion and a toe portion and the strap portion extends between the heel portion and the toe portion; and
- wrapping the toe portion over and around the heel portion or the heel portion over and around the toe portion until a heel facing edge of the toe portion is aligned with a toe facing edge of the heel portion, such that the toe portion and heel portion form the insole portion and the strap portion is arched over the insole portion.
13. The method according to claim 12, wherein a bottom surface of the insole portion can be secured to an outsole structure of an article of footwear.
14. The method according to claim 12, wherein the strap portion is substantially rectangular in shape.
15. The method according to claim 12, wherein the patterned base is made from a flexible material.
16. The method according to claim 15, wherein the flexible material comprises neoprene.
17. An article of footwear comprising:
- an outsole structure; and
- an insole/strap layer secured to the outsole structure, wherein the insole/strap layer comprises an insole portion and a strap portion, wherein the insole portion comprises a heel portion and a toe portion and the strap portion extends between the heel portion and the toe portion such that the toe portion is wrapped over and around the heel portion or the heel portion is wrapped over and around the toe portion until a heel facing edge of the toe portion is aligned with a toe facing edge of the heel portion, such that the toe portion and heel portion form the insole portion and the strap portion is arched over the insole portion.
18. The article of footwear according to claim 17, wherein the insole/strap layer is made from a flexible material.
19. The article of footwear according to claim 18, wherein the flexible material comprises neoprene.
Type: Application
Filed: Dec 8, 2016
Publication Date: Jun 14, 2018
Inventor: Aaron K. Seid (Beaverton, OR)
Application Number: 15/373,355