FOOTWEAR AND LAST
A footwear last (1) comprising a hind foot section and a forefoot section joined by a midfoot section. The forefoot section is defined by a three reference points which define a reference point circumference (9, FIGS. 1 and 2). The hind foot section is equivalent to a predetermined shoe (20) size (37) while the forefoot section is equivalent to a shoe (20) size (37) between 2 and 3 sizes larger than said predetermined shoe (20) size (37) using the Paris point system. An article of footwear made using said last (1) comprises an upper (22), a midsole (30, FIG. 6) and an outer sole (40). The upper (22) has an outer layer (21) and an inner layer, which inner layer comprises an elastic panel (25) arranged to cover the first and/or fifth metatarsophalangeal joint of a user. The midsole (30) has a first layer and a second layer, wherein the first layer is arranged to line the footbed of the shoe (20) and the second layer is arranged to provide a shock absorbing layer. The outer sole (40) is secured to the upper (22) on assembly to complete the article of footwear. FIG. 3 A footwear last (1) comprising a hind foot section and a forefoot section joined by a midfoot section. The forefoot section is defined by a three reference points which define a reference point circumference (9, FIGS. 1 and 2). The hind foot section is equivalent to a predetermined shoe (20) size (37) while the forefoot section is equivalent to a shoe (20) size (37) between 2 and 3 sizes larger than said predetermined shoe (20) size (37) using the Paris point system. An article of footwear made using said last (1) comprises an upper (22), a midsole (30, FIG. 6) and an outer sole (40). The upper (22) has an outer layer (21) and an inner layer, which inner layer comprises an elastic panel (25) arranged to cover the first and/or fifth metatarsophalangeal joint of a user. The midsole (30) has a first layer and a second layer, wherein the first layer is arranged to line the footbed of the shoe (20) and the second layer is arranged to provide a shock absorbing layer. The outer sole (40) is secured to the upper (22) on assembly to complete the article of footwear.
The present invention relates to articles of footwear suitable for users with foot deformities. In particular, but not exclusively, hallux valgus, frequently known as a bunion.
In anatomy, the hallux is the first toe or big toe. Hallux valgus is a deformity of the foot caused by a deviation of the first metatarsal bone. It is often accompanied by the formation of a bursa over the first metatarsophalangeal joint. Bursitis, that is, inflammation of the bursa causes severe pain and/or discomfort. Over time, the sesamoid bones beneath the first metatarsal may also become deviated. Further, hallux valgus may also be accompanied by discomfort when pressure is applied to the first metatarsophalangeal joint or said joint moves, or by arthritis of the first metatarsophalangeal joint and/or altered range of motion of said joint.
According to Nix, Smith and Vicenzino (J Foot Ankle Res. 2010; 3:21) prevalence of hallux valgus is on average 23% for adults between the ages of 18 and 65 and 35.7% in people over the age of 65. Prevalence is higher in females and also increases with age.
Treatment for hallux valgus can be either surgical or non-surgical. Non-surgical-options include use of, among others, insoles, bunion pads or splints and toe spacers. In addition, hallux valgus sufferers often wear wider footwear or buy a larger size to accommodate the hallux valgus. Nevertheless, in more extreme cases, surgical intervention may be necessary.
Regardless of whether poorly fitting footwear, such as shoes a size larger than those required by a person or shoes that fit the toes too tightly, cause hallux valgus, it is widely agreed that poorly fitting shoes exacerbate bunions. Currently, footwear options suitable for hallux valgus sufferers include wider fit shoes, typically flat. Some alternatives include extra cushioning to alleviate foot pain while other orthopaedic alternatives may include toe spacers.
Although footwear suitable for hallux valgus sufferers may be available, people with hallux valgus often have secondary and/or additional foot problems. For example, hallux valgus is often accompanied or exacerbated by foot over-pronation, that is, placing most of a person's weight on the inside edge of the foot when walking or running thereby causing the foot to tilt inwards.
A tailor's bunion or bunionette is a deformity of the foot caused by a deviation of the fifth metatarsal bone. It can also be accompanied by a bursa, arthritis and/or altered function of the fifth metatarsophalangeal joint and/or deviation of the relevant sesamoid bones. Prevalence of bunionettes has not been established.
In shoemaking, a last is a model or mould for shaping or repairing footwear shaped to replicate or resemble the human foot. Traditionally, lasts were hand carved in wood; however, in modern manufacture, lasts are typically made from a resin.
Historically, footwear was custom-made and handcrafted by shoemakers. Modern footwear manufacture is generally based on mass production of footwear assembled on a last.
Current footwear manufacture involves cutting of suitable material to produce a shape or shapes which will eventually become the footwear upper. Once the shape or shapes is or are cut, the material components are sewn together and, if necessary, said material components are treated and any embellishments or fastenings attached. Once a footwear upper has been created, said uppers are assembled on a last and a lasting sock is secured to the edge of the uppers to hold the upper in place and mould the article of footwear into the shape of a foot. Subsequently, either a heel or an outsole is secured to the underside of the lasting sock. If the heel, if any, is secured first, the outsole is then attached. Alternatively, if the outsole is secured first and the shoe comprises a heel, said heel is attached. Additional treatment of the sole or footwear upper, if required, is then carried out; for example, most manufacturers secure an insole and an internal or lining sock including a brand name and/or logo across the interior length of the shoe. In some instances, a midsole, if any, is secured to the lasting sock before the shoe is lasted, that is assembled on the last, or to the lining sock, when said lining sock is secured. Finally, the shoe is subjected to quality control and brushing (or similar treatments) and packaged. Certain types of shoe such as closed shoes and/or welted shoes require additional manufacturing steps.
Footwear manufacturers have tried to accommodate and/or cater for people who suffer from feet problems such as hallux valgus or bunionettes. However, fashion-led shoe construction is seldom altered and, when it is, the results are typically ineffective from a comfort and/or design perspective. Further, even when suitable footwear is produced, said footwear is generally produced to address a single problem, for example, flat feet or hallux valgus.
The present invention seeks to provide footwear for people with hallux valgus and/or bunionettes. Further, the present invention seeks to provide footwear suitable for hallux valgus sufferers having secondary and/or additional foot problems.
According to a first aspect of the present invention, there is provided an article of footwear for a hallux valgus sufferer, the article of footwear comprising: an upper having an outer layer and an inner layer, the inner layer comprising an elastic panel arranged to cover the first and/or fifth metatarsophalangeal joint of a user; a midsole comprising a first layer and a second layer, wherein the first layer is arranged to line the footbed of the shoe and the second layer is arranged to provide a shock absorbing layer; and an outer sole arranged to engage the ground, the outer sole being secured to the upper on assembly to complete the article of footwear.
Preferably, the elastic panel is made from a layer of polychloroprene. More preferably, the polychloroprene is foamed polychloroprene.
Advantageously the article of footwear further comprises a third layer located between the first and second layers, which third layer is arranged to provide additional support for a ball of a foot. In a preferred embodiment, the midsole further comprises an anti-pronation element. In a further preferred embodiment the anti-pronation element is made from polyurethane memory foam.
In yet another embodiment, the first, second and third layers are made from urethane memory foam. Preferably, the first layer is made of a urethane memory foam having higher compression force deflection properties and resilience properties than the compression force deflection properties and resilience properties of the urethane memory foam of the second layer. More preferably, the third layer is made of a urethane memory foam harder than the urethane memory foam of the first layer and higher resilience properties than the urethane memory foam of the second layer.
Preferably, the article of footwear further comprises an insole having a lining arranged to accommodate a foot. More preferably, the article of footwear further comprises a shock resistant heel-piece.
In yet another preferred embodiment, the article of footwear is a slingback, a court shoe, a boot, a peep toe shoe or a ballerina flat.
According to a second aspect of the present invention, there is provided a footwear last comprising a hind foot section and a forefoot section joined by a midfoot section; the forefoot section is defined by a first, second and third reference points having a reference point circumference; wherein the hind foot section is equivalent to a predetermined shoe size determined by using the Paris point footwear sizing system and the forefoot section has a reference point circumference equivalent to a shoe size between 1.5 and 3.5 sizes determined by using the Paris point footwear sizing system larger than said predetermined shoe size.
Advantageously, the reference point circumference of the last measures between 220 mm and 260 mm. In a preferred embodiment, a European size 37 as determined by using the Paris point footwear sizing system has a reference point circumference of between 230 mm and 235 mm and reference point circumference increases or decreases by 2.5 mm per half size.
Preferably, the footwear last comprises a tread surface, which tread surface measures between 80 mm and 85 mm. More preferably, the tread surface measures between 81.5 mm and 82.5 mm.
In a preferred embodiment, the footwear last has a toe depth of between 20 mm and 25 mm.
Preferred embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:
In the drawings, like parts are denoted by like reference numerals.
Referring now to
The front portion of the last is defined by a first point representing the first metatarsophalangeal joint A of a foot and a second point representing the fifth metatarsophalangeal joint B of a foot. An imaginary line on the base of the last between the first and second points is known as the bottom support surface or tread point 2 and corresponds to the ball of a foot. The circumference of the last between these joint points defines the ball girth 8. This anterior portion of the last defines the toe box, that is, the portion arranged to cover and protect the toes in a shoe. If a last 1 is for manufacturing high heels, the base of the heel is on a horizontal plane higher than that of the tread point 2. The vertical distance between the base of the heel portion and the tread point 2 is known as heel elevation 6 while the curve defined by the outline of the contoured base of the last is called heel gradient or pitch. According to an embodiment of the present invention, a last is graded across European shoe sizes 36 to 42 and is shaped to accommodate a foot with a bunion and/or bunionette. When designing a last in accordance with European tradition, it is generally accepted that three traditional reference points will be used as a marker on the last instead of the ball girth 8. These reference points are selected for ease of visibility on the last and allow for accurate measurements when the lasts are graded across different sizes. These reference points are located on either side of the last 1 and the top of the last and are placed a little closer to the heel relative to points A and B and the ball girth. The sizing measurements consist of measuring the circumference 9 around these reference points, this dimension will be referred to as reference point circumference 9 and is typically located between the standard ball girth 8 and instep girth (not shown). Thus, the reference point circumference 9 is located around 0.5 to 20 mm higher relative to the ball girth 8. A last in accordance with an embodiment of the present invention comprises a reference point circumference 9, a ball girth 8 and a bottom support surface 2 width greater than those used in standard lasts. Specifically, for a European size 37, the ball girth is between 227 mm and 229 mm while the tread point or bottom support surface 2 measures between 79 mm and 82.5 mm. The bottom support surface 2 provides an increase between 1 and 4 mm in relation to a standard tread point for an equivalent standard last, which is typically around 76-78 mm. Further, the reference point circumference 9 for a European size 37 is between 223 mm and 234 mm, and increases or decreases by 2 to 2.5 mm per half size. This represents an increase in reference point circumference, usually in a range of 215 to 220 mm and generally about 218 mm, of between 9 and 16 mm over a standard last. Accordingly, the reference point circumference 9 of the last of the present invention is increased by the equivalent of two to three European shoe sizes relative to the traditional reference point circumference of a standard last of the same type. However, the overall appearance of a shoe produced using the last of the present invention is not significantly altered. Finally, toe depth 5 is also increased for the purposes of this invention, from a standard toe depth of 14 mm to a depth of 20-21 mm.
The length 11 of a last for a heeled European size 37 shoe is approximately between 253 and 263 mm increasing or decreasing by 3.3 mm per half a size assuming the heel elevation 6 is approximately between 4 and 9 cm. The last 1 usually has a toe spring 3 in a range of 9 to 12 mm. Development of the last 1 of the present invention was carried out by hand-carving traditional wooden lasts and then using said wooden lasts to mould a final last in polyethylene resin. Intermediate adjustments were carried out by shaving the traditional wooden lasts with a rasp and or adding small amounts of putty to the lasts. After each adjustment, a revised version of the wooden last was made. Subsequently, a corresponding polyethylene version was also made. To manufacture a shoe in accordance with a preferred embodiment of the present invention described below in relation to
As mentioned above in relation to
The following table shows four examples of a size 37 last according to the present invention:
Examples 1, 2 and 3 relate to lasts having a heel elevation of between 40 and 80 mm. Example 4 relates to a last arranged to be used in the manufacture of flat footwear (i.e. footwear having a heel elevation of no more than 25 mm).
Referring now to
In use, the elastic panel 25 is arranged to provide cushioning and protection over the first metatarsophangeal joint while remaining invisible from the outside of the assembled shoe 20. When the shoe 20 is not in use, the elastic panel 25 returns to its original shape. Referring now to
Referring now to
Referring now to
The cushioning layer 32 is provided under the lining 29. In this embodiment the cushioning layer 32 is made of PORON™ Plus Cushioning memory foam having a thickness of 3 mm. This cushioning layer 32 is lightweight and flexible and combines a cushioning effect with energy return to protect joints and soft tissue. The cushioning layer 32 is adhered to the length of the leather lining 29 and its outline is contoured to provide a cut-out portion arranged to receive the anti-pronation element 33. Further, the contoured shape of the cushioning layer 32 provides clearance over the front and back sections of the lasting sock 39a and 39b. The edge of the anterior portion of the cushioning layer is skived to maximise space for the wearer's toes in the toe box. The contoured edges of the cushioning layer 32 are also skived. In this example the shoe 20 comprises a heel 42 and therefore the base of the foot bed corresponds to the ball of a wearer's foot. The middle layer 34 is contoured to provide additional cushioning for the ball of a foot. The memory foam used in this instance is PORON™ Slow Rebound Soft. This memory foam has lower compression force deflection and resilience properties than those of the memory foam used for the cushioning layer 32. As a result, the middle layer 34 provides additional stability and improves balance of a wearer. The middle layer 34 has a thickness of 2 mm and, in use, is adhered to the base layer 36 as described below. The anterior edge of the toe portion of the middle layer 34, defined by the broken line shown in
By combining a base 36 and a middle layer 34 on the front portion of the lasting sock 39a, the shoe 20 of the present invention allows the properties of both layers 34, 36 to merge thus providing excellent shock absorption, stability and comfort for joints and soft tissue. The combined layers 34, 36 distribute pressure evenly thereby improving support and stability. Further, each material of the midsole 30 returns to its original shape after use and moulds to a foot when worn; therefore the shoe 20 provides a customised fit every wear. It should be noted that although the middle 34 and base layers 36 of the midsole 30 in this embodiment are provided as a double layer, either layer could be absent or both layers could be integral.
As mentioned above, hallux valgus is typically worsened by over-pronation, whether to account for the deviated bones, due to pes planus (flat feet) or both. In a preferred embodiment, the present invention comprises an element 33 arranged to prevent over-pronation. As shown in
Although the article of footwear described above comprises an elastic panel arranged to cover the first metatarsophalangeal joint of a user, it should be obvious to the skilled person that a second panel could be arranged to cover the fifth metatarsophalangeal joint of a user. Further, it should also be apparent that an article of footwear may comprise a single elastic panel arranged to cover the fifth metatarsophalangeal joint. Moreover, it should also be clear that an article of footwear may include a lining made from polychloroprene or a toe box lining made from polychloroprene, in this case, the lining would be the elastic panel.
It should be apparent to the skilled person that materials other than polychloroprene or the specific polychloroprene described above could be used to manufacture the elastic panel. For example, NEOGREEN™, Guayule, THERMOCLINE™ material from Fourth Element Limited or ARIAPRENE™ synthetic rubber material.
Additionally, it should also be apparent that the elastic modulus of the material used could be different to that described above and that an elastic modulus lower than 50 MPa (0.05 GPa) could be suitable.
Moreover, it should be clear that the pattern for the elastic panel could have a universal size or could be sized in accordance with numerical sizes and/or half sizes.
In addition, it should be obvious that the midsole described above could have one integral layer comprising two layers of memory foam or two instead layers of the three layer construction described above.
It should also be apparent that any suitable alternative to the urethane memory foams described above could be used.
Although specific dimensions for an anti-pronation element have been defined, it should be clear to a skilled person that an anti-pronation element could be manufactured in a range of different sizes comprising a length of 5 to 7.5 cm, a width of 3 to 4 cm and a height of 2 to 8 mm.
Further, the last and article of footwear described above have a specific heel elevation and a heel gradient; however, it should be obvious that both heel elevation and gradient can be varied to produce, for example, a flat shoe having no heel elevation or gradient or a minimal heel elevation and gradient. It should also be apparent to a skilled person that the last length mentioned above is an example and is variable depending on heel elevation and heel gradient. In addition, the lasting sock construction described could be replaced with any other suitable lasting sock construction.
Although the shoe described in relation to the above figures has a pointed toe, it should be clear to a skilled person that this is not necessary and that the toe box may have any shape, for example almond toe, round toe or peep toe. Further, it should also be clear that the invention could be applied to any other type of footwear such as boots, slingbacks, mules, sandals, flat shoes, etc. It should also be obvious that types of shoes that do not have a closed heel construction, such as slingbacks or mules may not include an anti-pronation element, depending on the shoe design. Further, the elastic panel may be cut or split in sandals and other types of shoe.
Claims
1. An article of footwear for a hallux valgus sufferer, the article of footwear comprising:
- an upper having an outer layer and an inner layer, the inner layer comprising an elastic panel arranged to cover the first and/or fifth metatarsophalangeal joint of a user;
- a midsole comprising a first layer and a second layer, wherein the first layer is arranged to line the footbed of the shoe and the second layer is arranged to provide a shock absorbing layer; and
- an outer sole arranged to engage the ground, the outer sole being secured to the upper on assembly to complete the article of footwear.
2. The article of footwear according to claim 1, wherein the elastic modulus of the elastic panel is between two and three orders of magnitude lower than the elastic modulus of a material of the outer layer.
3. The article of footwear according to claim 1, wherein the elastic panel is made from a layer of polychloroprene.
4. The article of footwear according to claim 3, wherein the polychloroprene is foamed polychloroprene.
5. The article of footwear according to claim 1, further comprising a third layer located between the first and second layers, which third layer is arranged to provide additional support for a ball of a foot.
6. The article of footwear according to claim 1, the midsole further comprising an anti-pronation element.
7. The article of footwear according to claim 6, wherein the anti-pronation element is made from polyurethane memory foam.
8. The article of footwear according to claim 5, wherein the first, second and third layers are made from urethane memory foam.
9. The article of footwear according to claim 8, wherein the first layer is made of a urethane memory foam having higher compression force deflection properties and resilience properties than the compression force deflection properties and resilience properties of the urethane memory foam of the second layer.
10. An The article of footwear according to claim 8, wherein the third layer is made of a urethane memory foam harder than the urethane memory foam of the first layer and higher resilience properties than the urethane memory foam of the second layer.
11. The article of footwear according to claim 1, further comprising an insole having a lining arranged to accommodate a foot.
12. The article of footwear according to claim 1, further comprising a shock resistant heel-piece.
13. The article of footwear according to claim 1, wherein said article of footwear is a slingback, a court shoe, a boot, a peep toe shoe or a ballerina flat.
14. A footwear last comprising a hind foot section and a forefoot section joined by a midfoot section; the forefoot section is defined by first, second and third reference points having a reference point circumference; wherein the hind foot section is equivalent to a predetermined shoe size determined by using the Paris point footwear sizing system and the forefoot section has a reference point circumference equivalent to a shoe size between 2 and 3 sizes determined by using the Paris point footwear sizing system larger than said predetermined shoe size.
15. The footwear last according to claim 14, wherein the reference point circumference of a European size 37 as determined by using the Paris point footwear sizing system last measures between 217 mm and 260 mm.
16. The footwear last according to claim 14, wherein the reference point circumference of the last measures between 9 mm and 20 mm more than the reference point circumference of a standard last.
17. The footwear last according to claim 16, wherein the reference point circumference the last measures between 9 mm and 16 mm more than the reference point circumference of a standard last.
18. The footwear last according to claim 14, wherein a European size 37 as determined by using the Paris point footwear sizing system has a reference point circumference of between 230 mm and 235 mm and reference point circumference increases or decreases by 2 mm to 2.5 mm per half size.
19. The footwear last according to claim 14, wherein the footwear last comprises a tread surface, which tread surface measures between 79 mm and 85 mm.
20. The footwear last according to claim 19, wherein the tread surface measures between 79 mm and 82.5 mm.
21. The footwear last according to claim 14, wherein the footwear last has a toe depth of between 20 mm and 25 mm.
Type: Application
Filed: Feb 27, 2018
Publication Date: Jan 16, 2020
Inventor: Lisa KAY (London)
Application Number: 16/487,963