SOCK-LINED FOOTWEAR AND ASSOCIATED MANUFACTURING METHOD

Abstract

The present disclosure concerns a sock-lined footwear upper defining a foot-receiving cavity and comprising a sock having an outer surface and an inner surface at least partially delimiting the foot-receiving cavity and comprising a heel counter area; an outer layer covering at least partially the outer surface of the sock; and a heel pad at least partially secured to the inner surface of the sock in the heel counter area thereof. The present disclosure also concerns such a heel pad, an item of sock-lined footwear comprising such an upper and a method for manufacturing such an item of sock-lined footwear.

Description

PRIOR APPLICATION

The present application claims priority from U.S. provisional patent application No. 62/829,224, filed on Apr. 4, 2019, and entitled “Sock-lined footwear and associated manufacturing method”, the disclosure of which being hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The technical field relates to footwear and, more particularly, to sock-lined footwear, and to associated manufacturing methods.

BACKGROUND

Sock-lined footwear, such as boots, is used for instance in outdoor recreational activities as well as in a number of industrial and professional uses. One type of sock-lined footwear includes an inner layer—or inner sock—fully covered by an outer layer of waterproof material, such as vulcanized rubber or polyurethane. This double-layered construction provides a light-weight boot that fits the foot of the wearer.

It has been noticed that when the wearer walks with their item of sock-lined footwear, their foot tends to move out of a foot-receiving cavity of the item of sock-lined footwear. This phenomenon is sometimes called heel-flopping. Such a displacement of the foot within the foot-receiving cavity, by being repeated, can injure the wearer, for instance by irritating the skin of the wearer. Moreover, the wearer might also have to regularly reposition their foot in the foot-receiving cavity, which is not satisfactory. In view of the above, there is a need for sock-lined footwear which would be able to overcome or at least minimize some of the above-discussed prior art concerns.

BRIEF SUMMARY

It is therefore an aim of the present invention to address the above-mentioned issues.

According to a general aspect, there is provided a sock-lined footwear upper defining a foot-receiving cavity and comprising: a sock having an outer surface and an inner surface at least partially delimiting the foot-receiving cavity and comprising a heel counter area; an outer layer covering at least partially the outer surface of the sock; and a heel pad at least partially secured to the inner surface of the sock in the heel counter area thereof.

According to another general aspect, there is provided a heel pad for a sock-lined footwear upper comprising an inner sock having an inner surface at least partially delimiting a foot-receiving cavity and comprising a heel counter area, the heel pad having a length and a height and comprising: an outer surface securable to the inner surface of the inner sock in the heel counter area thereof; an opposed inner surface; and at least one heel-abutting portion protruding forwardly and creating at least one protrusion on the inner surface, the at least one heel-abutting portion extending along at least a portion of the length, the heel-abutting portion being shaped and dimensioned to extend at least partially above a heel of a user's foot at least partially engaged into the foot-receiving cavity when the heel pad is at least partially secured to the inner sock.

According to another general aspect, there is provided an item of sock-lined footwear comprising: an outsole having an inner surface and an outer surface; and a sock-lined footwear upper according to the present disclosure, the sock-lined footwear upper extending from the outsole, the heel pad being adjacent to the outsole.

According to another general aspect, there is provided a method for manufacturing an item of sock-lined footwear, the method comprising: providing a heel pad and a sock having an outer surface and an inner surface comprising a heel counter area; securing the heel pad to the inner surface of the sock, in the heel counter area thereof; providing a footwear last having an outer surface with a heel pad-receiving recess formed therein; positioning the sock over the footwear last with the heel pad at least partially received in the heel pad-receiving recess; covering at least partially the outer surface of the sock with a vulcanizable material; and forming at least partially an upper of the item of sock-lined footwear with said vulcanizable material.

According to another general aspect, there is provided a method for manufacturing a sock-lined footwear comprising securing a heel pad to an inner surface of a sock, in a heel counter area, providing a last having an outer surface with a heel pad recess defined therein, positioning the sock over the last with the heel pad being received in the heel pad recess; covering an outer surface of the sock with a vulcanizable material and forming an upper of the sock-lined footwear with said vulcanizable material.

According to another general aspect, there is provided a sock-lined footwear upper defining a foot-receiving cavity and comprising a sock having an outer surface and an inner surface comprising a heel counter area, an outer layer at least partially bonded to the outer surface of the sock, and a heel pad secured to the inner surface of the sock in the heel counter area.

According to yet another general aspect, there is provided sock-lined footwear comprising an outsole having an inner surface and an outer surface; and an upper according to the present disclosure, the upper extending from the outsole.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional side view of an item of sock-lined footwear having a heel pad in accordance with one embodiment;

FIG. 2 is a front elevation view of the heel pad illustrated in FIG. 1;

FIG. 3 is a right-side elevation view of the heel pad of FIG. 2;

FIG. 4 is a sectional view of the heel pad of FIG. 2 taken along cross-section lines A-A;

FIG. 5 is a front elevation view of a heel pad in accordance with another embodiment;

FIG. 6 is a sectional view of the heel pad of FIG. 5 taken along cross-section lines B-B;

FIG. 7 is a sectional view of the heel pad of FIG. 5 taken along cross-section lines C-C;

FIG. 8 is a front elevation view of a heel pad in accordance with another embodiment;

FIGS. 9 and 10 are schematic drawings of a mold assembly for forming the heel pad of FIG. 2, the mold assembly being configured respectively in a closed configuration and in an open configuration;

FIG. 11 is a schematic drawing of a footwear last for forming the sock-lined footwear of FIG. 1; and

FIG. 12 is a flowchart representing steps of a method for manufacturing an item of sock-lined footwear, in accordance with an embodiment.

DETAILED DESCRIPTION

In the following description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures are optional and are given for exemplification purposes only.

Moreover, it will be appreciated that positional descriptions such as “above”, “below”, “forward”, “rearward”, “left”, “right” and the like should, unless otherwise indicated, be taken in the context of the figures and correspond to the position and orientation of the sock-lined footwear and corresponding parts when being worn by a user, with the “front” corresponding to a position closer to a toe portion of an item of sock-lined footwear and the “back” corresponding to a position closer to a heel portion of the item of sock-lined footwear. Positional descriptions should not be considered limiting.

To provide a more concise description, some of the quantitative expressions given herein may be qualified with the term “about”. It is understood that whether the term “about” is used explicitly or not, every quantity given herein is meant to refer to an actual given value, and it is also meant to refer to the approximation to such given value that would reasonably be inferred based on the ordinary skill in the art, including approximations due to the experimental and/or measurement conditions for such given value.

It is to be understood that the phraseology and terminology employed herein is not to be construed as limiting and are for descriptive purpose only. The principles and uses of the teachings of the present disclosure may be better understood with reference to the accompanying description, figures and examples. It is to be understood that where the claims or specification refer to “a” or “an” element, such reference is not be construed that there is only one of that element. It is to be understood that where the specification states that a component, feature, structure, or characteristic “may”, “might”, “can” or “could” be included, that particular component, feature, structure, or characteristic is not required to be included.

Methods of the present invention may be implemented by performing or completing manually, automatically, or a combination thereof, selected steps or tasks. The term “method” may refer to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the art to which the invention belongs. Meanings of technical and scientific terms used herein are to be commonly understood as by one of ordinary skill in the art to which the invention belongs, unless otherwise defined.

The present invention may be implemented in the testing or practice with methods and materials equivalent or similar to those described herein.

Sock-Lined Footwear Structure

Referring now to the drawings, and more particularly to FIG. 1, there is shown an item of sock-lined footwear 100 (or double-layered composite footwear 100), in accordance with one embodiment. The item of sock-lined footwear 100 includes an outsole 102 and an upper 104 (or sock-lined footwear upper 104 or double-layered composite footwear upper 104) extending upwardly—substantially vertically, in the embodiment shown—from the outsole 102 and, in some embodiments, secured to the outsole 102. The upper 104 comprises an outer layer 120 (or waterproof layer 120) extending upwardly from the outsole 102.

In the embodiment shown, the upper 104 includes a curved sidewall 106 which defines, with the outsole 102, a foot-receiving cavity 108 sized and shaped to receive at least partially a foot of a wearer. The foot-receiving cavity 108 extends above the outsole 102. It is to be noted that in the following description, unless otherwise stated, the terms “inner” and “outer” should be understood relatively to the foot-receiving cavity 108.

The outsole 102 includes an inner (top) surface 110 (or foot-facing surface 110) which faces upwardly towards the upper 104 and into the foot-receiving cavity 108 and an outer (bottom) surface 112 (or ground-facing surface 112), opposite the inner surface 110, that is designed to contact, either directly or indirectly, a ground when the item of sock-lined footwear 100 is worn. In the illustrated embodiment, the item of sock-lined footwear 100 is a boot so that the upper 104 is dimensioned to cover an ankle and at least a portion of a shin of the wearer.

In the embodiment shown, the item of sock-lined footwear 100 further comprises a sock 114 (or footwear inner layer or inner sock) having an outer surface 116 (or waterproof layer-facing surface) and an opposed inner surface 118 (foot-facing surface). The sock 114 is inserted in the foot-receiving cavity 108, defined by the outer layer 120 of the upper 104 and the outsole 102, and is superposed to the inner surfaces of the outer layer 120 and the outsole 102 to at least partially line same. The outer layer 120 (and more particularly an inner surface thereof) of the upper 104 is at least partially bonded—for instance molded or vulcanized or secured by any other suitable mechanical fasteners—onto the outer surface 116 of the sock 114.

The item of sock-lined footwear 100 further comprises a heel pad 122 secured to the inner surface 118 of the inner sock 114, adjacent to (or in the vicinity of) the outsole 102 (of a rear portion or heel-supporting portion thereof, in the embodiment shown) when the sock 114 is inserted in the foot receiving cavity 108.

In the embodiment shown, the inner sock 114 is shaped and sized to receive at least partially the wearers foot and to extend upwardly over the ankle and cover at least a portion of the wearer's shin.

The inner sock 114 can be at least partially made of a fabric material, such as nylon, cotton, canvas, fleece, insulation, wool, mesh, felt or other selected materials.

The inner surface 118 of the sock 114 comprises a heel counter area 124 configured to face a heel of the wearer when the foot of the wearer is received in the foot receiving cavity 108, and a sole area 125, configured to face a sole of the foot of the wearer.

The outer layer 120 of the upper 104 (in particular at least a portion of the inner surface thereof) being bonded to—for instance molded or vulcanized onto—the outer surface 116 of the sock 114, it is understood that the sock 114 cannot be removed from the foot receiving cavity 108 of the upper 104 (i.e. the sock 114 is irremovably engaged with the outer layer 120, i.e. the sock 114 cannot be separated from the outer layer 120 without damaging at least partially at least one of the sock 114 and the outer layer 120). Still in the illustrated embodiment, the outer layer 120 of the upper 104 of the item of sock-lined footwear 100 is at least partially manufactured from a moldable material such as polyurethane, rubber or any other moldable material which a skilled addressee would consider to be appropriate. It is understood that the moldable material from which the outer layer 120 is at least partially manufactured is chosen to be lightweight, durable, and to have insulative properties.

Heel Pad

In the embodiment shown, the heel pad 122 is secured to the inner surface 118 of the sock 114, for instance in the heel counter area 124 thereof.

As represented in particular in FIGS. 2 to 4, the heel pad 122 has an inner surface 130 (or foot-facing surface 130) and an opposed outer surface 132 (or inner sock-facing surface 132) superposable to the inner surface 118 of the sock 114. In the embodiment shown, the heel pad 122 is sewed, for instance along at least a portion of a peripheral border 134 thereof (or along at least a portion of a periphery thereof), to the inner sock 114. Other embodiments could be conceived in which the heel pad 122 would be glued to the inner surface 118 of the sock 114, stitched or secured by any other suitable mechanical fasteners to the sock 114.

As represented for instance in FIGS. 3 and 4, the heel pad 122 comprises an inner layer 131 defining the inner surface 130, an outer layer 133 defining the outer surface 132, and a resilient material layer 135—such as latex or any other resilient material—sandwiched between the inner layer 131 and the outer layer 133. For instance, in the embodiment shown, at least one of the inner and outer layers 131, 133 comprises a layer of tissue, such as jersey knit.

In the embodiment shown, the heel pad 122 has a substantially semi-circular shape so that the peripheral border 134 comprises a substantially straight (or horizontal) peripheral edge 136 (or sole-facing edge 136) defining a diameter d1 of the heel pad 122, and an arcuate peripheral edge 138 extending above the substantially straight peripheral edge 136, when the heel pad 122 extends in a substantially vertical plane. In some embodiments, the first diameter d1 (substantially corresponding to a substantially horizontal length of the heel pad 122) is comprised between about 30 mm and about 220 mm. In some other embodiments, the first diameter d1 is comprised between about 50 mm and about 170 mm. In some other embodiments, the first diameter d1 is comprised between about 70 mm and about 150 mm. In some other embodiments, the first diameter d1 is comprised between about 90 mm and about 130 mm. In yet some other embodiments, the first diameter d1 is comprised between about 100 mm and about 120 mm.

The heel pad 122 defines a height h1, considered substantially centrally, and substantially perpendicular to the horizontal (or straight) peripheral edge 136 (substantially vertically in the embodiment shown). In some embodiments, the height h1 is comprised between about 7 mm and about 90 mm. In some other embodiments, the height h1 is comprised between about 15 mm and about 60 mm. In some other embodiments, the height h1 is comprised between about 25 mm and about 50 mm. In yet some other embodiments, the height h1 is comprised between about 30 mm and about 40 mm.

The substantially straight peripheral edge 136 of the heel pad 122 extends proximate the sole area 125 of the inner surface 118 of the sock 114. In the embodiment shown, the straight peripheral edge 136 is secured to, or in the vicinity of, the sole area 125 of the inner surface 118 of the sock 114. The arcuate peripheral edge 138 is arranged in (for instance secured to) the heel counter area 124 of the inner surface 118 of the sock 114.

In the embodiment shown, the heel pad 122 further comprises one or more heel-abutting portions, for instance one or more elongated cushioning pads 140 protruding inwardly, i.e. the cushioning pads define protrusions on the inner surface 130, and extending along at least a portion of the length (substantially corresponding to the diameter d1, in the embodiment shown) of the heel pad 122. As detailed below, the heel-abutting portions are shaped and dimensioned to extend at least partially above a heel of the wearer when the wearer's foot is at least partially engaged in the foot-receiving cavity 108 and to at least partially circumscribe same upwardly.

In the embodiment shown, as represented in FIG. 2, two elongated cushioning pads 140 are formed or provided in an upper portion 142 of the heel pad 122, near an upper part of the arcuate peripheral edge 138 of the peripheral border 134. The two elongated cushioning pads 140 are formed symmetrically relative to an axis X1 extending substantially vertically (or centrally). In the embodiment shown, the axis X1 defines an axis of symmetry of the heel pad 122.

In the embodiment shown, the two elongated cushioning pads 140 define together a convexity towards an apex 143 of the heel pad 122. In other words, in the embodiment shown, the elongated cushioning pads 140 at least partially substantially follow the arcuate peripheral edge 138 of the peripheral border 134.

In the embodiment shown, each of the elongated cushioning pads 140 is substantially rectangular in shape and defines an approximate length 11 and an approximate width w1. In the embodiment shown, the length 11 is substantially inclined with regards to a horizontal direction. For instance, the length 11 defines a pad inclination angle α1 comprised between about 5 degrees and about 80 degrees. In some embodiments, the pad inclination angle α1 is comprised between about 10 degrees and about 60 degrees. In some embodiments, the pad inclination angle α1 is comprised between about 20 degrees and about 50 degrees. In yet some other embodiments, the pad inclination angle α1 is comprised between about 30 degrees and about 40 degrees.

In some embodiments, the length 11 of the elongated cushioning pad 140 is comprised between about 15 mm and about 60 mm. In some other embodiments, the length 11 is comprised between about 25 mm and about 50 mm. In yet some other embodiments, the length 11 is comprised between about 30 mm and about 40 mm.

In some embodiments, the width w1 of the elongated cushioning pad 140 is comprised between about 15 mm and about 60 mm. In some other embodiments, the width w1 is comprised between about 25 mm and about 50 mm. In yet some other embodiments, the width w1 is comprised between about 30 mm and about 40 mm.

In the embodiment shown, as represented in FIG. 3, at least a portion of a peripheral border of the elongated pads 140 is substantially rounded (i.e. defines a convexity towards the foot-receiving cavity 108) in order to limit the risk of injuring the heel of the wearer when abutting there against.

In the embodiment shown, the heel pad 122 also comprises one or more depressions formed in the inner surface 130 of the heel pad 122. For instance, the heel pad 122 comprises a central depression 144, for instance substantially circular in shape, formed in a lower part 146 of the heel pad 122, and further comprises an elongated depression 148 extending along at least a portion of the lower part 146 of the heel pad 122. In the embodiment shown, the elongated depression 148 extends at least partially below the elongated cushioning pads 140, and at least partially intersects the central depression 144. The depressions 144, 148 are shaped and dimensioned to provide space to the heel of the wearer, so as to limit the risk of heel friction against the heel pad 122, more particularly against the inner surface 130 thereof, when the item of sock-lined footwear 100 is worn. In the non-limitative embodiment shown, the elongated depression 148 extends from one side to the opposite side of the arcuate peripheral edge 138 of the peripheral border 134.

In some embodiments, the central depression 144 has a diameter d2 comprised between about 10 mm and about 50 mm. In some other embodiments, the diameter d2 is comprised between about 20 mm and about 40 mm. In yet some other embodiments, the diameter d2 is about 30 mm.

In the embodiment shown, the central depression 144 is spaced apart from the lower peripheral edge 136 (or substantially horizontal or straight peripheral edge 136, in the embodiment shown). In some embodiments, the central depression 144 is spaced apart from the lower peripheral edge 136 from a distance d4 (considered with respect to a lower portion of a peripheral border of the central depression 144) comprised between about 2 mm and about 30 mm. In some other embodiments, the distance d4 between the lower (or straight) peripheral edge 136 and the central depression 144 (i.e. a lower end thereof) is comprised between about 5 mm and about 20 mm. In some other embodiments, the distance d4 between the straight peripheral edge 136 and the central depression 144 is comprised between about 10 mm and about 15 mm.

The elongated depression 148 extends between an upper edge 149 and a lower edge 151. For instance, at least one of the upper and lower edges 149, 151 are substantially curved-shaped along at least a portion of the length (corresponding to the diameter d1 in the embodiment shown in which the heel pad 122 has a substantially semi-circular shape) of the heel pad 122. For instance, the upper and lower edges 149, 151 are non-linear and substantially parallel to each other. As represented in FIG. 2, a distance d3 between the upper edge 149 and the straight peripheral edge 136 (or lower portion 136) of the peripheral border 134 of the heel pad 122 varies along the length of the heel pad 122. In some embodiments, the distance d3 at a central portion of the heel pad 122 (i.e. in a section in which the central depression 144 is formed in the embodiment shown) is comprised between about 30 mm and about 60 mm. In some embodiments, the distance d3 is comprised between about 40 mm and about 50 mm. In some other embodiments, the distance d3 at the central portion of the heel pad 122 is about 45 mm.

In the embodiment shown, the elongated depression 148 extends symmetrically on each side of the substantially vertical axis X1.

In the embodiment shown, a distance between the upper edge 149 of the elongated depression 148 and the lower edge 136 (or straight peripheral edge 136) of the peripheral border 134 (forming a sole-facing edge varies along the length (i.e. along the diameter d1 in the embodiment shown) of the heel pad 122. In the embodiment shown, the distance between the upper edge 149 and the straight peripheral edge 136 reaches a maximum corresponding to the distance d3 at the central portion. In some embodiments, a distance d5 between the upper edge 149 and the straight peripheral edge 136 proximate the arcuate peripheral edge 138 of the peripheral border 134 is comprised between about 10 mm and about 40 mm. In some other embodiments, the distance d5 in the vicinity of the arcuate peripheral edge 138 of the peripheral border 134 is comprised between about 20 mm and about 30 mm. In some other embodiments, the distance d3 proximate the arcuate peripheral edge 138 is about 25 mm. In some embodiments, the distance between the upper edge 149 and the straight peripheral edge 136 reaches a minimum between the central portion and the vicinity of the arcuate peripheral edge 138 of the peripheral border 134.

As represented in FIGS. 3 and 4, the heel pad 122 thus presents a variable thickness along at least one of a height and the diameter d1 (or length) of the heel pad 122. In other words, the thickness of the heel pad 122 varies on a surface area thereof. In the embodiment shown, the heel pad 122 is dividable, considered along a vertical direction thereof, into a heel-bordering portion 162 (comprising at least partially the upper portion 142 of the heel pad 122), a middle portion 164 and a sole-adjacent portion 166 (comprising the lower part 146 of the heel pad 122). The middle portion 164 thus extends between the heel-bordering portion 162 and the sole-adjacent portion 166.

In the portions of the heel pad 122 distinct from the portions comprising the cushioning pads 140 and the portions in which the depressions 144, 148 are formed, for instance at least partially in the middle portion 164, a first thickness t1 is comprised between about 1 mm and about 8 mm. In some other embodiments, the first thickness t1 is comprised between about 2 mm and about 6 mm. In some other embodiments, the first thickness t1 of the heel pad 122 is comprised between about 3 mm and about 5 mm. In yet some other embodiments, the first thickness t1 is about 4 mm.

The heel pad 122 presents a second thickness t2 in an area comprising the cushioning pads 140, corresponding to a thickness of the heel-bordering portion 162. In some embodiments, the second thickness t2 is comprised between about 5 mm and about 15 mm. In some embodiments, the second thickness t2 (i.e. the thickness of the heel-bordering portion 162) is comprised between about 7 mm and about 12 mm. In some embodiments, the second thickness t2 is comprised between about 8 mm and about 11 mm. In yet some other embodiments, the second thickness t2 is about 9.5 mm.

The heel pad 122 presents a third thickness t3 in the lower part 146 thereof in which the elongated depression 148 is formed. In some embodiments, the third thickness t3 (i.e. the thickness of the sole-adjacent portion 166) is comprised between about 0.5 mm and about 5 mm. In some other embodiments, the third thickness t3 is comprised between 1 mm and about 4 mm. In some other embodiments, the third thickness t3 is comprised between about 2 mm and about 3 mm. In yet some other embodiments, the third thickness t3 is about 2.5 mm.

In other words, in the embodiment shown, the thickness t2 of the heel-bordering portion 162 is greater than the thickness t1 of the middle portion 164. Moreover, in the embodiment shown, the thickness t3 of the sole-adjacent portion 166 is smaller than the thickness t1 of the middle portion 164 (and thus smaller than the thickness t2 of the heel-bordering portion 162).

In the embodiment show, as represented in FIG. 4, the heel pad 122 presents a fourth thickness t4 in the region of the sole-adjacent portion 166 in which the central depression 144 is formed. In some embodiments, the fourth thickness t4 is smaller than about 2 mm. In some other embodiments, the fourth thickness t4 is smaller than about 1 mm. In yet some other embodiments, the fourth thickness t4 is about 0.5 mm.

In the embodiment shown, as represented in FIGS. 3 and 4, a thickness of an area of the heel-bordering portion 162 which does not comprise the cushioning pads 140 and a thickness of an area of the sole-adjacent portion 166 in which no depressions are formed substantially correspond to the first thickness t1 of the heel pad (i.e. to the thickness t1 of the middle portion 164).

As represented in FIG. 4, the central depression 144 has an increasing depth toward a depression center 147 thereof. In other words, the central depression 144 defines a concavity. As represented in FIG. 4, in the embodiment wherein the central depression 144 at least partially intersects the elongated depression 148, and considered downwardly along the height h1 (i.e. towards the lower portion 136), the thickness of the heel pad 122 firstly decreases at the upper edge 149 of the elongated depression 148, then increases at an upper peripheral border 145 of the central depression 144, then decreases toward the depression center 147, then increases toward a lower peripheral border 141 of the central depression 144. In the embodiment shown, the thickness of the heel pad 122 at the lower peripheral border 141 is substantially equal to the first thickness t1 of the middle portion 164.

As mentioned above, the heel pad 122, and more particularly the elongated cushioning pads 140, are dimensioned and arranged to cooperate with the heel of the wearer of the item of sock-lined footwear 100, so as to prevent, or at least reduce, a flopping of the item of sock-lined footwear 100 when the wearer walks.

In some embodiments, the inner surface 130 of the heel pad 122 is directly in contact with the heel of the wearer, or with a sock worn by the wearer. In some other embodiments, the item of sock-lined footwear 100 further comprises an inner shoe (not represented) removably positioned in the foot-receiving cavity 108 of the item of sock-lined footwear 100. The inner surface 130 of the heel pad 122 is thus in contact with the removable inner shoe, to prevent, or at least reduce, the flopping of the removable inner shoe in the foot-receiving cavity 108 when the wearer walks. In other words, the inner shoe forms an additional layer between the foot of the user when received in the foot-receiving cavity 108 and the sock 114.

Moreover, since the heel pad 122 is secured to the inner surface 118 of the sock 114, it cannot be displaced in the foot-receiving cavity 108 or removed out of the foot-receiving cavity 108. Thereby, the heel-abutting portions comprising the elongated cushioning pads 140, which are designed to form an abutment against a portion of the heel of the wearer, to limit or prevent a vertical movement of the heel in the foot-receiving cavity 108 when the wearer walks, remain substantially at the same location within the foot-receiving cavity 108.

It is appreciated that the shape and the configuration of the heel pad 122, as well as the shape and the configurations of its peripheral border 134, the shape, the number and the configuration of its heel-abutting portions comprising the cushioning pads 140, and its depressions 144, 148 can vary from the embodiment shown.

For instance, a heel pad having a substantially triangular or square shape could easily be conceived and/or having one single cushioning pad and/or more than two elongated cushioning pads and/or more or less than a central depression and an elongated depression. Furthermore, the shape and the configuration of the cushioning pads can vary from the embodiment shown. Moreover, the shape, the configuration and the location of central depression and the elongated depression can vary from the embodiment shown.

For instance, as represented in FIGS. 5 to 7, it could be conceived a heel pad 1122 with an elongated depression 1148 and a central depression 1144 (substantially circular, in the embodiment shown), formed in an inner surface 1130 thereof, wherein the central depression 1144 and the elongated depression 1148, at the portion of the heel pad 1122 where the elongated depression 1148 and the central depression 1144 intersect, form together a continuously increasing depth towards a center 1147 of the central depression 1144, i.e. the heel pad 1122 decreases in thickness.

Moreover, as represented in FIGS. 6 and 7, in the embodiment shown, the heel pad 1122 comprises two substantially rectangular elongated cushioning pads 1140 protruding inwardly, i.e. the cushioning pads 1140 define protrusions on the inner surface 1130. In the embodiment shown, at least in a heel-bordering portion 1162 of the heel pad 1122, the heel pad 1122 is formed of at least two layers: a cushioning layer 1137 forming at least partially the elongated cushioning pads 1140, and a core layer 1135, for instance at least partially made of a resilient material, such as latex or any other resilient material, the two layers being secured (i.e. bonded) to each other. The cushioning layer 1137 might have properties (such as resilient and/or softness properties) different from the properties of the core layer 1135. In the embodiment shown, the core layer 1135 also forms at least partially a middle portion 1164 and a sole-adjacent portion 1166 of the heel pad 1122. A lower portion 1139 of the sole-adjacent portion 1166 could, for instance, be formed in a different material. As represented in FIG. 5, the portion of the heel pad 1122 in which the central depression 1144 is formed could be formed in at least two distinct materials, for instance a first material forming at least partially a central area 1150 of the central depression 1144, and a second material forming at least partially a peripheral area 1152 of the central depression 1144.

As shown in FIG. 8, it could also be conceived a heel pad 2122 with no depressions formed in an inner surface 2130 thereof. In the embodiment shown, the heel pad 2122 also comprises two elongated cushioning pads 2140 formed or provided symmetrically relative to an axis X1 extending substantially vertically and centrally. It could also be conceived a heel pad that would comprise a single elongated cushioning pad with sections thereof that would extend on each side of the central axis X1.

Sock-Lined Footwear Manufacturing Method

The present disclosure also relates to a method 200 for manufacturing an item of sock-lined footwear 100 comprising a heel pad 122 in accordance with the present disclosure.

The method 200 firstly comprises a step 202 of providing a heel pad 122 and a sock having an outer surface 116 and an inner surface 118 comprising a heel counter area 124. In the embodiment shown, the step 202 of providing the heel pad 122 comprises a step of forming the heel pad 122, for instance and without being limitative by at least partially molding it, for instance with a mold assembly 300 as represented in FIGS. 9 and 10. The mold assembly 300 comprises, in the embodiment shown, a lower mold 310 in which two heel pad-forming cavities 320 are formed, and an upper mold 330. As represented in FIG. 10, in which the mold assembly 300 is configured into an open configuration, depressions and protrusions are formed in the heel pad-forming cavities 320 that substantially correspond to the shape of the depressions, pads and abutting portions of the heel pads 122 to be formed.

The mold assembly 300 is also configurable into a closed configuration, as represented in FIG. 6, in which one or more materials, such as latex or any other resilient material, can be injected, to form a heel pad 122 in each of the heel pad-forming cavities 320. Then the mold assembly 300 is configured into the open configuration to remove the formed heel pads 122 from the heel pad cavities 320. The method might further comprise a step of arranging additional layers, for instance at least partially made of tissue, in the mold assembly 300, so as to form inner and/or outer layers of the heel pads 122.

The method 200 then comprises a step 204 of securing the heel pad 122 to the inner surface 118 of the sock 114, in the heel counter area 124 thereof. In some embodiments, the method 200 comprises sewing the heel pad 122 to the sock 114, to the inner surface 118 thereof. In some other embodiments, the heel pad 122 is glued to the inner surface 118 of the sock 114, stitched or secured by a combination of different techniques so as to be permanently (i.e. irremovably) secured to the inner surface 118 of the sock 114. It is understood that it is not necessary that an entirety of an outer surface 132 of the heel pad 122 be secured to the inner surface 118 of the sock 114.

The method 200 then comprises a step 206 of providing a footwear last 400, as represented in FIG. 11, having an outer surface 402 with a heel pad-receiving recess 410 formed therein, for instance in a heel counter area 404 thereof. The method 200 further comprises a step 208 of positioning the sock 118 over the footwear last 400 with the heel pad 122 being at least partially received in the heel pad-receiving recess 410 of the footwear last 400. In other words, the heel pad 122 is sandwiched between the footwear last 400 and the inner surface 118 of the sock 114. It is understood that the footwear last 400 is dimensioned so that the sock 114 is fitted on the footwear last 400 and that the heel pad-receiving recess is dimensioned for the heel pad 122 to be stably received therein.

The method 200 then comprises a step 210 of covering at least partially the outer surface 116 of the sock 114 with a vulcanizable material (such as, for instance, polyurethane, rubber or any other moldable vulcanizable material which a skilled addressee would consider to be appropriate). The method 200 then comprises a step 212 of forming a footwear upper 104 of the item of sock-lined footwear 100 with the vulcanizable material. In the embodiment shown, the step 212 comprises bonding the vulcanizable material to the outer surface 116 of the sock 114.

In an embodiment, the step 210 of covering at least partially the outer surface 116 of the sock 114 comprises superposing at least a layer of the vulcanizable material onto the outer surface 116 of the sock 114. The step 212 of forming the upper 104 comprises vulcanizing the vulcanizable material so as to bond to the outer surface 116 of the sock 114 and to form the upper 104 of the item of sock-lined footwear 100.

In another embodiment, the step 210 could comprise a step of providing an outer mold and positioning the outer mold over the sock 114 positioned over the footwear last 400 to enclose the sock 110 between the outer mold and the footwear last 400. The outer mold could be dimensioned so that a space is formed between an inner surface of the outer mold and the outer surface 116 of the sock 114. The dimensions of this space depend on the final dimensions of the item of sock-lined footwear 100. The method 200 could further comprise injecting the vulcanizable material between the outer surface 116 of the sock 114 and the inner surface of the outer mold and vulcanizing the vulcanizable material so as to bond to the outer surface 116 of the sock 114 and to form the upper 104 of the item of sock-lined footwear 100.

Once the vulcanizable material is vulcanized, the outer layer 120 formed by the vulcanized material and the sock 114 are secured to each other so as to form the item of sock-lined footwear 100.

The manufacturing method 200 might further comprise a step of providing an outsole 102 and securing (for instance gluing or using any other suitable mechanical fastener) the outsole 102 to the upper 104.

It is understood that the present invention is not limited to the above described embodiments. Several alternative embodiments and examples have been described and illustrated herein. The embodiments of the invention described above are intended to be exemplary only. A person of ordinary skill in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. It is understood that the invention may be embodied in other specific forms without departing from the central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. Accordingly, while the specific embodiments have been illustrated and described, numerous modifications come to mind. The scope of the invention is therefore intended to be limited by the scope of the appended claims.

Claims

1. A sock-lined footwear upper defining a foot-receiving cavity and comprising:

a sock having an outer surface and an inner surface at least partially delimiting the foot-receiving cavity and comprising a heel counter area;

an outer layer covering at least partially the outer surface of the sock; and

a heel pad at least partially secured to the inner surface of the sock in the heel counter area thereof.

2. The sock-lined footwear upper according to claim 1, wherein the heel pad has a sole-facing edge, a length, a height, an inner surface at least partially delimiting the foot-receiving cavity and an opposed outer surface at least partially secured to the inner surface of the sock, and wherein the heel pad comprises at least one heel-abutting portion protruding inwardly and extending along at least a portion of the length of the heel pad, in an upper portion thereof, the heel-abutting portion creating a thickness variation in the heel pad and being shaped and dimensioned to extend at least partially above a heel of a user's foot at least partially engaged into the foot-receiving cavity.

3. The sock-lined footwear upper according to claim 2, wherein said at least one heel-abutting portion comprises one or more elongated cushioning pads protruding inwardly and comprising a peripheral border at least partially rounded.

4. The sock-lined footwear upper according to claim 2, wherein said at least one heel-abutting portion comprises two elongated cushioning pads, and wherein the heel pad has an axis of symmetry extending substantially vertically between said two elongated cushioning pads.

5. The sock-lined footwear upper according to claim 2, wherein the heel pad comprises one or more depressions formed in the inner surface and creating an additional thickness variation in the heel pad, and wherein, considered along the height of the heel pad, said one or more depressions comprises an elongated depression extending below said at least one heel-abutting portion.

6. The sock-lined footwear upper according to claim 5, wherein the elongated depression has upper and lower edges, and wherein a distance between the upper edge and the sole-facing edge of the heel pad varies along the length of the heel pad.

7. The sock-lined footwear upper according to claim 5, wherein said one or more depressions further comprises a substantially circular central depression having an increasing depth towards a center thereof.

8. The sock-lined footwear upper according to claim 7, wherein the elongated depression at least partially intersects the central depression.

9. The sock-lined footwear upper according to claim 2, wherein, considered along the height of the heel pad, the heel pad has a middle portion extending below the upper portion comprising the at least one heel-abutting portion, and, considered along at least a portion of the length of the heel pad, a thickness of the upper portion is greater than a thickness of the middle portion.

10. The sock-lined footwear upper according to claim 9, wherein the heel pad further comprises a sole-adjacent portion, wherein, considered along the height of the heel pad, the middle portion extends between the upper portion and the sole-adjacent portion, and wherein, considered along at least a portion of the length of the heel pad, a thickness of the sole-adjacent portion is smaller than the thickness of the middle portion.

11. The sock-lined footwear upper according to claim 1, wherein the heel pad comprises a periphery sewed at least partially to the inner surface of the sock.

12. The sock-lined footwear upper according to claim 1, wherein the heel pad comprises an inner layer, an outer layer and a resilient material layer at least partially made of latex sandwiched between the inner and outer layers.

13. A heel pad for a sock-lined footwear upper comprising an inner sock having an inner surface at least partially delimiting a foot-receiving cavity and comprising a heel counter area, the heel pad having a length and a height and comprising:

an outer surface securable to the inner surface of the inner sock in the heel counter area thereof;

an opposed inner surface; and

at least one heel-abutting portion protruding forwardly and creating at least one protrusion on the inner surface, the at least one heel-abutting portion extending along at least a portion of the length and being shaped and dimensioned to extend at least partially above a heel of a user's foot at least partially engaged into the foot-receiving cavity when the heel pad is at least partially secured to the inner sock.

14. The heel pad according to claim 13, wherein the heel pad has a substantially semi-circular shape having an apex and being delimitated by an arcuate peripheral edge and a substantially straight peripheral edge, said at least one heel-abutting portion comprising two elongated cushioning pads extending adjacent to the arcuate peripheral edge and defining a convexity towards the apex, and wherein the heel pad has an axis of symmetry extending substantially vertically between said two elongated cushioning pads.

15. The heel pad according to claim 14, further comprising an elongated depression formed in the inner surface and extending, considered along the height of the heel pad, below said two elongated cushioning pads.

16. The heel pad according to claim 15, further comprising a substantially circular central depression formed in the inner surface, the elongated depression at least partially intersecting the central depression.

17. An item of sock-lined footwear comprising:

an outsole having an inner surface and an outer surface; and

a sock-lined footwear upper according to claim 1, the sock-lined footwear upper extending from the outsole, the heel pad being adjacent to the outsole.

18. The item of sock-lined footwear according to claim 17, wherein the heel pad is adjacent to the outsole.

19. A method for manufacturing an item of sock-lined footwear, the method comprising:

providing a heel pad and a sock having an outer surface and an inner surface comprising a heel counter area;

securing the heel pad to the inner surface of the sock, in the heel counter area thereof;

providing a footwear last having an outer surface with a heel pad-receiving recess formed therein;

positioning the sock over the footwear last with the heel pad at least partially received in the heel pad-receiving recess;

covering at least partially the outer surface of the sock with a vulcanizable material; and

forming at least partially an upper of the item of sock-lined footwear with said vulcanizable material.

20. The method according to claim 19, wherein securing the heel pad to the inner surface of the sock further comprises sewing the heel pad to the inner surface of the sock.