Force-Mitigating Athletic Shoe

Abstract

An athlete in any athletic event generates forces on and subjects their lower extremities to forces which are unique to that athlete's mass, speed and strength. These forces are also affected by the composition of the playing field surface, shoe design and construction and other factors. It is possible to determine, according to these factors, the level of force above which injury to the athlete's lower extremities is inevitable—the pre-injury force threshold. This pre-injury force threshold is then used to design and build an athletic shoe which will provide a force-mitigating deformation induced by forces equal to the particular athlete's pre-injury force threshold. This deformation of the athletic shoe prevents injury to the athlete's lower extremities. This deformation may be induced by designing the sole of an athletic shoe with specifically engineered incised cut-outs or channels in the athletic shoe sole.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 15/145,774 filed on 3 May 2016, [now U.S. Pat. No. 10,383,395]. This application claims the benefit of U.S. 62/156,276 filed on 3 May 2015. This application incorporates by reference U.S. patent application Ser. No. 15/145,774 filed on 3 May 2016, [now U.S. Pat. No. 10,383,395] and 62/156,276 filed on 3 May 2015.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

SEQUENCE LISTING

Not Applicable

BACKGROUND OF THE INVENTION

Each year in North America there are approximately 250,000 ACL injuries—about 70% of which are non-contact incidents.¹ A near universally accepted and scientifically supported explanation for this non-contact statistic is the rotational and translational forces created when a player makes a sudden change in direction or stops. Exacerbating this natural force generation is athletic-shoe/playing-surface interface traction. Decades of private and academic studies prove a causal relationship between the increased desire for traction at the athletic-shoe/playing-surface interface and injurious forces that this traction puts on the ACL. At some point, the human body is naturally unable to compensate for this force. Boden, Griffin and Garrett posit in their 2000 paper titled “Etiology and Prevention of Noncontact ACL Injury” the hormonal, anatomic and neuromuscular factors that may predispose athletes to ACL injuries. Regardless, athletic shoe manufacturers continue to produce shoes with ever more traction. Today, those shoes are being used on artificial turf, which is also designed to provide maximum traction. ¹ Griffin L Y, Noncontact Anterior Cruciate Ligament Injuries: Risk Factors and Prevention Strategies, Journal of the American Academy of Orthopaedic Surgeons: 2000; 8:141-150

Clearly, the conditions exist for even higher incidences of non-contact ACL injuries that sideline athletes of every age, gender and skill level. Yet few attempts at preventing non-contact ACL injuries have involved a viable athletic-shoe solution. Results have yielded shoe designs with unstable vertical profiles that compromise athletic performance and increase injury risk. U.S. Pat. No. 3,668,792 A (York) Jan. 8, 1971, entitled Breakaway Athletic Safety Shoe describes a breakaway system that, under duress, separates a spring-biased lower sole of the shoe from the upper section of the sole. U.S. Pat. No. 7,254,905-B2 (Dennison) Aug. 14, 2007, entitled Releasable Athletic Shoe Sole details a fully detachable lower sole with a mechanism designed to release when a pre-determined and specifically longitudinally directed force is applied. Published US Application 2013/0318832 A1 (Brown, et al,) Dec. 5, 2013, entitled Self-Recovering Impact Absorbing Footwear, proposes an athletic shoe design which will allow the wearer of the shoe uninterrupted usage while dampening forces that surpass an injury threshold using a system of internal beams of various heights coupled with an internal air valve system. In spite of these, the incidence of non-contact ACL injuries continues to rise—painful proof that a practical solution has yet to be realized.

SUMMARY OF THE INVENTION

As they progress through an athletic event, every athlete generates and subjects their lower extremities to various forces that are unique to his or her mass, speed, and strength. These forces are also affected by the composition of the playing field surface, by shoe sole design and construction, as well as by other factors. By determining, according to these and other factors, the level of force at which injury is inevitable [i.e., the target pre-injury, force threshold], an athletic shoe sole can be created to provide a mitigating deformation induced by a particular athlete's pre-determined, target pre-injury force threshold. This mitigating deformation prevents injury to an athlete's lower extremity joints. A mitigating deformation of as little as 2 degrees can reduce by threefold injurious forces such as torque (Groeger, Lena, “Injury Risks for the Female Athlete—Part 1”). After the athlete has progressed through that particular force-generating movement, the shoe's sole instantly returns to its original shape.

The present invention involves three embodiments of an athletic shoe designed to provide a mitigating deformation induced by a particular athlete's pre-determined, target, pre-injury force threshold and a method of preventing injury to an athlete's lower extremity joints. As different athletes, according to mass, speed, strength, playing surface conditions, etc. generate a wide range of forces, a wide range of force thresholds must be contemplated. Each embodiment of the invention permits an athletic shoe sole to be designed and constructed to permit a mitigating deformation induced by a particular athlete's pre-determined, target, pre-injury force threshold. This construction method allows a fine-tuning of the force threshold, allowing an individual athlete to have a shoe built to protect him or her from injurious forces.

The first embodiment is a shoe whose sole comprises multiple thin layers of specifically engineered composite materials. Each of the sole's layers comprises a filler material with embedded fibers in various anisotropic orientations. The assembled layers provide both translational [i.e., heel to toe] as well as lateral [i.e., side to side] and rotational [i.e., twisting] rigidity and strength, similar in performance to a traditional athletic shoe's thermoplastic elastomer or carbon fiber sole. Because an anisotropic composition provides strength and rigidity against forces perpendicular to the fibers, the inventive sole can be constructed to provide rigidity and strength only up to a pre-determined, target, pre-injury force threshold. When an athlete's pre-determined, target pre-injury force threshold is reached, the sole deforms, thus mitigating the stress which the shoe can impart to the athlete's lower extremity joints. After the athlete has progressed through that particular force-generating movement, the shoe's sole instantly returns to its original shape.

The second embodiment is a shoe whose sole has a series of cut-outs comprising channels or voids cut into the sole material. The sole is designed to provide both translational [i.e., heel to toe] as well as lateral [i.e., side to side] and rotational [i.e., twisting] rigidity and strength, similar in performance to a traditional athletic shoe's thermoplastic elastomer or carbon fiber sole. However, because of the width, depth, area, location, geometry and orientation of the channels or voids, the sole can be constructed to provide rigidity and strength only up to a pre-determined, target pre-injury force threshold. When an athlete's pre-determined, target pre-injury force threshold is reached, the sole deforms, thus mitigating the stress which the shoe can impart to the athlete's lower extremity joints. As with the first embodiment, after the athlete has progressed through the particular force-generating movement, the shoe's sole instantly returns to its original shape.

The third embodiment is a shoe whose sole has a series of cut-outs comprising geometric shapes which are then filled with an elastomeric material similar to the material of the remainder of the sole, but with differing force-resisting properties than the rest of the sole. The sole of the third embodiment also provides both translational [i.e., heel to toe] as well as lateral [i.e., side to side] and rotational [i.e., twisting] rigidity and strength, similar in performance to a traditional athletic shoe's thermoplastic elastomer or carbon fiber sole. Because of the geometry, size, location and orientation of the filled in cut-outs in the sole, and because of the force-resisting properties of the filler material, the sole is constructed to provide rigidity and strength only up to a pre-determined, target pre-injury force threshold. When an athlete's pre-determined, pre-injury force threshold is reached, the sole deforms, thus mitigating the stress which the shoe can impart to the athlete's lower extremity joints. As with the first and second embodiments, after the athlete has progressed through the particular force-generating movement, the shoe's sole instantly returns to its original shape.

The invention also involves a method of preventing injury to an athlete's lower extremity joints comprising the step of determining for a specific athlete in a specific playing field situation a series of target, pre-injury force thresholds. With these force thresholds determined, an athletic shoe is constructed with a sole which is designed to temporarily deform when the shoe sole is subjected to the pre-determined target pre-injury force threshold and to then return to its original form when the force applied to the shoe sole falls below the pre-determined target pre-injury force threshold.

As different athletes, according to mass, speed, strength, playing surface conditions, etc. generate a wide range of force, a wide range of force thresholds must be contemplated. By constructing the sole of the shoe of the first embodiment with multiple thin layers, each with a unique and specific anisotropic fiber orientation, those layers can be combined into hundreds of different combinations. This construction method allows a fine-tuning of the force threshold, allowing an individual athlete to have a shoe built to protect him or her from injurious forces.

In the shoe of the first embodiment, the rigidity and strength of a particular layer will depend on the number, orientation, composition and individual strength of the fibers embedded within that layer. Several layers will have fiber orientation specifically related to providing rigidity and strength, as well as force-mitigating deformation against translational force [i.e., heel to toe]. Others of the layers, while adding to overall forward-force characteristics, will be oriented to provide rigidity and strength, as well as force-mitigating deformation against rotational force [i.e., torque]. Still other of the layers, while adding to overall forward-force and torque characteristics, will be oriented to provide rigidity and strength, as well as force-mitigating deformation against lateral [i.e., side to side] forces. Each layer will be evaluated in the context of it being combined with other layers to create the desired athlete-specific force-mitigating deformation.

In the shoe of the second embodiment, the rigidity and strength of the shoe sole will depend on the width, depth, area, location, geometry and orientation of the channels, the sole can thus be constructed to provide rigidity and strength only up to the pre-determined, target pre-injury force threshold.

In the shoe of the third embodiment, the rigidity and strength of the shoe sole will depend on the geometry, size, location and orientation of the filled in cut-outs in the sole, and the force-resisting properties of the filler material. The sole can thus be constructed to provide rigidity and strength only up to the pre-determined, target pre-injury force threshold. It is noted that this filler material may be a material similar to the fibrous material used to construct the sole of the first embodiment shoe.

The fibers bound into the sole materials may include, but are not limited to, carbon, silicon carbide, graphene, glass, nylon, metallic, aramid fibers, and various other natural and/or synthetic materials. The matrix binding and protecting the fibers may include, but will not be limited to, various polymers, natural and/or synthetic rubbers, thermoplastics, polyvinyl chloride, polyethylene, polypropylene, styrene butadiene, isobutylene, isoprene butadiene, and the like. The materials comprising the filler material of the third embodiment sole may be the same materials described above in regard to the matrix binding and protecting the fibers. The filler material may or may not include the bound fibers described above.

For all embodiments of the invention, construction of the shoe sole is contemplated as a 3-D printed process, with printed layers forming a collective printed sole originating with different materials, chemistries, optional reinforcing and arrayed fibers, etc. to allow for full, athlete-specific customization of the properties of the structure of the sole. For all the embodiments, the sole materials will comprise various layers with specific elasticity, flexural and tensile strength characteristics spanning a wide overall range of said characteristics. For the third embodiment, sole materials will be similar to those of the first two embodiments and the filler material, as noted above, will be similar to the sole materials but may or may not include bound fibers.

The invention involves three embodiments of an athletic shoe whose composition and construction will provide rigid lateral stability and strength during normal athletic movement. However, at a pre-determined, athlete-specific, target pre-injury force threshold the sole temporarily deforms to prevent injury to the athlete's lower extremity joints. The invention is intended to encompass cleated and/or nubbed field shoes as well as tennis, handball, volleyball, basketball and other athletic footwear. The primary joint of concern is the knee's ACL.

The invention also comprises a method of preventing injury to an athlete's lower extremity joints. The method comprises determining for a specific athlete in a specific playing environment a unique target pre-injury force threshold. Given this target pre-injury force threshold, a customized athletic shoe having a composite sole comprising multiple thin layers of specifically engineered composite materials is built for a specific athlete in a specific playing environment. Shorten, et al surmised that the ‘. . . interaction (between shoe and playing surface) suggests that appropriate shoe selection for a given surface is an important element in risk reduction.’ (Shorten, Hudson, and Himmelsbach, “Shoe-Surface Traction of Conventional and In-Filled Synthetic Turf Football Surfaces”). The composite sole of the shoe will provide the athlete sufficient traction and stability in the specific playing environment but will temporarily deform when the shoe is subjected to the target pre-injury force threshold, thus preventing injurious force from being applied to the athlete's lower extremity joints.

Given the current state of the art in shoe construction, it is possible to calculate the target force threshold and construct a unique and athlete-specific athletic shoe for a given playing environment and other factors using modern 3D printing technology. It is possible, for example, to provide a customized athletic shoe for a particular athlete in a specific playing environment [e.g., (natural grass vs. synthetic turf, wet vs. dry, etc., etc.], or even for the first part of an athletic event and then to provide another customized athletic shoe for the athlete to wear during another portion of the same athletic event. As an example, a customized athletic shoe could be built for an athlete for a football or soccer game on a particular day with a specific playing environment as described supra. If the specific playing environment changes during the athletic event, for example, due to rain or snow or playing field deterioration which could affect the target force threshold, another shoe could be available or could even be built in time for the athlete to wear the new shoe in the second half [or later portions] of the game.

This method will also accommodate changes in the athlete's physical situation, which often occur during an athletic event. For example, an injury to the athlete's leg or foot may mandate a different target force threshold; in that instance, a new shoe can be constructed to immediately accommodate this changed physical situation. Muscle fatigue, for example, could warrant constructing another shoe for the second half of the athletic event. Orchard and Powell concluded by analyzing 5,910 NFL games that not only field composition affected injury rates, but also cold weather vs. hot weather, wet vs. dry conditions, and even early season vs. later season condition of athletes as well as playing surfaces. The factors that lowered shoe/playing surface traction (and resulting force) also reduced injury risk (Orchard, J. W., Powell, J. W., “Risk of Knee and Ankle Sprains Under Various Weather Conditions in the National Football League,” 1993, July). By using pre-constructed portions of the athletic shoe specific to a given athlete and/or venue, it may even be possible to make new shoes, as necessary, for each quarter of a football game.

Use of 3-D printing construction method allows fine-tuning of the composite sole to construct a sole that can prevent the generation of injurious force to an athlete's lower extremities.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the composite athletic shoe according to a first embodiment of the invention.

FIG. 2 is a view of the sole of the athletic shoe of FIG. 1.

FIG. 3 is a blown-up view of a portion of the shoe sole of FIG. 2.

FIG. 4 is another view of the sole of FIG. 2 showing the cutting plane A-A that determines the perspective of FIG. 5.

FIG. 5 shows a section of the sole of FIG. 2 now under a rotational stress and taken along the plane A-A as shown in FIG. 4.

FIG. 6 is an enlarged view of the section of FIG. 5 inside the circle B.

FIG. 7 shows a section of the sole of FIG. 2 also taken along the plane A-A as shown in FIG. 4. The sole is now being subjected to longitudinal stress.

FIG. 8 is an enlarged view of the section of FIG. 7 inside the circle C.

FIG. 9 is a cross-section of an athletic shoe according to the first embodiment of this invention but with more individual layers in the sole.

FIG. 10 is an exploded view of the shoe shown in FIG. 9.

FIG. 11 is a flow chart illustrating a method of the invention.

FIG. 12 is a plan view of the sole of a second embodiment of the invention.

FIG. 13 is a view taken along the plane D-D of the sole shown in FIG. 12.

FIG. 14 is a plan view of the sole shown in FIG. 12 deforming under the effects of an external torsion [i.e., torque] force.

FIG. 15 is a plan view of another version a sole constructed according to the second embodiment of the invention.

FIG. 16 is a plan view of an alternate construction of a sole constructed according to the second embodiment of the invention.

FIG. 17 is a view taken along the plane E-E of the sole shown in FIG. 16.

FIG. 18 is a plan view of another alternate version of a sole constructed according to the second embodiment of the invention.

FIG. 19 is a view taken along the plane F-F of the sole shown in FIG. 18.

FIG. 20 is a plan view of yet another alternate version of a sole constructed according to the second embodiment of the invention.

FIG. 21 is a view taken along the plane G-G of the sole shown in FIG. 20.

FIG. 22 is a plan view of yet another alternate version of a sole constructed according to the second embodiment of the invention.

FIG. 23 is a view taken along the plane H-H of the sole shown in FIG. 22.

FIG. 24 is a plan view of yet another alternate version of a sole constructed according to the second embodiment of the invention.

FIG. 25 is a view taken along the plane I-I of the sole shown in FIG. 24.

FIG. 26 is a plan view of a sole constructed according to the third embodiment of the invention.

FIG. 27 is a view taken along the plane J-J of the sole shown in FIG. 26.

FIG. 28 is a plan view of a second variation of a sole constructed according to the third embodiment of the invention.

FIG. 29 is a plan view of third variation of a sole constructed according to the third embodiment of the invention.

FIG. 30 is a plan view of a fourth variation of a sole constructed according to the third embodiment of the invention.

FIG. 31 is a plan view of the sole shown in FIG. 30 deforming under the effects of an external torsion [i.e., torque] force.

FIG. 32 is a plan view of a fifth variation of a sole constructed according to the third embodiment of the invention.

FIG. 33 is a plan view of the sole shown in FIG. 32 deforming under the effects of an external longitudinal force.

DETAILED DESCRIPTION

The athletic shoe 10 according to a first embodiment of the invention is shown in FIGS. 1-8. The athletic shoe soles shown in FIGS. 1-8 are designed to protect an athlete's lower extremities against both injurious torsional [i.e., torque] forces and injurious longitudinal forces.

The shoe sole shown in FIGS. 1-8 comprises an upper body 12 and a multi-layer composite sole 14. Multi-layer composite sole 14 is shown in FIGS. 2-8 as comprising 5 thin layers of materials, although the exact number of layers could be more or less than 5 depending upon the specific situation the shoe is designed for. As shown in FIG. 3, sole 14 comprises layers 20, 21, 22, 23 and 24. Layers 20, and 24 are designed to provide rigid translational [i.e., straight ahead] stability during competition, like a traditional athletic shoe, only up to a pre-determined, athlete-specific, target pre-injury force threshold. These layers will also contribute limited rigidity during lateral as well as rotational [i.e., twisting] force generation. Layers 21 and 23 also will contribute to overall translational rigidity, as well as rotational stability only up to a pre-determined, athlete-specific, pre-injury force threshold [i.e., the target, pre-injury force threshold]. The athlete-specific/target-force-specific anisotropic fiber orientation in the sole's layers will allow the sole to temporarily deform in response to, and to dissipate, the specific target force that would otherwise cause injurious stress to that particular athlete's lower extremities.

Sole 14 is shown in FIG. 4 in its unstressed condition. As shown in FIGS. 5 and 6, sole 14 has been subjected to a rotational force equivalent to the pre-determined, target, pre-injury force threshold at which point layers 21 and 23 have temporarily deformed about the shoe's rotational axis to alleviate and prevent the application of injurious force to the athlete's lower extremities.

As shown in FIG. 6, the anisotropic fibers in layers 21 and 23 have caused the layers to temporarily deform under the application of the pre-determined target pre-injury force threshold. When the event that generated the target force threshold has passed, the layers immediately return to their unstressed condition.

Sole 14 is also shown in FIGS. 7 and 8. Sole 14 is shown as having 5 layers of material, although—as noted above—the exact number of layers could be more or less than 5 depending upon the specific situation the shoe is designed for. As shown in FIGS. 7 and 8, sole 14 comprises layers 20, 21, 22, 23, and 24 as in FIGS. 5 and 6. Layers 20, 22 and 24 are designed to provide rigid translational [i.e., straight ahead] stability during competition, like a traditional athletic shoe, only up to a pre-determined, athlete-specific, target pre-injury force threshold. These layers will also contribute limited rigidity during lateral and rotational [i.e., twisting] force generation. Layers 21 and 23 also will contribute to overall translational rigidity, as well as lateral and rotational strength and stability only up to a pre-determined, athlete-specific, target pre-injury force threshold. The athlete-specific/target-force-specific anisotropic fiber orientation in the sole's layers will allow the sole to temporarily deform in response to, and to dissipate, the specific target force that might otherwise cause injurious force to that particular athlete's lower extremities.

FIGS. 7 and 8 illustrate the sole being subjected to a longitudinal [i.e., heel to toe] force equivalent to the pre-determined target, pre-injury force threshold. The layers 20, 22 and 24 have temporarily deformed in the longitudinal direction to alleviate and prevent the application of injurious longitudinal force to the athlete's lower extremities. As shown in FIG. 8, the anisotropic fibers in layers 20, 22 and 24 have caused the layers to temporarily deform in the longitudinal direction under the application of the target, pre-injury force threshold. When the event that generated the target, pre-injury force threshold has passed, the layers immediately return to their unstressed condition.

FIG. 9 illustrates a variation of the first embodiment of the athletic shoe with a seven-layer sole. Shoe 30 comprises upper 31 and multi-layered sole 32. Shoe 30 also has a sock liner 33. Sole 32 comprises layers 34, 35, 36, 37, 38, 39, and 40. Certain of these layers can be designed to deform upon application of a longitudinal target, pre-injury force threshold. Certain of the other layers can be designed to deform upon application of a lateral target, pre-injury force threshold and of a rotational target, pre-injury force threshold.

Shoe 30 is shown in an exploded view in FIG. 10. In this embodiment layers 35 and 37 are the layers that temporarily deform upon application of the longitudinal target, pre-injury force threshold. Layers 36 and 38 will temporarily deform upon application of the rotational target, pre-injury force threshold and layers 34 and 39 will temporarily deform upon application of the lateral [i.e., side-to-side] target, pre-injury force threshold.

It is noted that in the above example in FIG. 10 there is no particular significance as to which layers temporarily deform to mitigate which type of target, pre-injury force threshold. Obviously, any of the layers could be selected to mitigate any particular type of target, pre-injury force threshold. Nor is there any particular significance in this example as to how many individual layers will temporarily deform to mitigate a particular target, pre-injury force threshold. In this example, two layers were used to mitigate each of the three types of target-pre-injury force thresholds, but more layers or fewer could also have been used, depending upon the exact circumstances of the particular athlete-specific factors and the particular environmental factors. With this embodiment, the athlete's lower extremities can be protected against injurious longitudinal, rotational and lateral [i.e., side-to-side] forces.

The method 50 of the invention is illustrated in FIG. 11. The method comprises determining for a particular athlete, in a specific playing environment, the athlete-specific factors contributing to the longitudinal, rotational and lateral [i.e., side-to-side] target, pre-injury force thresholds. These factors are then inputted at 51. Next, the environment-specific factors contributing to the longitudinal, rotational and lateral [i.e., side-to-side] target, pre-injury force thresholds are determined. These factors are inputted at 52 and the longitudinal, rotational and lateral [i.e., side-to-side] target, pre-injury force thresholds are determined at 53. This information is then used to build an athletic shoe sole customized for the particular athlete in the specific playing environment at 54. A customized athletic shoe is then built at 55 using the customized sole built at 54. The athlete then uses the customized shoe in a playing event. At certain, pre-determined times during the playing event, the athlete-specific factors are re-evaluated at 56. Also at these pre-determined times, the environmental-specific factors are re-evaluated a 57. The changes to these factors are evaluated at 57 and if they have been significantly changed, new longitudinal, rotational and lateral [i.e., side-to-side] target, pre-injury force thresholds are determined and a new customized sole and shoe are built for use by the athlete for the remainder of the event. Using modern 3-D printing technology, it is possible to build several customized shoes for the athlete during the course of an event.

FIGS. 12-14 show a force-mitigating athletic shoe sole constructed according to the second embodiment of the invention. The three figures will be described together with it being understood that elements shown in one figure may or may not be shown in the other figures.

Sole 70 is a multi-layer composite force-mitigating sole similar in construction to the first embodiment soles shown and described above. Multi-layer composite sole 70 is shown as comprising composite layers 73, 74, and 75, although the exact number of layers could be more or less, as desired. Sole 70 comprises materials similar to those of the first embodiment. Multi-layer sole 70 has a cut-out or channel 72 incised into the outer surface of layer 73. Channel 72 is shown in the figures as being incised into the forward portion of sole 70. It should be understood that the exact placement of channel 72 can and will vary depending upon the desired force-resisting characteristics of sole 70 just as the width, depth and exact pathway of channel 72 can and will be varied depending upon the desired force-resisting characteristics of sole 70. It is noted that even though channel 72 is only shown in the figures as being incised into an outer layer of the sole, it could also be incised into an internal layer, if desired.

Channel 72 follows a somewhat serpentine pathway and is designed to strategically weaken sole 70 such that sole 70 will temporarily deform in response to, and to dissipate, the specific target force that might otherwise cause injurious force to that particular athlete's lower extremities. Layers 73, 74, and 75 will also provide limited rigidity during lateral and rotational [i.e., twisting] force generation. Layers 73, 74, and 75 also will contribute to overall translational rigidity, as well as lateral and rotational strength and stability. The width, depth, geometry and exact pathway of channel 72 can be varied to provide the exact response desired to provide a mitigating deformation induced by a particular athlete's pre-determined, target pre-injury force threshold.

FIG. 14 shows sole 70 deforming under stress from an externally applied torque. The rear end of sole 70 has twisted upwardly in response to the stress and the portion of sole 70 containing channel 72 has distorted in response to the stress. The twisted portion of sole 70 is shown at 70′ and the untwisted portion is shown by a dashed line at 70. The undistorted channel 72 is shown as a dotted line while the distorted channel is shown as a solid line at 72′.

FIG. 15 shows a variation of the second embodiment of the invention with a channel 71 incised into the outer surface of sole 100. Channel 71 is somewhat shallower than channel 72 shown in FIGS. 12-14 and extends for a much greater length with more undulations than channel 72. As in the soles show above, the exact width, depth, geometry and pathway of channel 71 can be varied to provide the exact response desired to provide a mitigating deformation induced by a particular athlete's pre-determined, pre-injury force threshold.

FIG. 16 shows a plan view of an alternate construction of a force-mitigating sole constructed according to the second embodiment of the invention. It is noted that FIG. 17 is a view taken along the plane E-E of the sole shown in FIG. 16. FIGS. 16 and 17 will be described together. Sole 70′ has 4 separate channels 72″ incised into an outer layer 73 of the sole 70′. It is noted that the channels of the sole of the second embodiment do not have to be continuous as shown in FIGS. 12-15 and described supra. Channels 72 are separate chevron-shaped channels oriented with the points forward and are placed generally in the middle of sole 70″ as shown.

FIG. 17 shows a view of a force-mitigating sole 70″ taken along the plane E-E in FIG. 16. It is noted that FIG. 17 is a view taken along the plane E-E of the sole shown in FIG. 16. FIGS. 16 and 17 will be described together. Channels 72″ are incised into the outer layer 73′ of sole 70″. As shown, sole 70″ comprises 3 layers 73′, 74′ and 75′. It is noted that there could be more layers than the three shown or there could be less layers, as desired.

FIG. 18 is a plan view of another alternate version of a force-mitigating sole constructed according to the second embodiment of the invention. It is noted that FIG. 19 is a view taken along the plane F-F of the sole shown in FIG. 18. FIGS. 18 and 19 will be described together. Sole 76 is comprises three layers 78, 79 and 80. Channels 77 are again chevron-shaped as shown in FIG. 18 and are incised into an internal layer of sole 76. In this figure, the channels 77 are incised into middle layer 79—although they could just as well be in layer 80.

FIG. 20 is a plan view of another alternate version of a force mitigating sole constructed according to the second embodiment of the invention. It is noted that FIG. 21 is a view taken along the plane G-G of the sole shown in FIG. 20. FIGS. 20 and 21 will be described together. Sole 81 is comprises three layers 83, 84 and 85. It is important to note that the channels of a sole constructed according to the second embodiment of the invention may be of many different shapes and have geometry differing from what is shown in the Figures. In this version, channels 82 are irregular curves and are incised into an internal layer of sole 81. In this figure, the channels 82 are incised into middle layer 84—although they could just as well be in layer 85. Channels 82 are irregular curves and they are not spaced at uniform intervals as clearly shown in FIGS. 20 and 21.

FIG. 22 illustrates yet another alternate version of a force-mitigating sole constructed according to the second embodiment of the invention. It is noted that FIG. 23 is a view taken along the plane H-H of the sole shown in FIG. 22. FIGS. 22 and 23 will be described together. Force-mitigating sole 86 has 4 irregular curve channels 87 which are similar to but shorter than the channels 82. It is noted that channels 87 are not uniformly spaced along the length of sole 86 as clearly shown in FIGS. 22 and 23. It is also noted that a fifth channel 88 is positioned behind the channels 87 in a direction towards the heel of force-mitigating sole 86. This illustrates the fact that the various channels which comprise the second embodiment of the force-mitigating sole may not be the same length or shape, as desired.

FIG. 24 is a plan view of yet another alternate version of a force-mitigating sole constructed utilizing portions of all three embodiments of the invention. It is noted that FIG. 25 is a view taken along the plane I-I of the sole shown in FIG. 24. FIGS. 24 and 25 will be described together. In the third embodiment of the invention, the force-mitigating sole is strategically weakened to provide the desired temporary deformation by providing inserts in the sole rather than by providing a channel incised into the sole. However, there is no reason why a force-mitigating sole cannot be constructed using multiple embodiments of the invention in the same force-mitigating sole. Indeed, a force-mitigating sole may be constructed using all of the embodiments of the invention. This is illustrated in FIGS. 24 and 25. Force-mitigating sole 92 comprises three layers 97, 98 and 99. Sole 92 has cut-outs 93, 93′, 94 and 94′ incised into inner layer 98, although the cut-outs could be in layer 99 or layer 97, if desired. These inserts are made of a composite filler material similar to the sole materials described above; however, the filler material may or may not include bound fibers. The filler material of the inserts will have force-resisting characteristics that are different [and perhaps substantially so] than the materials comprising remaining portions of sole 92. These differences in material properties assist in providing the desired weakening in sole 92 to permit it to provide a mitigating deformation induced by a particular athlete's pre-determined, target pre-injury force threshold. In addition, the exact location of the inserts within the sole, the number of inserts, their geometric shape, and their depth are all characteristics which can be varied in order to provide the exact response desired to provide a mitigating deformation of sole 92 induced by a particular athlete's pre-determined, target pre-injury force threshold. It is noted that inserts 93, 93′, 94 and 94′ are shown with dotted line borders and in a lighter color in FIG. 24 than they are shown in FIG. 25. This is because the inserts 93, 93′, 94 and 94′ are actually hidden in FIG. 24 while insert 94′ shown in FIG. 25 is not hidden. Channels 95 and 96 are also incised into inner layer 98. In this manner, channels 95 and 96 may be designed to deform in order to mitigate a rotational [i.e., torque] target, pre-injury force threshold. Inserts 93, 93′, 94 and 94′ could then be designed to deform in response to a lateral [i.e., side to side] target, pre-injury force threshold. In addition, portions of layer 98 of force-mitigating sole 92 could be designed with anisotropic fibers oriented in such a manner to deform in response to a longitudinal [i.e., heel to toe] target, pre-injury force threshold. It is noted that inserts 93, 93′, 94 and 94′ and channels 95 and 96 do not have to be in the same layer of force-mitigating sole 92. For example, the anisotropic fibers could be in layer 97, the inserts could be in layer 99 and channels 95 and 96 could be in layer 98. These arrangements are only illustrative of the underlying principle here that any of the three force-mitigating elements disclosed herein could be in any layer of a multiple-layer sole.

FIGS. 26-33 show a third embodiment of the invention. In this embodiment the sole is strategically weakened to provide the desired temporary deformation via inserts in the sole rather than by incising a channel in the sole. FIGS. 26 and 27 will be described together with it being understood that elements shown in one figure may or may not be shown in the other figure. It is noted that the inserts are all shown in the forward [toe] portion of the sole. Obviously, one or more inserts could be positioned in the mid portion of the sole, or even in the heel portion of the sole, if desired.

Sole 110 is a multi-layer composite sole similar in construction to the first and second embodiment soles shown and described above. The forward portion of sole 110 contains 4 inserts, 112, 112′, 114 and 114′. These inserts are made of a composite filler material similar to the sole materials described above; however, the filler material may or may not include bound fibers. The filler material of the inserts will have force-resisting characteristics that are different [and perhaps substantially so] than the materials comprising remaining portions of sole 110. These differences in material properties assist in providing the desired weakening in sole 110 to permit it to provide a mitigating deformation induced by a particular athlete's pre-determined, target pre-injury force threshold. In addition, the exact location of the inserts within the sole, the number of inserts, their geometric shape, and their depth are all characteristics which can be varied in order to provide the exact response desired to provide a mitigating deformation of sole 110 induced by a particular athlete's pre-determined, pre-injury force threshold.

Sole 110 is a multi-layer composite sole comprising layers 111, 111′ and 111″. As with the other embodiments of the invention, the number and composition of layers in sole 110 can and will vary depending upon the exact force-resisting response desired. In FIG. 27, insert 114′ is shown as being the same thickness as layer 111. Obviously, the thickness of the inserts can also be varied as desired. Inserts 112, 112′, 114 and 114′ are shown as being contained within the outer layer of sole 110; however, they could be placed in other layers of sole 110, if desired.

FIG. 28 shows a variation of the third embodiment of the invention. Multi-layer composite sole 115 is shown with four inserts 116, 116′, 117 and 117′. These inserts comprise a material with significantly different force-resisting characteristics than the material comprising inserts 112, 112′, 114 and 114′. As an example, a shoe with the inventive sole may be designed for a specific athlete for a specific event. During the event, which could be a football game, a soccer game or perhaps a rugby match, the weather changes substantially and the playing field becomes much slicker due to heavy rain. Following the method shown and described above, a new shoe using sole 115 could be constructed for the specific athlete [for instance, during the halftime break]. Since conditions are much slicker on the playing field, a shoe with sole 110 having inserts 112, 112′, 114 and 114′ might be too stiff for the changed playing conditions and a new shoe would be constructed with sole 115 having inserts 116, 116′, 117 and 117′ made of a material significantly less stiff than the material comprising inserts 112, 112′, 114 and 114′.

FIG. 29 shows another variation of the third embodiment of the invention. Multi-layer composite sole 120 is shown with four inserts 121, 121′, 122 and 122′. The previous examples of the third embodiment have had inserts all made from the same filler material. It is possible to provide in one sole inserts made from different filler materials. This is illustrated in FIG. 19. Inserts 121 and 121′ are made from a material similar to that used for inserts 116, 116′, 117 and 117′ of sole 115 shown in FIG. 28. Inserts 122 and 122′ are made from a material that has different force-resisting characteristics than the material used for the inserts for sole 115. This variation permits fine-tuning of the force-resisting characteristics of sole 115.

FIGS. 30-33 show yet another variation of the third embodiment of the invention. In previous variants of the third embodiment, the inserts have been oriented in a generally longitudinal [i.e., heel to toe] direction within the sole. In this embodiment, inserts 135 are oriented generally transverse to the sole 130. This is illustrated in FIG. 30 by lines 138. In FIG. 31 sole 130 is shown being stressed and deformed by a torsional [i.e., torque] force. The original position of the rear portion of sole 130′ is shown by a dashed line. The deformed position is shown at 130 by a solid line. Inserts 135 have changed shape in response to the torsional force as shown in FIG. 31 and have also assumed a different orientation as shown by lines 138′. As in previous versions of this embodiment, the size, orientation, geometric shape, placement within the sole outline, and composition of the insert filler material are all factors that will assist in determining the force-mitigating properties of the particular sole. Also as indicated above, it is possible to have some or all of the inserts 135 be in a layer within the shoe sole and not on an outer layer.

FIGS. 32 and 33 show a shoe sole similar to that shown in FIGS. 30 and 31; however, this sole is being stressed by a longitudinal [i.e., heel to toe] force. Sole 140 has multiple inserts 145 shown on the outer layer of the sole. As shown in FIG. 33, when sole 140 is subjected to a longitudinal force, inserts 145 temporarily deform to essentially “shorten” the shoe and in doing so provide a force-mitigating deformation of the particular shoe to prevent injury to the athlete's lower extremities and joints.

Each embodiment of the invention provides protection from injurious force to an athlete's lower extremity joints by providing a temporary force-mitigating deformation in the athlete's specifically configured shoe. Unlike other attempts to correct this problem, applicants have provided a shoe with a sole that is designed to temporarily deform when the sole is subjected to the pre-determined target pre-injury force threshold and to then return to its original form when the force applied to the shoe sole falls below the pre-determined target pre-injury force threshold.

The purpose of this invention is to protect the lower extremities of an athlete from injury. If you think of an athlete's leg as a column of connected links from the sole of the athletic shoe all the way up to the athlete's hip, the weakest link in the column is the athlete's ACL. One way of looking at this invention is to change this situation and make the sole of the athletic shoe the weakest link—instead of the ACL—so that the sole of the athletic shoe deforms before the athlete's ACL can deform [and be injured].

Claims

1. A force-mitigating shoe designed to protect a wearer's lower extremity joints from injurious stress caused by an applied force equivalent to a pre-determined target, pre-injury force, said shoe comprising:

an upper body and a force-mitigating sole attached to said upper body;

wherein said pre-determined target, pre-injury force comprises at least a pre-determined longitudinal target, pre-injury force; and

wherein said force-mitigating sole comprises:

at least a first layer of specifically engineered material;

wherein said first layer of material is specifically engineered to provide rigid translational stability to a wearer's foot when said first layer is subjected to forces below the level of said pre-determined longitudinal target, pre-injury force;

wherein said first layer of material is provided with at least one channel incised into said first layer to permit said first layer to become less rigid and temporarily deform in the same direction as said pre-determined longitudinal target, pre-injury force when said first layer of material is subjected to a force equivalent to said pre-determined longitudinal target, pre-injury force.

2. The force-mitigating shoe of claim 1, wherein said first layer of specifically engineered material is specifically engineered such that after said first layer has deformed when subjected to an applied force equivalent to said pre-determined longitudinal target, pre-injury force and said applied force drops below the level of said pre-determined longitudinal target, pre-injury force, said first layer instantly returns to its original shape.

3. The force-mitigating shoe according to claim 2, wherein said force-mitigating-sole comprises at least a second layer of material.

4. The force-mitigating shoe according to claim 3 wherein said second layer of material is the outer layer of said force-mitigating sole and said first layer of material is an inside layer of said force-mitigating sole such that said second layer of material covers said first layer of material.

5. The force-mitigating shoe according to claim 3 wherein said channel is elongated and follows a serpentine path back and forth across said first layer of material.

6. The force-mitigating shoe according to claim 3 wherein said first layer of material is the outer layer of said force-mitigating sole and said second layer of material is an inside layer of said force-mitigating sole such that said first layer of material covers said second layer of material.

7. The force-mitigating shoe according to claim 3 wherein said first layer of material comprises multiple elongated channels spaced along the surface of said first layer of material.

8. The force-mitigating shoe according to claim 7 wherein said multiple elongated channels are discontinuous.

9. The force-mitigating shoe according to claim 7 wherein said multiple elongated channels are chevron-shaped and spaced at irregular intervals along said first layer of material.

10. The force-mitigating shoe according to claim 3, wherein said pre-determined target, pre-injury force further comprises a pre-determined lateral target, pre-injury force;

wherein said second layer of material is specifically engineered to provide rigid lateral stability to a wearer's foot when said second layer is subjected to forces below the level of said pre-determined target, pre-injury force; and,

wherein said second layer of specifically engineered material is provided with at least one channel incised into said first layer to permit said first layer to become less rigid and temporarily deform in the same direction as said pre-determined lateral target, pre-injury force when said second layer of material is subjected to a force equivalent to said pre-determined lateral target, pre-injury force.

11. The force-mitigating shoe of claim 10, wherein said second layer of specifically engineered material is specifically engineered such that after said second layer has deformed when subjected to an applied force equivalent to said pre-determined lateral target, pre-injury force and said applied force drops below the level of said pre-determined lateral target, pre-injury force, said second layer instantly returns to its original shape.