U.S. patent application number 10/326247 was filed with the patent office on 2003-05-08 for inflatable lining for footwear with protective and comfortable coatings or surrounds.
Invention is credited to Lakic, Nikola.
Application Number | 20030084593 10/326247 |
Document ID | / |
Family ID | 26850350 |
Filed Date | 2003-05-08 |
United States Patent
Application |
20030084593 |
Kind Code |
A1 |
Lakic, Nikola |
May 8, 2003 |
Inflatable Lining for footwear with protective and comfortable
coatings or surrounds
Abstract
The invention is an inflatable inner sole for footwear which has
a flexible, inflatable enclosure with an inflation system that
preferably includes an on-board air pump and a pressure relief
valve. In this invention the inner sole has a sheet and/or foam
cover or surround on the flexible enclosure for enhanced comfort.
Useful sheet covers can be plastic, including rubber, films in
solid or foamed state, or fabric which are applied against the
upper, wearing surface of the inflatable enclosures. The covers can
be bonded only to the edges of the inflatable enclosures to permit
relative movement between the covers and enclosures, or can be
bonded to the top surface of the enclosures, or formed as surrounds
which encapsulate the inflatable enclosures.
Inventors: |
Lakic, Nikola; (Indio,
CA) |
Correspondence
Address: |
David E. Allred
MYERS DAWES & ANDRAS
Suite 1150
19900 MacArthur Blvd.
Irvine
CA
92612
US
|
Family ID: |
26850350 |
Appl. No.: |
10/326247 |
Filed: |
December 20, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10326247 |
Dec 20, 2002 |
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09658164 |
Sep 8, 2000 |
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6510624 |
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60153256 |
Sep 10, 1999 |
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Current U.S.
Class: |
36/29 |
Current CPC
Class: |
A43B 17/035 20130101;
A43B 5/0407 20130101 |
Class at
Publication: |
36/29 |
International
Class: |
A43B 013/20 |
Claims
What is claimed is:
1. An inflatable inner sole for footwear which comprises: a. an
inflatable enclosure formed of first and second sheets of plastic
film bonded together by a continuous seam defining a peripheral
flange surrounding a surface field and forming a sealed interior
with a plurality of discontinuous seams extending across said field
to form interconnecting, internal passageways within the sealed
interior; b. a flexible cover sheet overlying the upper surface of
the sealed enclosure bonded about its periphery to the peripheral
flange and unbonded to the field of said upper surface. c. an
inflation system comprising an inlet port and an outlet port
communicating with said sealed interior, inflation means in said
inlet port and a pressure control valve having a valve inlet, valve
operator and valve outlet with its inlet communicating with said
outlet port.
2. The inflatable inner sole of claim 1 including a peripheral rim
of elastomer overlying said peripheral flange and bonding the
periphery of said cover sheet to said peripheral flange of said
inflatable enclosure.
3. The inflatable inner sole of claim 1 wherein said cover sheet is
a laminate of fabric and an underlayer of elastomer.
4. The inflatable inner sole of claim 1 including an overlay sheet
lying between said cover sheet and inflatable enclosure and
spanning across said field of said inflatable enclosure.
5. The inflatable inner sole of claim 1 wherein said inner sole has
a shape to extend over the heel and metatarsal area of said
footwear.
6. The inflatable inner sole of claim 1 wherein said inner sole has
a shape to extend over the entire sole of said footwear.
7. The inflatable inner sole of claim 1 including a plurality of
apertures through said discontinuous seams.
8. The inflatable inner sole of claim 7 including a second
plurality of apertures through said cover sheet.
9. An inflatable inner sole for footwear which comprises: a. an
inflatable enclosure formed of first and second sheets of plastic
film bonded together in a continuous seam defining a peripheral
flange surrounding a surface field and forming a sealed interior
with a plurality of discontinuous seams extending across said field
to form interconnecting, internal passageways within the sealed
interior; b. a layer of flexible plastic overlying and bonded to
said upper surface of said inflatable enclosure; c. a flexible
cover sheet overlying and bonded to the upper surface of said
flexible plastic; d. an inflation system comprising an inlet port
and an outlet port communicating with said sealed interior,
inflation means in said inlet port and a pressure control valve
having a valve inlet, valve operator and valve outlet with its
inlet communicating with said outlet port.
10. The inflatable inner sole of claim 9 wherein said plastic is
natural or synthetic rubber.
11. The inflatable inner sole of claim 9 wherein said plastic is a
flexible synthetic thermoplastic.
12. The inflatable inner sole of claim 9 including discontinuous
seams in the arch area of said inner sole which form a medial
recess in said inner sole.
13. The inflatable inner sole of claim 12 including an air pump
mounted in said medial recess and comprising a flexible bulb with a
valve inlet port having an inlet check valve and a valve outlet
port having an outlet check valve.
14. The inflatable inner sole of claim 13 including an air pump
housing located in said recess with said check valves mounted in
said housing and also including a normally closed pressure relief
valve having a valve operator accessible in said recess to release
air from said sealed enclosure.
15. The inflatable inner sole of claim 9 wherein said layer
surrounds said inflatable enclosure.
16. The inflatable inner sole of claim 15 wherein said inflatable
enclosure has a through opening surrounded by a continuous circular
seam and including an air pump comprising a flexible bulb with an
air pump outlet port connected to said inlet port of said sealed
enclosure by an outlet check valve and an air pump inlet port
communicating exteriorly of said enclosure by an inlet check
valve.
17. The inflatable inner sole of claim 16 including a supply tube
extending from said flexible bulb to said air pump inlet and outlet
ports.
18. The inflatable inner sole of claim 17 including discontinuous
seams in the arch area of said inner sole which form a medial
recess with said check valves located in said recess and said
supply tube extending between said flexible bulb and said
recess.
19. The inflatable inner sole of claim 18 wherein said pressure
control valve is also located in said recess and including a
flexible tube connecting between the valve outlet port and at least
one of said second plurality of apertures.
20. The inflatable inner sole of claim 19 wherein said pressure
control-valve is an automatic pressure relief valve with an
internal spring biasing said valve operator into a closed position
with adjustment means permitting user adjustment of the tension on
said spring.
21. The inflatable inner sole of claim 20 wherein said pressure
relief valve is positioned in said recess with the valve operator
exposed in said recess for access to a user for adjustment of the
pressure setting of said valve.
22. The inflatable inner sole of claim 9 including at least one
continuous seam continuously extending across said field of said
enclosure to divide said enclosure into at least two independent
inflatable chambers.
23. The inflatable inner sole of claim 22 including an air port in
each of said chambers, each connected to a tube which communicates
with a respective inflation means exteriorly of the inflatable
enclosure.
24. The inflatable inner sole of claim 23 including discontinuous
seams in the arch area of said inner sole which form a medial
recess in said inner sole and wherein each of said respective
inflation means are mounted in said recess.
25. The inflatable inner sole of claim 24 wherein each of said
inflation means comprises an assembly of a connector for attachment
of an external air supply tube and a relief valve.
26. The inflatable inner sole of claim 25 wherein said enclosure
has two continuous seams which divide said sealed enclosure into
three independent inflatable chambers.
27. The inflatable inner sole of claim 26 wherein an independent
inflatable chamber is located at each of the heel, instep and
metatarsal areas of said inner sole.
28. The inflatable inner sole of claim 9 wherein said discontinuous
seams extend transversely across the metatarsal area of said inner
sole and including flexible magnetic plates positioned beneath the
transverse seams of the inflatable enclosure.
Description
[0001] This Application is entitled to the benefit under 35 USC
119(e) of Provisional Application No. 60/153,256 filed on Sep. 10,
1999.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to an inflatable lining for footwear,
particularly to an inflatable inner sole with protective and
comfortable coatings and surrounds and method for its
manufacture.
[0004] 2. Brief Statement of the Prior Art
[0005] Inner soles have been provided for shoes and boots which are
formed of a compressible, elastic material such as cellular plastic
foams, foam rubber, etc. These inner soles have provided only
limited shock absorbency, resulting in little no significant
improvement in wearer comfort.
[0006] Some prior investigators have provided inner soles with
inflated cushions at either the toe and heel areas, and some have
provide cushions at both areas with circulation between the two
cushions. The cushions have been provided with mechanisms to
circulate air and ventilate the shoe or boot during walking
activities. Examples of these are: U.K. Patents 2,189,679 and
357,391; U.S. Pat. Nos. 3,180,039, 2,716,293, 1,213,941 and German
Patent 3,144,207.
[0007] Sport socks are also available for hikers and runners which
have a double layer of fabric on the undersurface of the sock in an
attempt to prevent blisters.
[0008] In some foot apparel, notably in ski boots, an outer shell
is molded from plastic and is lined with an inner shoe. Adjustment
has been made to the tightness of the outer shell and air bags have
been provided across the instep region of the shoe, and elsewhere,
and have been provided with an air pump to pressure the air bags,
thus forcing the foot against the sole and creating a snugness of
the fit of the ski boot. U.S. Pat. No. 4,730,403 and German Patent
2,321,817 are representative of these ski boots.
[0009] A water-filled inner sole for shoes has recently been
marketed under the trade name "Walk On Water". While this is an
attempt to increase wearer comfort, water is heavy,
non-compressible and the inner sole cannot be adjusted for
firmness, and cannot provide shock absorbency. Additionally, water
is unsuited for use in freezing climates. Also, a leak will wet the
inside of the bootwear, and this inner is not breathable.
[0010] Another recently marketed innovation is that disclosed in
U.S. Pat. Nos. 4,183,156; 4,340,626 and 4,817,304 in which an
inflatable inner sole or sole insert is permanently inflated with
halogenated hydrocarbon gases. Since it is impossible to preclude
diffusion of gases through the plastic, the inflatable insert or
inner sole is acknowledged to experience a rapid increase in
pressure shortly after manufacture, followed by a slowly declining
pressure, thus failing to provide a stable condition. The pressure
of the inflatable member also cannot be adjusted by the wearer for
varying conditions of use and comfort.
[0011] None of the aforementioned prior devices provides a simple,
inexpensive solution to comfortable wear and walking in a shoe or
boot. The foam inner soles have only a limited value and limited
shock absorbency. The remainder of the prior devices, including the
pressurization system for ski boots are relatively complex and
costly and are often too bulky and cumbersome. Consequently, these
devices are not readily acceptable for everyday activities.
[0012] In my prior patent (U.S. Pat. No. 5,846,063) I disclose and
claim inflatable linings with an on board inflation pump and relief
valve which is readily adaptable to mass manufacturing techniques.
A preferred application of the inflatable enclosure is that of an
inflatable inner sole of footwear.
OBJECTIVES OF THE INVENTION
[0013] It is an objective of this invention to provide a light
weight, shock-absorbing inflatable lining which enhances the fit,
stability and comfort of footwear.
[0014] It is also an objective of this invention to provide the
aforementioned inflatable lining with an on-board air pump and
relief valve to permit the wearer to adjust the lining from firm to
soft support, as desired for the wearer's weight and or
activity.
[0015] It is an additional objection of this invention to provide
an inflatable lining as an inner sole for footwear such as shoes,
boots and sandals, having an arch pillow and a contour conforming
to the wearer's foot, which preferably will massage the wearer's
foot.
[0016] It is likewise an objection of this invention to provide an
inflatable lining as an inner sole for orthopedic footwear to treat
and prevent foot disorders.
[0017] It is a further objective of this invention to provide an
inflatable lining with a surface which will prevent blister
formation.
[0018] It is a further objective of this invention to provide the
aforementioned inflatable linings with a fabric and/or foam
covering for comfort enhancement.
[0019] It is also an objective of this invention to provide a
simple method for manufacture of the inflatable lining.
[0020] Other and related objectives will be apparent from the
following description of the invention.
BRIEF DESCRIPTION OF THE INVENTION
[0021] This invention comprises an inflatable lining for footwear
which has sheet and/or foam coatings or surrounds for enhanced
comfort and a method for its manufacture. Useful sheet coatings can
be plastic films or fabric and, when used, are applied against the
wearing surface of the lining. Plastic foam, when used, alone or in
combination with sheet coatings, can be applied to either surface
of the lining, preferably as a surround which encapsulates the
inflated lining. The inflatable linings are preferably those
described in my prior patent (U.S. Pat. No. 5,846,063) which
include an on-board air pump and relief valve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention will be described with reference to the
figures of which:
[0023] FIG. 1 is a plan view of an inflatable inner sole
encapsulated in an elastomeric material with an on-board air pump
and adjustable relief valve;
[0024] FIG. 2 is a cross sectional view along line 2-2' of the
inner sole of FIG. 1;
[0025] FIG. 3 is a cross sectional view along line 3-3' of the
inner sole of FIG. 1;
[0026] FIG. 4 is a cross sectional view along line 4-4' of the
inner sole of FIG. 1;
[0027] FIG. 5 is a perspective view of the inflatable inner sole of
FIG. 1;
[0028] FIG. 6 is an enlarged sectional view of a portion of FIG. 2
to illustrate the construction of the inflatable lining of the
inner sole;
[0029] FIG. 7 is a plan view of an alternative inflatable inner
sole having an upper elastomeric coating with an on-board air pump
and adjustable relief valve;
[0030] FIG. 8 is a cross sectional view along line 8-8' of the
inner sole of FIG. 7;
[0031] FIG. 9 is a cross sectional view along line 9-9' of the
inner sole of FIG. 7;
[0032] FIG. 10 is a cross sectional view along line 10-10' of the
inner sole of FIG. 7;
[0033] FIG. 11 is an enlarged cross sectional view of an
alternative upper coating;
[0034] FIG. 12 is an enlarged cross sectional view of a second
alternative coating;
[0035] FIG. 13 is a plan view of an alternative inner sole which
has an inflated enclosure over the heel and arch areas of the sole
and is encapsulated in an elastomeric material with an on-board air
pump and adjustable relief valve;
[0036] FIG. 14 is a cross sectional view along line 14-14' of the
inner sole of FIG. 13;
[0037] FIG. 15 is a cross sectional view along line 15-15' of the
inner sole of FIG. 13;
[0038] FIG. 16 is a cross sectional view along line 16-16' of the
inner sole of FIG. 13;
[0039] FIGS. 17-20 are plan and sectional views of an alternative
inflatable inner sole with embedded magnets;
[0040] FIG. 21 is a plan view the air pump and check valve assembly
used with the inflatable linings;
[0041] FIG. 22 is a view of a check valve used in the air pump and
check valve assembly;
[0042] FIG. 23 is a sectional view along line 23-23' of FIG. 21,
with the relief valve omitted;
[0043] FIG. 24 is a sectional view along line 24-24' of FIG.
21;
[0044] FIG. 25 is a view of an alternative check valve useful in
the air pump and relief valve assembly;
[0045] FIG. 26 is a plan view of an alternative inflatable inner
sole with an on board air pump in the heel of the inner sole and
with an adjustable relief valve;
[0046] FIG. 27 is a cross sectional view along line 27-27' of the
inner sole of FIG. 26;
[0047] FIG. 28 is a cross sectional view along line 28-28' of the
inner sole of FIG. 26;
[0048] FIG. 29 is a cross sectional view along line 29-29' of the
inner sole of FIG. 26;
[0049] FIG. 30 is a perspective view of the inflatable inner sole
of FIG. 26;
[0050] FIGS. 31-36 are plan and sectional views of the heel air
pump used in the inner sole shown in FIG. 26;
[0051] FIGS. 37-40 are views of the check valve assembly used in
the inner sole of FIG. 26;
[0052] FIGS. 41-44 are views of the pressure control valve used in
the inner sole of FIG. 26;
[0053] FIG. 45 is a plan view of an alternative inflatable inner
sole without an on-board air pump;
[0054] FIG. 46 is a cross sectional view along line 46-46' of the
inner sole of FIG. 45;
[0055] FIG. 47 is a cross sectional view along line 47-47' of the
inner sole of FIG. 45;
[0056] FIG. 48 is a cross sectional view along line 48-48' of the
inner sole of FIG. 45;
[0057] FIG. 49 is a sectional view of the relief valve and
connector to attach an external source of pressured gas to the
inner sole of FIG. 45;
[0058] FIG. 50 is a perspective, partial sectional view of the
inflatable inner sole shown in FIGS. 45-48;
[0059] FIG. 51 illustrates an external air pump useful with the
inflatable inner sole shown in FIGS. 45-48;
[0060] FIGS. 52-54 are views of an adapter, a connector, and a
needle valve air source useful with the inflatable inner sole of
FIGS. 45-48; and
[0061] FIG. 55 is a perspective view of an orthopedic insert for
use with the inflatable inner soles of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0062] Referring now to FIGS. 1-5, the invention as applied to an
inflatable inner sole will be described. The inflatable inner sole
10 is shown in plan view in FIG. 1, in sectional views in FIGS.
2-4, in perspective, partial sectional view in FIG. 5 and in an
enlarged sectional view in FIG. 6. The inflatable inner sole 10
which has an inflatable enclosure 11 that extends across the entire
sole including the heel area 13, the arch or instep area 15, the
toe area 22 and metatarsal area 20. The inflatable enclosure 11 is
formed by a first sheet 12 and a coextensive second sheet 14 of
substantially the same shape and size. These sheets can be best
seen in the enlarged sectional view, FIG. 6. The first and second
sheets 12 and 14 are bonded together in a continuous peripheral
seam 16 that extends about the heel area 13 and the instep area 15
of the inner sole 10. The seam is sufficiently wide to form an
annular flange 17 which is die cut to approximately the correct
size and shape for the particular inner sole. The flange 17 is
oversized, however, to permit the user to trim the inner sole 10 to
the exact shape and size of the wearer's footwear.
[0063] The first and second sheets 12 and 14 are preferably plastic
and most preferably are thermoplastic, so that conventional heat
sealing can be used for forming the seams. The most preferred
thermoplastic material is polyurethane, however, other suitable
materials include ethylene, and ethylene vinyl acetate copolymers,
polyethylene, polypropylene, polyvinyl chloride, etc. Natural or
synthetic rubber can also be used.
[0064] The first sheet 12 and second sheet 14 are also bonded
together with a plurality of discontinuous seams 34, 36 and 38 and
40 which form tubular, interconnecting passageways 56 through the
heel area 13 and passageways 28 through the instep area 15 of the
inner sole 10. The inflatable enclosure 11 also has a plurality of
discontinuous, transverse seams 74 in the metatarsal area 20 and
toe area 22 to impart flexibility to the inner sole 10 and to form
interconnecting passageways 29 which extend across these areas to
permit the wearer to control the firmness and support of the inner
sole simply by controlling the inflation pressure within the
inflatable enclosure 11.
[0065] The spacing between adjacent seams controls the size
(diameter) of the passageways 28 and 29. If desired, some areas of
the inflatable enclosure 11 can be unseamed to form air pillows.
The size and spacing of the interconnecting passageways and pillows
can easily be varied during manufacture to adapt the inner sole to
the particular shoe. Thus, the pillows and passageways in the arch
area can be small in size to fit conventional shoes with integral
arch supports or large in size for use with shoes having flat or
near flat soles, to provide an arch support. In either case, the
firmness of the inner sole 10 can be regulated by adjustment of the
air pressure within the inflatable enclosure 11.
[0066] Preferably, the seams have a plurality of through
perforations or apertures 32 which extend entirely thorough the
first and second sheets 12 and 14 and are entirely surrounded by a
seam 30. The spacing, size and number of these discontinuous seams
can be varied greatly, as desired, to provide the maximum comfort
and convenience to the wearer of a shoe fitted with the inflatable
inner sole 10.
[0067] The C-shaped heel seam 34 forms a heel pillow 54 and a heel
peripheral tubular passageway 56. There is a small C-shaped arch
pillow 58 which is formed by seams 16, 36 and 40 and which forms a
medial recess 62 that receives the inflation assembly 60 which
includes an air pump 61 and relief valve 63. The inflatable inner
sole 10 is intended for use as a replacement insert for shoes which
have some arch support. Therefore this embodiment 10 has a small
arch pillow 58, sufficient to encircle the pump and relief valve
assembly 60.
[0068] The inflatable enclosure 11 is encapsulated in a matrix 52
formed of an elastomeric material such as synthetic rubber, e.g.,
polyurethane, or a foamed compressible plastic such as polyurethane
foam, polyethylene foam, etc. The step of encapsulating the
inflatable enclosure 11 is performed by placing the inflated
enclosure 11 in a mold and injecting the elastomer or foaming
resin. One or more apertures 33 can be provided which extend
through the matrix 52. The compressibility of the foam or elastomer
can be selected to provide a suitably soft and comfortable feel to
the inner sole 10 and the firmness and shock absorbency of the
inner sole 10 can thus be controlled by the inflation pressure
which is maintained in the inflatable enclosure 11.
[0069] The upper or wear surface of the inner sole 10 is covered
with an outer layer 64 of fabric. The fabric may be Nylon such as
widely used in inflatables produced by Mann Industries, Inc., of
Framingham, Mass., or material produced by Faytex Corp., Weymouth,
Mass., like DRI-LEX.RTM. LINING, HYDROFIL.RTM. Nylon from Allied
Signal. The moisture absorbing qualities of the HYDROFIL Nylon
draws moisture away from the skin keeping the user dry, cool and
comfortable.
[0070] In reference to other illustrations of the invention, the
components of this inner sole which are the same as those of
previously described inner sole 10 are identified with the same
numbers as used in FIGS. 1-6.
[0071] FIGS. 7-10 illustrate an alternative inflatable inner sole
18 which has an upper layer 24 of elastomer matrix. This embodiment
is quite similar to that shown in FIGS. 1-6, however, the
inflatable enclosure 11 is not encapsulated within a matrix of
elastomer or foam. Instead, the layer 24 of elastomer is formed on
the upper surface of the first sheet of the inflatable enclosure 11
and the under surface of the inflatable enclosure 11 rests on the
inside wall of the sole of the footwear, forming open channels 26
beneath the enclosure 11.
[0072] FIG. 11 is a cross sectional view of an alternative inner
sole 144 which is particularly useful in sport shoes such as cross
country shoes for runners and hikers, as the construction permits
movement between the inflatable enclosure 11 and the upper cover
140. In this construction, the inflatable enclosure 11 is
surrounded with a peripheral upper rim 136 of elastomer or foam,
leaving the areas between the inflated passageways such as
connecting passageway 56 and pillow 54 void, which minimizes the
bulk and weight of the inner sole 144 and provides an air chamber
138 above the inflatable enclosure 11. A fabric 148 is bonded to an
underlayer 142 of thermoplastic, such as polyurethane and the
underlayer 142 is bonded to the peripheral upper rim 136, leaving
the field of the surface of the inflatable enclosure 11 unbonded to
the cover 140, thereby permitting relative movement between the
cover 140 and the inflatable enclosure 11. This inflatable inner
sole is formed by placing the inflatable enclosure, in an inflated
state, onto a support plate with a peripheral surface beneath the
enclosure flange 17 and by providing a rim which surrounds the
outer edge of the enclosure flange 17 to contain a liquid
prepolymer which is poured about the periphery of the enclosure and
cured into the elastomer or foam edge. The fabric 148 is coated
with an underlayer 142 of elastomer and then placed over the
enclosure and bonded to the peripheral edge 136 of elastomer or
foam. If desired, a minor amount of a lubricant can be included in
the chamber 138 to reduce frictional resistance between the cover
140 and field surface of the enclosure 11. The resultant inner sole
144 has an inflatable enclosure which is inflated under pressure
and another air chamber 138 at atmospheric pressure for enhanced
comfort. The bulk and weight of the inner sole 144 is minimal.
[0073] FIG. 12 illustrates a cross sectional view of another
alternative inner sole 146 which also permits relative movement
between an upper cover 153 and the inflatable enclosure 11. In this
embodiment, an overlay 150 of Teflon, or of synthetic or natural
rubber or other thermoplastic, in solid or foamed state, is placed
over the inflatable enclosure 11. In this illustration the overlay
150 does not extend to the peripheral edge 17 of the enclosure and
is not bonded to the enclosure, although it could extend and be
bonded to the peripheral edge 17. The cover 153, which comprises a
laminate of fabric 148 bonded to an underlayer 151 of a
thermoplastic such as polyurethane, is placed over the inflatable
enclosure 11 and overlay 150 and is heat sealed to the peripheral
flange 17 of the inflatable enclosure 11. As with the inner sole
144 illustrated in FIG. 11, this inner sole 146 also, has an air
chamber 138. If desired, the inflated enclosure can be provided
with apertures 32 to permit air movement between the open channels
26 beneath the inflatable enclosure 11 and the air chamber 138.
Also, air circulation through the footwear can be achieved by
providing apertures 152 through the overlay 150 and cover 153.
These apertures can be formed by die cutting through the cover
during finishing operations.
[0074] Referring now to FIGS. 13-16, another embodiment of the
invention is illustrated in which the inflatable enclosure 72 of
the inner sole 70 extends over the heel area 13 and instep area 15
of the inner sole, but does not extend over the metatarsal area 20
or the toe area 22. Flexibility of the inflated inner sole 70 is
achieved with the transverse portion 50 of the peripheral seam 16.
In this embodiment, comfort and support of the toe and metatarsal
areas is provided by the compressibility of the elastomeric matrix,
which can be of natural or synthetic rubber in solid or foam
texture or of other compressible foams, e.g., polyethylene
foam.
[0075] FIGS. 17 through 20 are plan and sectional views of an
alternative inflatable inner sole 76, which is similar with inner
sole 10 described in FIGS. 1-6. The only addition in this
embodiment are thin plastic magnetic plates 78 which are
encapsulated inside the elastomeric matrix 52 beneath inflatable
enclosure 11. These plates are provided in accordance with current
popular opinion to enhance blood flow to areas adjacent the
magnets, combating fatigue and weakness. The thin plastic magnetic
plates 78 are flexible and are strategically positioned beneath the
transverse seams 74 of the inflatable enclosure 11 to allow normal
flexing and bending of the inner sole 10.
[0076] FIGS. 21 through 24 are plan and sectional views of the pump
and relief valve assembly 60 which permits the wearer to adjust the
inflation pressure within the inflatable enclosure 11 to any
desired comfort level or support. The construction and operation of
this assembly is described in my prior patent (U.S. Pat. No.
5,846,063). The assembly 60 includes a compressible pump dome 80
which has an undercut 90 for ease of depression. The housing 92 of
the assembly 60 and has two cavities 94 and 96 which receive two
duck-bill check valves (also shown in FIG. 20); inlet check valve
98 and outlet (discharge) check valve 100. An enlarged
cross-sectional view of a subassembly 23 of the check valves is
shown in FIG. 25. Prior to insertion into the housing cavities 94
and 96, each of the duckbill check valves 98 and 100 are inserted
into a protective brass sleeve 102 and brass cup 104 which has an
opening 106 for air passage. Each valve is captured in the assembly
with its flange 135 locked between the sleeve 103 and cup 104. The
assembly is then inserted into cavities 94 and 96 of the pump
housing 92 illustrated in FIGS. 21, 22 and 24. As the housing 92 is
formed of soft plastic, the protective sleeves 102 and cups 104
prevent accidental squeezing of the check valves when forces are
applied to the housing 92.
[0077] A relief valve operator 108 is inserted into a valve cavity
110 of the relief valve housing 92 and a coil spring 112 is
positioned beneath the operator 108 to provide a biased force which
seats the seal ball 114 on the lower end of the relief valve
operator 108 to seat against the valve aperture 116. There is a
passageway 118, which connects the cavity beneath dome 80 and check
valve assembly 27. The outlet passage from check valve 100 extends
over tunnel 120, through passageway 122 and through opening 124 on
the first flexible plastic sheet 12 into the inflatable enclosure.
The tunnel 120 accepts a mandrel (metal bar) which is a removable
part of the metal sealing die to heat seal the area 179, beneath
tunnel 120, to seal the entire periphery of the cavity beneath the
dome 80, thereby providing air circulation only through the check
valves 98 and 100. The inlet check valve 98 receives air through
side opening 126 and discharges into the cavity beneath pump dome
80. There is a recess 128 on top surface of the relief valve
housing 92 to prevent from accidental activation of the relief
valve operator 108 when in contact with existing shoe lining. An
aluminum sleeve 180 is inserted inside cavity 110 to reinforce
housing 92 to prevent accidental squeezing and activation of the
relief valve.
[0078] There is a flange 130 around the assembly 60 to permit
permanent attachment of the assembly to a supporting surface,
usually a plastic sheet by heat sealing or any other alternative
process.
[0079] Referring now to FIGS. 26-30, the invention is illustrated
as an inflatable inner sole 30 which has an air pump 35 located
beneath the wearer's heel so that normal walking and running
activities will provide inflation pressure to the inflatable
enclosure. The heel portion of the inflatable enclosure has a
circular opening 37 which is surrounded by a continuous seam 168 to
receive the heel air pump 35. The air pump 35 comprises a generally
flat, flexible, resilient bulb that is integrally connected to a
flexible passageway 39, located underneath seam 182, which extends
to the arch area. The passageway 39 is connected with flexible
tubes 41, which provides air to the pump through its inlet check
valve 44, and to a second flexible, discharge tube 41 which
discharges air from the pump 35 into enclosure 31 through check
valve 45. The check valves 44 and 45 can be placed in the tubes 41.
The inflation enclosure 31 also has a pressure control valve 46
which is mounted in recess 62 for access to the wearer to permit
adjustment of the internal pressure, or firmness of the inner sole
as desired by the wearer. As described hereinafter, the excess air
released by the pressure control valve passes through tube 134
which is connected to one or more of the apertures 33 preferably
located in the toe area of the inner sole 30 to ventilate the
footwear during walking or running activities. During fabrication
of the inner sole 30, the flexible tubes, pump 35, discharge check
valve 47 and pressure control valve 46 will be secured permanently
by the surrounding matrix 52.
[0080] FIGS. 31-34 are plan and sectional views of a heel air pump
35 which is formed with an upper part 156 which has the shape and
form of the cavity formed underneath the heel area of the
inflatable enclosure 31 by seams 168 and 182, and a lower flat part
158 which are sealed with a peripheral seam 160. The pump 35 has an
integral passageway 39 which has two ports; inlet port 162 and
discharge port 164. It can be made from polyurethane, kraton,
silicon, rubber,etc., any material that is soft, has good
resiliency, good memory and is durable. There is a slot 166 on the
upper part of the pump to accept circular seam 168 of the
inflatable enclosure 31. This pump can be assembled by heat sealing
or a permanently glued seam.
[0081] FIGS. 35 and 36 are sectional views of alternative air pumps
172 and 174. The air pump 172 shown in FIG. 35 has a dome 176 which
is received within the circular seam 168 and which can be heat
sealed to the seam. The air pump 174 shown in FIG. 36 is a flat
circular chamber 178 which is received in the circular area beneath
the inflatable enclosure 170.
[0082] FIGS. 37-40 are views of the discharge check valve assembly
47. There is a duck bill check valve 23 mounted in the housing 49.
The inlet port 51 and outlet port 53 align with openings (not
shown) of the lower sheet of the inflatable enclosure and the
housing has a flange 55 for permanent attachment of the assembly to
the enclosure by heat sealing or other bonding techniques.
[0083] FIGS. 41-44 illustrate the automatic adjustable relief valve
assembly 46 which has a housing 57 having intersecting passageways
59, 132 and 133. The large diameter passageway 59 receives a ball
valve member 65 which is biased against the spherically concave
terminus 66 of the passageway 59 by a spring 67. Tension on the
spring 67 is adjustable by advance or retraction of the spring
retainer 68 in its threaded engagement in sleeve 131 which is
permanently seated in passageway 59. The inlet passageway 132
communicates with the enclosure 31 and the outlet passageway 133
discharges beneath the enclosure 31 through tube 134 discharging
air through the apertures 32 and 33 of the inner sole 30. This
establishes a forced air circulation in the shoe. The housing 57
has a peripheral flange 69 which is permanently bonded to the lower
sheet of the enclosure 31. As shown in FIG. 42, the spring retainer
68 has an end slot 71 to receive a tool blade, permitting the
wearer to advance or retract its position in passageway 59.
[0084] FIGS. 45-48 are planar and sectional views of an alternative
inflatable inner sole 73, which has an inflatable enclosure 75 that
is divided into three independent chambers 77, 79 and 81, which are
located at the front (toe and metatarsal), arch and heel areas of
the inner sole 73. These chambers have apertures 27, 82 and 83,
each of which communicates with a respective connector assembly 84.
The connector assemblies are located in recess 62 and are connected
to the inflatable chambers by flexible tubes 85, 86 and 87 which
are bonded to the apertures 27, 82 and 83. The location of the
connector assemblies is best shown in FIG. 50 which is a
perspective and sectional view of the inflatable inner sole 73.
This embodiment uses an external source of inflation gas, e.g.,
compressed air or other gas such as carbon dioxide which is
attached to the connector assemblies 84.
[0085] FIG. 49 is a sectional view of the connector/valve assembly
84. The connector/valve assembly 84 is conventional inflation valve
similar to valves available from Schrader Automotive Inc.,
Nashville, Tenn. 37202. A valve 89 having a valve member 183 is
resiliently biased into a closed position against valve seat 184 by
an internal spring (not shown). A valve member 183 is secured to a
rod 99 which extends through the valve 89 to an upper end 99 which
serves as a valve operator to permit opening of the valve. The
valve 89 has external threads which are threadably received within
a connector housing 88. The upper end of a neck 91 of the valve 89
is conical to permit removable attachment of tubing. The lower end
of valve 89 has a rubber ring 95 which seats against an internal
shoulder 93 of the housing 88 for resiliently sealing within the
connector housing. The connector housing has a conical connector
leg 186 to receive a tubing such as tube 85.
[0086] FIG. 51 is a perspective view of an external hand pump 101.
It has a flexible bulb 103, inlet check valve 105, outlet check
valve 107 and flexible tube 109 which can be connected to the
connector assemblies 84.
[0087] FIG. 52 is a perspective view of an adapter 111 which
enables inflation of the inner sole in absence of the hand pump. It
has flexible tube 113 which contains a rubber needle valve 115
similar to the needle valves used in basketballs, footballs, soccer
balls, volleyballs, to permit use of a needle air pump 117 having a
pump cylinder 119 with an air discharge needle 121, as shown in
FIG. 54. Alternatively other air sources such as pressured
cylinders of air, nitrogen or carbon dioxide could be substituted
for the air pump.
[0088] FIG. 55 is a perspective view of an orthopedic layer 123
which has a recess 125 to receive the air pump 61 described and
illustrated with regard to FIGS. 31 through 36. In this
application, the orthopedic layer 123 is placed beneath or above
the inflatable inner sole 10 of FIG. 1. Orthopedic inserts such as
layer 123 are usually custom made inserts worn in shoes to support
the foot, especially for sports. The layer 123 is a plastic plate
127 with a shape and form to provide arch support. The plate 127
has plastic ribs 129 around recess 125.
[0089] The invention has been described with reference to the
illustrated and presently preferred embodiment. It is not intended
that the invention be unduly limited by this disclosure of the
preferred embodiment but instead by the elements and their
equivalents set forth in the following claims.
* * * * *