U.S. patent application number 10/757874 was filed with the patent office on 2005-07-14 for footwear with expanded thermoplastic beads in the footbed.
Invention is credited to Iannacone, Gail.
Application Number | 20050150132 10/757874 |
Document ID | / |
Family ID | 34740102 |
Filed Date | 2005-07-14 |
United States Patent
Application |
20050150132 |
Kind Code |
A1 |
Iannacone, Gail |
July 14, 2005 |
Footwear with expanded thermoplastic beads in the footbed
Abstract
Footwear (e.g., shoes, sandals, boots, etc.) is constructed with
small beads stuffed into the footbed, so that can the beads can
shift about due to pressure on the footbed by the user's foot
during normal use. Preferably, the beads are made of expanded
polystyrene, and have an average diameter between about two thirds
and about one mm. The resulting footwear is very comfortable. In
some sandal embodiments, the straps are also stuffed with the same
type of beads
Inventors: |
Iannacone, Gail; (New York,
NY) |
Correspondence
Address: |
PROSKAUER ROSE LLP
PATENT DEPARTMENT
1585 BROADWAY
NEW YORK
NY
10036-8299
US
|
Family ID: |
34740102 |
Appl. No.: |
10/757874 |
Filed: |
January 14, 2004 |
Current U.S.
Class: |
36/11.5 |
Current CPC
Class: |
A43B 7/146 20130101;
A43B 3/105 20130101 |
Class at
Publication: |
036/011.5 |
International
Class: |
A43B 003/12 |
Claims
I claim:
1. A sandal comprising: a sole comprising (a) a lower sole, (b) a
flexible upper sole, and (c) a plurality of unamalgamated beads
disposed between the upper sole and the lower sole; and at least
one strap connected to the sole and configured to secure the sole
to the bottom of a user's foot.
2. The sandal of claim 1, wherein the beads that are disposed
between the upper sole and the lower sole are enclosed in a thin
and flexible inner bag, the bag being disposed between the upper
sole and the lower sole.
3. The sandal of claim 1, wherein the upper sole is made of
fabric.
4. The sandal of claim 1, wherein the upper sole is made of stretch
jersey fabric.
5. The sandal of claim 1, wherein the beads are roughly spherical
expanded thermoplastic beads.
6. The sandal of claim 1, wherein the beads are roughly spherical
expanded polystyrene beads having an average diameter between about
two thirds and about one mm, and wherein the plurality of beads
comprises at least ten thousand beads.
7. The sandal of claim 6, wherein the upper sole is made of a
lightweight fabric.
8. The sandal of claim 7, wherein the beads that are disposed
between the upper sole and the lower sole are enclosed in an inner
bag made of a lightweight fabric, the bag being disposed between
the upper sole and the lower sole.
9. The sandal of claim 1, wherein the at least one strap is stuffed
with unamalgamated, roughly spherical, expanded thermoplastic
beads.
10. The sandal of claim 1, wherein the at least one strap is
stuffed with unamalgamated, roughly spherical, expanded polystyrene
beads having an average diameter between about two thirds and about
one mm.
11. A shoe comprising: a sole comprising (a) a lower sole, (b) a
flexible upper sole, and (c) a plurality of unamalgamated small
beads disposed between the upper sole and the lower sole; and an
upper connected to the sole and configured to secure the sole to
the bottom of a user's foot.
12. The shoe of claim 11, wherein the beads that are disposed
between the upper sole and the lower sole are enclosed in a thin
and flexible inner bag, the bag being disposed between the upper
sole and the lower sole.
13. The shoe of claim 11, wherein the upper sole is made of
fabric.
14. The shoe of claim 11, wherein the upper sole is made of cotton
jersey stretch knit fabric.
15. The shoe of claim 11, wherein the beads are roughly spherical
expanded thermoplastic beads.
16. The shoe of claim 11, wherein the beads are roughly spherical
expanded polystyrene beads having an average diameter between about
two thirds and about one mm, and wherein the plurality of beads
comprises at least ten thousand beads.
17. The shoe of claim 16, wherein the upper sole is made of a
lightweight fabric.
18. The shoe of claim 17, wherein the beads that are disposed
between the upper sole and the lower sole are enclosed in an inner
bag made of a lightweight fabric, the bag being disposed between
the upper sole and the lower sole.
19. An article of footwear comprising: a lower sole having an upper
surface; sidewalls having an inner surface, wherein the sidewalls
are connected to the lower sole so as to form a recess that is
bounded by the inner surface of the sidewalls and the upper surface
of the lower sole; a plurality of unamalgamated small beads
disposed in the recess; a thin and flexible upper sole disposed on
top of the beads and arranged to retain the beads within the
recess; and wherein the beads are free to shift around within the
recess when pressure is applied to the beads through the upper
sole.
20. The article of footwear of claim 19, wherein: (a) the recess
occupies an area that is at least half as large as the area of the
upper sole, (b) at least one part of the recess is at least one
about one quarter inch deep, and (c) the plurality of beads
comprises at least ten thousand beads.
21. The article of footwear of claim 20, wherein the beads are
roughly spherical expanded polystyrene beads having an average
diameter between about two thirds and about one mm.
22. The article of footwear of claim 21, wherein the beads are
enclosed in a bag made of a lightweight fabric, and the flexible
upper sole retains the beads within the recess by retaining the bag
within the recess.
23. The article of footwear of claim 21, further comprising at
least one strap connected to at least one of the lower sole, the
sidewalls, and the upper sole, wherein the at least one strap is
adapted to hold the upper sole against the bottom of a user's
foot.
24. The article of footwear of claim 21, further comprising an
upper connected to at least one of the lower sole, the sidewalls,
and the upper sole, wherein the upper is adapted to hold the upper
sole against the bottom of a user's foot.
25. The article of footwear of claim 19, wherein the beads are
roughly spherical expanded thermoplastic beads.
26. The article of footwear of claim 19, wherein the beads are
roughly spherical expanded polystyrene beads having an average
diameter between about two thirds and about one mm, and wherein the
volume of beads includes at least ten thousand beads.
27. An article of footwear comprising: a volume of unamalgamated
small beads; a lower sole disposed beneath the volume of beads; and
a flexible covering disposed above the volume of beads, wherein the
beads are retained between the lower sole and the flexible
covering, and wherein, when the article of footwear is worn by a
person that is standing or walking, the volume of beads bears at
least some of the weight of the person.
28. The article of footwear of claim 27, wherein the beads are
enclosed in a thin and flexible inner bag, the bag being disposed
between the lower sole and the flexible covering.
29. The article of footwear of claim 27, wherein the beads are
roughly spherical expanded thermoplastic beads.
30. The article of footwear of claim 27, wherein the beads are
roughly spherical expanded polystyrene beads having an average
diameter between about two thirds and about one mm, and wherein the
volume of beads includes at least ten thousand beads.
Description
BACKGROUND
[0001] The present invention relates to footwear such as shoes,
sandals, and insoles. Due to the well known nature of these items,
a detailed description of the prior art is unnecessary.
SUMMARY OF THE INVENTION
[0002] At least one portion of the footwear (e.g., the footbed) is
filled with small beads that can shift about during normal use. In
some preferred embodiments, the beads are made of expanded
thermoplastic such as expanded polystyrene.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a top view of an embodiment of the invention, in
the form of a thong sandal.
[0004] FIG. 2 is a side view of the sandal of FIG. 1.
[0005] FIG. 3 is a top view of a lower sole assembly for use in the
sandal of FIG. 1.
[0006] FIG. 4A is a top view of a bag containing expanded
thermoplastic beads (ETBs) for use in the sandal of FIG. 1.
[0007] FIG. 4B is a section view of the bag of FIG. 4A, taken along
section line B-B in FIG. 4A.
[0008] FIG. 4C is a section view of the bag of FIG. 4A taken along
section line C-C in FIG. 4A.
[0009] FIG. 5 is another top view of the sandal of FIG. 1.
[0010] FIG. 6A is a section view that shows the internal structures
of a first embodiment of the sole of the FIG. 5 sandal, taken along
line 6-6 in FIG. 5.
[0011] FIG. 6B is a section view that shows the internal structures
of a second embodiment of the sole of the FIG. 5 sandal, taken
along line 6-6 in FIG. 5.
[0012] FIG. 6C is a section view that shows the internal structures
of a third embodiment of the sole of the FIG. 5 sandal, taken along
line 6-6 in FIG. 5.
[0013] FIG. 6D is a section view that shows the internal structures
of a fourth embodiment of the sole of the FIG. 5 sandal, taken
along line 6-6 in FIG. 5.
[0014] FIG. 7 is a section view, taken along lines 7-7 in FIG. 5,
showing details of the construction of the rear strap.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] FIGS. 1 and 2 are, respectively, top and side views of an
embodiment of the invention in the form of a thong sandal. The
illustrated sandal has a sole 12, and the sole has an upper surface
13. A rear strap 16 is connected to the sole 12 at the rear end of
the rear strap. A front strap 18 connects the forward end of the
rear strap 16 to the sole 12. An outsole 14 serves at the bottom
layer of the sole 12 and contacts the ground during normal use.
[0016] FIG. 3 is a top view of a lower sole assembly 30 that is
used in the first three embodiments of the sandal. From this top
view, only the side wall 32 and the upper surface 34 of the lower
sole assembly 30 are visible. The side walls 32 and upper surface
34 define a recess. The lower sole assembly 30 preferably comprises
rubber, plastic, leather, or any other similarly strong and
flexible material.
[0017] FIG. 4A shows a bag 40 that is preferably shaped so that it
will fit into the recess described above in connection with FIG. 3.
The bag 40 has a thin, flexible outer wall 42, and is filled with
filling 10 (shown in FIGS. 4B and 4C). The wall 42 is preferably
made of a lightweight fabric such as a stretch jersey fabric with a
weight on the order of about 3.5 to 7 ounces per square yard, which
provides a good degree of flexibility and strength. The bag 40 may
be sealed using any conventional approach (including but not
limited to sewed, glued, heat-sealed, etc.).
[0018] The FIG. 4A embodiment includes button holes 44 that provide
a path for the straps 16, 18 to pass through the bag 40 without
disturbing the bag's integrity or its ability to effectively
contain the filling 10. This configuration permits the rear strap
16 and the front strap 18 to be connected to the lower sole with a
strong and stable connection. FIG. 4B is a section view of the bag
40 taken along lines B-B in FIG. 4A, which passes directly through
a button hole 44. FIG. 4C is a section view of the bag 40 taken
along lines C-C in FIG. 4A, which does not pass through a button
hole. Taken together, FIGS. 4A-4C show how the bag wall 42 remains
intact despite the presence of the button holes 44, so as to
enclose the filling 10 within the bag.
[0019] The filling 10 is preferably made of expanded thermoplastic
beads (ETBs) that are roughly spherical in shape. The beads are not
amalgamated together (i.e., they are not united or combined into a
unified or integrated whole, as they might be in a block of
Styrofoam). Instead, the individual beads are preferably free to
move about with respect to one another, within the confines of the
bag 40. In one preferred embodiment, the mean diameter of the ETBs
is on the order of 0.8 mm. The size distribution of the beads may
be tightly centered about the mean diameter, so that most of the
beads would measure between about 0.7 and 0.9 mm. Alternatively,
the size distribution may vary more widely (e.g., with the size of
the beads ranging from 0.6-1.2 mm). In other embodiments, the
average size of the beads is between about 2/3 mm and 1 mm, or even
between about a 1/2 and 1.5 mm. The shape of the beads may also be
varied by, for example, using beads that are roughly oblate instead
of spherical.
[0020] Preferably, a sufficient quantity of beads is included to
form a bed that is, on average, at least about one quarter inch
thick. In some embodiments, for example, the filling will have a
volume of between about 2-5 cubic inches for adult size sandals,
and will contain more than 10,000 beads. The preferred packing
density for the beads within the bag 40 is preferably low enough so
that when a user walks on the sandal, the beads can shift around to
some extent (due to the pressure from the user's foot that is
transmitted through the flexible walls 42 of the bag 40), but high
enough so that the user's foot is supported by a layer of beads
that is at least a few beads thick.
[0021] While the most preferred material for the filling 10 is
expanded polystyrene beads, other types of expanded thermoplastic
beads (e.g., expanded polypropylene beads) may also be used. In
less preferred embodiments, other materials that share at least
some characteristics (e.g., size, shape, and resiliency) with the
preferred beads may be used instead of ETBs.
[0022] FIG. 5 is another top view of the sandal of FIG. 1, with
markings to indicate the various section views. As explained above
in connection with FIGS. 1 and 2, a rear strap 16 is connected to
the sole 12 at the rear end of the rear strap; and a front strap 18
connects the forward end of the rear strap 16 to the sole 12. FIGS.
6A-6D are section views, each taken along section line 6-6 in FIG.
5, of four different embodiments of the sole 12.
[0023] In the FIG. 6A embodiment, the sole 12 includes an outsole
14, a lower sole 36 that is affixed to the outsole, an upper sole
62, and a bag 40 filled with ETBs. The bag 40 is held in place
between the lower sole 36 and the upper sole 32 (thereby indirectly
retaining the ETBs between the lower sole and the upper sole). The
outsole 14 may be affixed to the lower sole 36 using, for example,
heat-fusing, cementing, or alternative affixing approaches that
will be apparent to persons skilled in the relevant arts. In this
embodiment, the lower sole 36 and the outsole 14, taken together,
correspond to the lower sole assembly 30 discussed above in
connection with FIG. 3. Returning now to FIG. 6A, the outsole 14 is
preferably made of a flexible and relatively tough material such as
leather, rubber, or EVA, or any other material that is
conventionally used for outsoles. The lower sole 36 is preferably
made of a flexible material such as leather, rubber, or foamed
plastic, or any other material that is conventionally used for
midsoles. The sidewalls 32 and the upper surface 34 of the lower
sole 36 define a recess. The bag 40 rests in that recess and is
shaped to match the recess. As discussed above, the bag 40 is
preferably filled with ETBs.
[0024] The upper sole 62 is disposed on top of the bag 40 and
secured to the lower sole assembly. The upper sole 62 is preferably
a thin, flexible material (e.g., stretch cotton jersey fabric with
a weight on the order of about 3.5 to 7 ounces per square yard).
Other fabrics or materials may be substituted therefore, including
but not limited to knit fabrics, woven fabrics, and flexible
leather. Such materials are preferably selected so that the upper
sole can transmit force from the user's foot to the ETBs in the bag
40, such that the ETBs can shift around to some extent in response
to the changes in pressure that occur during ordinary walking. The
upper sole 62 is preferably secured to either the lower sole 36 or
the outsole 14 (using, for example, adhesives, stitching, or any
other approach that provides a relatively strong and permanent
connection). Suitable attachment surfaces include the outer surface
of the sidewall 32 and/or the lower surface of the lower sole 36
and/or the upper surface of the outsole 14.
[0025] The upper sole 62 is disposed above the bag 40 so as to keep
the bag confined in the footbed between the upper sole 62 and the
lower sole 36. Note that although FIG. 6A depicts a space between
the upper sole 62 and the upper wall 42 of the bag 40, the
flexibility of the upper sole 62 will actually cause the upper sole
to rest directly on top of the upper wall 42 of the bag 40. They
are depicted separately, however, for explanatory purposes.
[0026] Returning now to FIG. 5, the sandal also includes a rear
strap 16 and a front strap 18. In embodiments where the bag 40 has
button holes 44 (as shown in FIG. 4A), the straps 16, 18 may be
connected directly to the lower sole assembly through the gaps in
the middle of the button holes 44. Preferably, the upper sole 62 in
these embodiments also includes button holes (not shown) that line
up with the button holes 44 of the bag 40, so the straps can pass
through both sets of button holes on their way down to the lower
sole assembly. Connecting the straps 16, 18 directly to the lower
sole assembly provides a relatively secure and strong mount for the
straps. In these embodiments, the straps may be secured to the
lower sole assembly using any of a variety of techniques that are
conventionally used for sandals, which will be apparent to persons
skilled in the relevant arts.
[0027] In an alternative embodiment neither the bag 40 nor the
upper sole 62 has button holes, and the straps 16, 18 are attached
directly to the upper sole 62 (e.g., by sewing the straps 16, 18
directly to the upper sole 62).
[0028] FIG. 6B depicts a second embodiment of the sole, taken along
lines 6-6 in FIG. 5. In the FIG. 6B embodiment, the sole 12
includes an outsole 14, a lower sole 36 that is affixed to the
outsole, and an upper sole 62. The volume between the lower sole 36
and the upper sole 32 is filled with ETBs 10, resulting in an
ETB-filled footbed. The FIG. 6B embodiment is therefore similar to
the FIG. 6A embodiment, except that the ETBs are not confined in a
separate inner bag. As a result, the description of the FIG. 6A
embodiment applies in large part to the FIG. 6B embodiment.
However, the absence of the inner bag with buttonholes makes it
more difficult to attach the straps directly to the lower sole
assembly, so variations in which the straps are connected to the
upper sole 62 are preferred for this embodiment.
[0029] FIG. 6C depicts a third embodiment of the sole, taken along
lines 6-6 in FIG. 5. The FIG. 6C embodiment is similar to the FIG.
6B embodiment, except that the lower sole 36 serves as the outsole
(in addition to performing its other functions). In this
embodiment, the lower sole 36, taken alone, corresponds to the
lower sole assembly 30 discussed above in connection with FIG. 3.
Because only a single material is used, different trade offs
between comfort and toughness may be required, as will be apparent
to persons skilled in the relevant arts. In addition, appropriate
changes to the way the upper sole 62 is connected to the lower sole
assembly 30 may be required, as will be apparent to persons skilled
in the relevant arts.
[0030] FIG. 6D depicts a fourth embodiment of the sole, taken along
lines 6-6 in FIG. 5. The FIG. 6D embodiment is similar to the FIG.
6C embodiment, except that the lower sole comprises two separate
pieces of material: the sidewalls 32 and the outsole 14. In this
embodiment, the sidewalls 32 and the outsole 14, taken together,
correspond to the lower sole assembly 30 discussed above in
connection with FIG. 3. Note that although it is not depicted in
FIGS. 6C and 6D, an inner bag may be added to those embodiments to
retain the ETBs, similar to the bag 40 (shown in FIGS. 4A-4C)
described above in connection with the FIG. 6A embodiment.
[0031] Optionally, the straps may be stuffed with the same material
that is used to fill the footbed (see reference numeral 10 in FIGS.
6A-6D), such as the preferred expanded polystyrene beads. FIG. 7
depicts a cross section of this type of strap, taken along section
line 7-7 of FIG. 5. In the illustrated embodiment, a double-walled
construction is used, and both walls 72, 74 are preferably
flexible. Note that although FIG. 7 depicts a space between the
inner wall 72 and the outer wall 74, in practice the walls will
touch in many places. They are depicted separately, however, for
explanatory purposes.
[0032] Similar materials to those described above in connection
with the upper sole 62 may be used for the walls 72, 74. The inner
wall 72 is hose-shaped, with the ends of the hose closed off to
keep the filling 70 contained. Because a double-walled construction
is used, the inner hose 72 need not be affixed directly to the
sole. Instead the inner hose is contained within an outer hose 74,
and the outer hose is affixed (e.g., sewn, glued, etc.) to the sole
12. Optionally, intermediate members may be used to connect the
outer hose to the sole (e.g., a member with a plug at one end for
connecting to the sole and an eyelet at the other end to accept the
end of the outer hose). In alternative embodiments, a single-walled
construction is used, in which case the single wall must be
connected to the sole (either directly or through an intermediate
member).
[0033] Prototypes of the sandals described above have proven to be
extremely comfortable.
[0034] While the present invention has been explained in the
context of the preferred embodiments described above, various
changes may be made to those embodiments and various equivalents
may be substituted without departing from the scope of the
invention, as will be apparent to persons skilled in the relevant
art. Examples of such changes include, but are not limited to,
using the ETB filling (or substitutes therefor) in other styles of
sandals (e.g., T-strap sandals, athletic sandals, etc.) or in other
types of footwear (e.g., insoles and footwear with uppers such as
shoes, sneakers, boots, etc.).
* * * * *