U.S. patent application number 10/905144 was filed with the patent office on 2006-06-22 for shoe sole with a loose fill comfort support system.
Invention is credited to Michael Hottinger.
Application Number | 20060130363 10/905144 |
Document ID | / |
Family ID | 36588662 |
Filed Date | 2006-06-22 |
United States Patent
Application |
20060130363 |
Kind Code |
A1 |
Hottinger; Michael |
June 22, 2006 |
SHOE SOLE WITH A LOOSE FILL COMFORT SUPPORT SYSTEM
Abstract
A shoe is provided with an outsole which contacts the ground, an
insole upon which a foot rests, and a midsole located between the
outsole and the insole, wherein the midsole absorbs impact by
providing a loose fill material throughout the midsole of the shoe
to cushion any force exerted upon the shoe, wherein the midsole is
divided into at least two compartments and each of the compartments
is filled with the loose fill material.
Inventors: |
Hottinger; Michael;
(Greendale, WI) |
Correspondence
Address: |
GEHRKE & ASSOCIATES, S.C.
123 N. 86th ST
WAUWATOSA
WI
53226
US
|
Family ID: |
36588662 |
Appl. No.: |
10/905144 |
Filed: |
December 17, 2004 |
Current U.S.
Class: |
36/28 ;
36/11.5 |
Current CPC
Class: |
A43B 13/04 20130101;
A43B 13/187 20130101; A43B 13/125 20130101; A43B 13/188 20130101;
A43B 3/108 20130101; A43B 13/16 20130101; A43B 1/0063 20130101 |
Class at
Publication: |
036/028 ;
036/011.5 |
International
Class: |
A43B 13/18 20060101
A43B013/18; A43B 3/12 20060101 A43B003/12 |
Claims
1. A shoe comprising: an outsole which contacts the ground; an
insole upon which a foot rests; and a midsole located between the
outsole and the insole, wherein the midsole absorbs impact by
providing a loose fill material throughout the midsole of the shoe
to cushion any force exerted upon the shoe.
2. A shoe according to claim 1, wherein the loose fill material is
derived from rubber tires.
3. A shoe according to claim 2, wherein the loose fill material is
crumb rubber.
4. A shoe according to claim 3, wherein a portion of the loose fill
material is adhesively bound together to form a composite layer of
crumb rubber.
5. A shoe according to claim 1, wherein the midsole is divided into
at least two compartments.
6. A shoe according to claim 5, wherein each of the compartments is
filled with the loose fill material.
7. A shoe according to claim 6, wherein the loose fill material is
crumb rubber.
8. A shoe according to claim 1, wherein the shoe includes an
athletic shoe, a casual shoe, a boot, a sandal or a dress shoe.
9. A shoe according to claim 1, wherein the insole is a polymer
foam lined with a fabric cover.
10. A shoe according to claim 1, wherein the outsole is
manufactured from elastomer styrene-butadiene rubber, leather, or
synthetic material.
11. A shoe comprising: an outsole which contacts the ground; an
insole upon which a foot rests; and a midsole located between the
outsole and the insole, wherein the midsole absorbs impact by
providing a loose fill material throughout the midsole of the shoe
to cushion any force exerted upon the shoe, wherein the loose fill
material is bound together with an adhesive.
12. A shoe according to claim 11, wherein the loose fill material
is derived from rubber tires.
13. A shoe according to claim 12, wherein the loose fill material
is crumb rubber.
14. A shoe according to claim 13, wherein the loose fill material
forms a composite layer of crumb rubber.
15. A shoe according to claim 11, wherein the midsole is divided
into at least two compartments.
16. A shoe according to claim 15, wherein each of the compartments
is filled with the loose fill material.
17. A shoe according to claim 16, wherein the loose fill material
is crumb rubber.
18. A shoe according to claim 11, wherein the shoe includes an
athletic shoe, a casual shoe, a boot, a sandal or a dress shoe.
19. A shoe comprising: an outsole which contacts the ground; an
insole upon which a foot rests; and a midsole located between the
outsole and the insole, wherein the midsole absorbs impact by
providing a loose fill material throughout the midsole of the shoe
to cushion any force exerted upon the shoe, wherein the midsole is
divided into at least two compartments and each of the compartments
is filled with the loose fill material.
20. A shoe according to claim 1 9, wherein the loose fill material
is crumb rubber.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to the comfort and
support in the sole of a shoe. In particular, the present invention
relates to a shoe with a sole that is filled with a loose fill
material such as crumb rubber for shock absorption, cushionability,
energy return, added comfort and stability.
[0003] 2. Discussion of the Related Art
[0004] Dress, casual and athletic shoes generally include an upper
leather portion and an inner lining that cover the top of the foot,
a counter placed between the upper leather portion and the lining
to provide rigidity at the heel, an insole upon which the foot
rests, an outsole which contacts the ground surface and possibly a
filler portion that is positioned between the insole and outsole.
The midsole of a shoe is a piece of material such as rubber or
leather that is often stitched or glued to the inside fabric
lining, upper leather portion, and the counter to hold the
construction together.
[0005] A filler is a material that fills the space formed between
the midsole and the outsole when the midsole is glued to the inside
lining, upper leather portion and the counter component. This
filler is normally glued in position and is manufactured from the
same material as the midsole.
[0006] The outsole is the bottom portion of the shoe that contacts
the ground or floor surface which is usually manufactured from
leather, rubber or any of several suitable synthetic materials. The
outsole is typically glued to the filler material.
[0007] The manufacture of shoes using conventional construction
methods is a complicated and expensive process. In this regard,
improvements are sought to simplify the construction process that
corresponding decrease the cost of manufacturing the shoe, while
maintaining all of the functionality of the shoe.
[0008] In the prior art, most improvements in shoe design have
focused on the midsole. The midsole is a shoe's main cushioning
system. An argument could be made that no part of the shoe has
benefited from science more and affects performance more than the
midsole. In early athletic shoes, especially in running shoes,
midsoles really did not exist. Early basketball shoes had some
rubber cushioning inside them, but nothing advanced and innovative
as the modern midsole found in every type of shoe from walking
shoes to basketball shoes. These innovations range from improved
foam midsoles to very complicated air and fluid systems. While
these increasingly complicated midsoles may improve performance,
the cost to manufacture these shoes has increased
exponentially.
[0009] Thus, there is a need in the art for a shoe having a
simplified midsole construction with softer density while providing
adequate cushioning and stability for every type of shoe or
boot.
[0010] What is needed, therefore, is a shoe with fill material that
provides the cushioning and support of a traditional midsole.
SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to provide a shoe
including an outsole which contacts the ground, an insole upon
which a foot rests, and a midsole located between the outsole and
the insole, wherein the midsole absorbs impact by providing a loose
fill material throughout the midsole of the shoe to cushion any
force exerted upon the shoe.
[0012] It is yet another object of the present invention to provide
a shoe including an outsole which contacts the ground, an insole
upon which a foot rests, and a midsole located between the outsole
and the insole, wherein the midsole absorbs impact by providing a
loose fill material throughout the midsole of the shoe to cushion
any force exerted upon the shoe, wherein the loose fill material is
bound together with an adhesive.
[0013] Still yet another object of the present invention is to
provide a shoe including an outsole which contacts the ground, an
insole upon which a foot rests, and a midsole located between the
outsole and the insole, wherein the midsole absorbs impact by
providing a loose fill material throughout the midsole of the shoe
to cushion any force exerted upon the shoe, wherein the midsole is
divided into at least two compartments and each of the compartments
is filled with the loose fill material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] A clear understanding of the various advantages and features
of the present invention, as well as the construction and operation
of conventional components and mechanisms associated with the
present invention, will become more readily apparent by referring
to the exemplary, and therefore non-limiting, embodiments
illustrated in the following drawings which accompany and form a
part of this patent specification.
[0015] FIG. 1 is a perspective view of a shoe with loose fill
support according to the preferred embodiment of the present
invention;
[0016] FIG. 2 is a cross-sectional view of the shoe with loose fill
support along line 2-2 of FIG. 1 according to the preferred
embodiment of the present invention;
[0017] FIG. 3 is a cross-sectional view of the heel of a shoe with
loose fill support along line 3-3 of FIG. 1 according to the
preferred embodiment of the present invention;
[0018] FIG. 4 is a cross-sectional view of the midsole of a shoe
with compartments to contain the fill in the shoe according to an
alternative embodiment of the present invention;
[0019] FIG. 5 is a cross-sectional view along line 5-5 of FIG. 4
according to the preferred embodiment of the present invention;
and
[0020] FIG. 6 is a cross-sectional view along line 6-6 of FIG. 4
according to the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Referring to FIG. 1, the present invention includes
generally a shoe 10 having an outsole 12, a midsole 14, and an
insole 16. In the preferred embodiment of the present invention,
shoe 10 is any shoe including but not limited to an athletic shoe,
a casual shoe, a boot, a sandal, a dress shoe, etc.
[0022] Outsole 12 of shoe 10 is commonly made from a variety of
materials including elastomer styrene-butadiene rubber or a carbon
fiber rubber. Lying on the bottom side of shoe 10, outsole 12's
main purpose is to provide friction and durability. Different
treads on outsoles 12 define shoe 10's purpose. For example, on an
athletic shoe, waffle-studded treads act like support columns to
absorb and dissipate impact.
[0023] Just above outsole 12 is midsole 14. Midsole 14 absorbs
impact by cushioning but also returns energy to the person wearing
shoe 10 (e.g., a runner). The most common material used in the
manufacturing of midsoles is a plastic foam consisting of ethylene,
vinyl, and acetate. Known in the field as polymer EVA, it contains
the properties of mouldability, resilience, flexibility, and
strength. It is, however, increasingly expensive to manufacture
various midsoles that strive to incorporate the latest innovations
including air and water cushioning devices.
[0024] Above midsole 14 is insole 16. Insole 16 is commonly made
from a polymer foam lined with a fabric cover. The main purpose of
insole 16 is to provide comfort and shock absorption at impact,
largely in the heel section of shoe 10. The cheap cost of the
polymer makes it easily replaceable. In the prior art,
manufacturers have developed an entire product line of additional
supports which can be inserted into insole 16 of shoe 10.
[0025] Referring to FIGS. 2-3, midsole 14 of shoe 10 serves a
variety of purposes including stability, flexibility, cushioning
and durability.
[0026] Flexibility--As the importance of cushioning systems became
the central focus of midsole research and design in the prior art
(especially related to athletic shoe research and development), the
midsole's contribution to overall foot and ankle stability was
somewhat ignored. This was driven by the boom in the running
movement, by people's in-store perception of what a good cushioning
system "felt" like, and by surveys in running magazines as to the
"best" cushioning offered in shoes.
[0027] The challenge is to try to find a cushioning system that is
soft enough to satisfy a person's perception of a soft shoe when
trying a shoe on in a store and, in turn would pass the tests set
up by sport research labs under contract to running magazines to
measure cushioning in a shoe which often resulted in a shoe that
was so soft that it provided minimal stability and contributed to
over pronation or supination and therefore other injuries.
[0028] The solution to this problem is to pay attention to
cushioning as well as modifying parts of the midsole to enhance
stability. Support structures like heel collars that are extensions
of the midsole that, in many cases are integrated with the upper,
is one innovation to midsoles that provides general stability and
cushioning. These types of systems, however, are increasingly
expensive to manufacture.
[0029] Flexibility--Like stability, flexibility is directly related
to the cushioning system used. As the design of full length
midsoles progresses, flexibility tends to be compromised. As
researchers start to define the nature of cushioning needs by
purpose and type of person, they in turn start to pay attention to
the need to provide flexibility to the regions of the foot where
flexible joints are found.
[0030] Most midsole designs now incorporate some type of flex line
in the midsole located near where the foot flexes naturally. This
flex line is closely aligned and integrated with the outsole's flex
lines.
[0031] Cushioning--As mentioned earlier, this is the main focus of
the midsole system. The need to deal with the impact forces that a
person encounters (especially an athlete participating in a sport
activity), is of paramount importance when designing a midsole
unit. For example, in basketball an athlete's midsole must absorb
over seven times the body weight of the athlete. A midsole spreads
out the force of impact so that it is not delivered full force
straight to the foot and legs of the person.
[0032] In the case of an athletic shoe, the cushioning needs of an
athlete are closely tied to an individual's biomechanics as well as
to the specific sport the athlete is participating in. For example,
a person's biomechanics (as defined by the bones, muscles,
ligaments and tendons) might be such that they are a heel striker
rather than a forefoot striker when running. In general, a heel
striker exhibits a key, potentially injurious, impact force at the
beginning of a stride cycle that is not seen in the impact record
of a forefoot striker. Therefore, the design for a midsole system
for a heel striker must pay particular attention to cushioning in
the heel area.
[0033] In turn, the cushioning system also plays a key role in the
overall energy consumption of an athlete during an event. The
natural cushioning system of the body is the musculoskeletal
system--the bones, muscles, ligaments and tendons, of the foot and
leg. The fat pads in the foot also play a major role in protecting
the foot from sudden and repeated impact. Operating this system
requires the use of the body's stored energy as it is dependent on
muscles contracting to help deal with the impact going through the
system. This works fine under normal conditions, like relaxed
walking over soft surfaces. When an athlete asks more of this
system by increasing the frequency and force of impacts through
training and participation in athletic events, more energy is
needed to help maintain performance. A shoe's cushioning system can
help by improving the efficiency of, or reducing, the energy needs
of the athlete.
[0034] A midsole design should provide some type of energy return
to the body when compressed. This energy return, or spring gives
lift to the foot and leg that normally would require muscular
contraction, and therefore cost the athlete in terms of energy.
[0035] Durability--In midsoles, traditional cushioning systems
based on rubber or foam materials tend to break down, or compact,
over time. As they break down they lose their ability to cushion
and provide energy return. The way these materials break down is
related to how they are constructed. Basically, the way to increase
the cushioning characteristic in a rubber or foam based midsole is
to increase the amount of air blown into the material. This air
produces bubbles. The larger the bubbles, the thinner the walls
surrounding them. The thinner the walls the shorter amount of time
needed to break them down.
[0036] Durability in midsoles is desirable since losing the
cushioning properties, as happens as traditional midsole materials
compact, can lead to injury. Many athletic shoes address this need
by introducing some type of hybrid midsoles that integrate
pressurized air, or liquid systems that do not lose their
cushioning characteristics over time.
[0037] Not all shoes, however, require these elaborate midsole
constructions in order to achieve stability, flexibility,
cushioning and durability. In many instances, only the highly
trained athlete requires the complex fluid and pressurized air
systems found in the midsoles of some of the athletic shoes on the
market. In order to drastically reduce manufacturing costs
associated with these complex systems, midsole 14 in the preferred
embodiment of the present invention includes a loose fill material
18 instead of a continuous section of material normally found in
midsole 14.
[0038] Loose fill 18 extends throughout midsole 14 from a front
section 20 of shoe 10 to a back section 22 of shoe 10.
[0039] In the preferred embodiment of the present invention,
material 18 is a crumb rubber, although other materials with
stability and cushioning properties may be used in place of this
material. From an engineering point of view, crumb rubber has a
number of special thermo-mechanical and chemico-physical
properties.
[0040] Crumb rubber is made by shredding scrap tires and as such,
it is a particulate material free of fiber and steel. It is
generally made commercially available in 50-pound bags or
2000-pounds bulk bags. The size of the rubber particles is graded.
The finest one can be as small as about 0.2 mm (Mesh #80) and
below. The gradation commonly used in rubberized asphalt pavement
is between about 2.0 mm to 0.5 mm (Mesh #10 to Mesh #40). Crumb
rubber is light in weight and is durable. From the safety
consideration, crumb rubber is a non-toxic and inert material.
[0041] In addition to crumb rubber fill material 18 being
inexpensive to use in the manufacturing of shoe 10, another
important fact is that crumb rubber is a recycled material, so that
as more is consumed, the greater the proportionate reduction in
scrap tires.
[0042] Crumb rubber is traditionally used in playground and
landscaping mulch for its shock absorbing capabilities. In the
present invention, the cushioning and shock absorbing properties
are integrated into midsole 14 to provide a person with maximum
comfort while drastically reducing the cost of manufacture of shoe
10.
[0043] There has been an enormous growth in the demand for recycled
tire rubber--crumb rubber--since the early 1990s, particularly in
North America. These newly rubberized products are often superior
to similar products made of conventional materials, and using
recycled rubber over virgin rubber further reduces manufacturing
costs.
[0044] FIGS. 4-6 illustrate an alternative embodiment of the
present invention that includes a first compartment 24 defined by a
wall 26 and a wall 28, a second compartment 30 defined by a wall 32
and a wall 34, a third compartment 36 defined by a wall 38 and a
wall 40, and a fourth compartment 42 defined by a wall 44 and a
wall 46. Therefore, a first divider 48 traverses the length of shoe
10 from front section 20 to back section 22. Divider 48 includes
walls 26, 34, 38 and 46. Similarly, a second divider 50 traverses
the width of shoe 10. Divider 50 includes walls 28, 32, 40 and
44.
[0045] Compartments 24, 30, 36 and 42 ensure the even distribution
of fill material 18 throughout the length of midsole 14 and guard
against uneven compaction of material 18. To further guard against
uneven distribution of material 18, fill material 18 may include an
adhesive that binds the loose crumb rubber 18 together to some
extent.
[0046] The scope of the application is not to be limited by the
description of the preferred embodiments described above, but is to
be limited solely by the scope of the claims that follow. For
example, a composite sheet of crumb rubber including a binding
adhesive may be used in place of loose fill crumb rubber to fill
midsole 14 of shoe 10 without departing from the scope of the
preferred embodiment of the present invention.
* * * * *