U.S. patent application number 11/286187 was filed with the patent office on 2007-05-24 for cushioning system for footwear.
Invention is credited to Steve Davis, Thomas Gray, James Lin, Gary Wakley.
Application Number | 20070113425 11/286187 |
Document ID | / |
Family ID | 37814420 |
Filed Date | 2007-05-24 |
United States Patent
Application |
20070113425 |
Kind Code |
A1 |
Wakley; Gary ; et
al. |
May 24, 2007 |
Cushioning system for footwear
Abstract
A midsole for footwear includes at least one solid or hollow
cushioning tube positioned therein for improving the cushioning of
the midsole. Preferably, the midsole includes a plurality of
cushioning tubes fabricated of an elastomeric material. The tubes
may vary in diameter and/or wall thickness relative to one another
for varying the cushioning and stability characteristics of the
system. Each tube may also vary in diameter and/or wall thickness
along its length.
Inventors: |
Wakley; Gary; (Moorestown,
NJ) ; Lin; James; (Princeton, NJ) ; Gray;
Thomas; (Kensington, NH) ; Davis; Steve;
(Newtown, PA) |
Correspondence
Address: |
PATENT DEPARTMENT;SKADDEN, ARPS, SLATE, MEAGHER & FLOM LLP
FOUR TIMES SQUARE
NEW YORK
NY
10036
US
|
Family ID: |
37814420 |
Appl. No.: |
11/286187 |
Filed: |
November 23, 2005 |
Current U.S.
Class: |
36/28 ; 36/29;
36/30R |
Current CPC
Class: |
A43B 13/20 20130101 |
Class at
Publication: |
036/028 ;
036/029; 036/030.00R |
International
Class: |
A43B 13/18 20060101
A43B013/18; A43B 13/20 20060101 A43B013/20; A43B 13/12 20060101
A43B013/12 |
Claims
1. A footwear cushioning system comprising; A midsole which
contains at least one cushioning tube formed of an elastomeric
material for absorbing shock, wherein said cushioning tube is at
generally horizontally oriented.
2. The system as set forth in claim 1, wherein said midsole
contains at least two tubes connected to one another to form a
cartridge.
3. The system as set forth in claim 1, wherein said midsole
contains at least two cushioning tubes located in different
locations.
4. The system as set forth in claim 1, wherein the at least one
cushioning tube has a diameter that varies along its length.
5. The system as set forth in claim 1, wherein the at least one
cushioning tube has a wall thickness which varies along its
length.
6. The system as set forth in claim 3, wherein the at least two
tubes vary in length relative to one another.
7. The system as set forth in claim 3, wherein the at least two
tubes have cross sectional shapes which differ from one
another.
8. The system as set forth in claim 1, wherein the cushioning tube
has a solid portion along its length.
9. The system as set forth in claim 3, wherein the at least two
cushioning tubes are oriented at different angles relative to the
longitudinal axis of the shoe.
10. The system as set forth in claim 1, wherein the cushioning tube
has an outer surface which is sealed within the midsole and a
hollow interior that allows air or other fluids to pass through the
tube.
11. The system as set forth in claim 2, wherein said tubes are
connected to one another with a member that permits air to pass
between said tubes.
12. The system as set forth in claim 3, wherein the midsole has a
cross-sectional height, and the at least two cushioning tubes are
located at different heights within the midsole.
13. The system as set forth in claim 1, wherein the midsole has a
top surface, and wherein the cushioning tube is located on the top
surface of the midsole.
14. The system as set forth in claim 1, wherein the midsole has a
bottom surface, and wherein the cushioning tube is located on the
bottom surface of the midsole.
15. The system as set forth in claim 1, wherein the midsole is
molded in two portions.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a cushioning means for the
midsole of an athletic shoe, and more particularly, where the
design of the device can be altered in such a way as to provide
different amounts of cushioning in different locations along the
midsole of the shoe.
[0003] This invention relates to an improved footwear cushioning
system. In particular, it is made from tubular shaped inserts
located within the midsole of the shoe, for example, in the
forefoot and/or heel areas. These tubular inserts provide a
variance in the cushioning and stability of the midsole, and can be
altered in such a way to provide specific cushioning, or if
desired, more stability in specific locations.
[0004] Stability of an athletic shoe is very important in
preventing the rolling over of the foot, called pronation or
supination. The cushioning means should not jeopardize the
stability of the shoe. With the present design, stability is not
sacrificed and cushioning is enhanced.
[0005] In addition, there are distinctively different cushioning
and stability needs in different areas of the midsole of the shoe.
The present invention is designed to provide the preferred amount
of cushioning and stability to the midsole of a shoe in the
forefoot and heel areas.
[0006] 2. Description of the Prior Art
[0007] Footwear cushioning is one of the most important features of
an athletic shoe where constant striking of the foot to the ground
can cause discomfort and injury. There have been numerous designs
to improve cushioning, most of which have focused on the materials
below the foot known (in descending order) as the sock liner,
insole, midsole, and outsole. The first part directly below the
foot is the sock liner, which can be made from a softer, more shock
absorbent material like a resilient foam or elastomeric material.
Below this is the insole, which is a more firm platform to which
the upper, consisting of fabric, leather, etc., is stitched.
Directly below this is the midsole, which is typically the thickest
portion and commonly uses a resilient foam material and therefore
offers the most alternatives to cushioning technology. Finally,
below the midsole is the outsole, which is the portion which
contacts the ground and needs to be harder with a tread pattern to
offer traction and durability.
[0008] An alternative midsole design is disclosed in U.S. Pat. No.
6,898,870 to Kita, who describes a corrugated sheet inside the
midsole which can vary in stiffness to provide varying cushioning
and stability means. This design is limited in that it cannot vary
the cushioning to particular areas, and is less effective in the
forefoot area where the midsole is of a minimal thickness.
[0009] Another alternative cushioning means is described by U.S.
Pat. No. 6,898,870 to Rohde, who achieves cushioning by using
columnar support elements, each with an aperture to control the
compliance or cushioning of each support element, with the option
of using plugs inserted into the apertures to further control the
compliance of the support elements. This design is limited by the
requirement of using these columnar support elements, which limit
the direction of the cushioning and stability means to basically a
vertical up and down action.
[0010] Still another alternative design for improving the
cushioning of an athletic shoe is shown by U.S. Pat. No. 5,787,509
to Wu, who describes a shoe sock liner design which incorporates a
resilient material with a plurality of cavities to provide shock
absorption means. This design is again limited by the thickness of
the sock liner, which traditionally is much thinner than the
midsole of a shoe.
[0011] The shoe cushioning system according to the present
invention substantially departs from the conventional concepts and
designs of the prior art and in doing so provides an apparatus
primarily developed for the purpose of improved cushioning while
maintaining stability as well as improved appearance.
[0012] Therefore, it can be appreciated that there exists a
continuing need for an improved athletic shoe cushioning systems.
In this regard, the present invention substantially fulfills this
need.
SUMMARY OF THE INVENTION
[0013] In view of the foregoing commonality inherent in the known
types of cushioning for footwear of known designs and
configurations now present in the prior art, the present invention
provides an improved footwear cushioning system. As such, the
general purpose of the present invention, which will be described
subsequently in greater detail, is to provide a new and improved
footwear cushioning system which has all the advantages of the
prior art and none of the disadvantages.
[0014] There has thus been outlined, rather broadly, the more
important features of the invention in order that the detailed
description thereof that follows may be better understood and in
order that the present contribution to the art may be better
appreciated. There are, of course, additional features of the
invention that will be described hereinafter and which will form
the subject matter of the claims attached.
[0015] In this respect, before explaining at least one embodiment
of the invention in detail, it is to be understood that the
invention is not limited in its application to the details of
construction and to the arrangements of the components set forth in
the following description or illustrated in the drawings. The
invention is capable of other embodiments and of being practiced
and carried out in various ways. Also, it is to be understood that
the phraseology and terminology employed herein are for the purpose
of descriptions and should not be regarded as limiting.
[0016] As such, those skilled in the art will appreciate that the
conception, upon which this disclosure is based, may readily be
utilized as a basis for the designing of other structures, methods
and systems for carrying out the several purposes of the present
invention. It is important, therefore, that the claims be regarded
as including such equivalent constructions insofar as they do not
depart from the spirit and scope of the present invention.
[0017] The present invention provides a new and improved cushioning
for footwear which has all of the advantages of the prior art of
known designs and configurations and none of the disadvantages.
[0018] The present invention provides a new and improved cushioning
for footwear which may be easily and efficiently manufactured and
marketed.
[0019] The present invention provides a new and improved cushioning
for footwear which is of durable and reliable construction.
[0020] The present invention provides a new and improved cushioning
for footwear which is susceptible of a low cost of manufacture with
regard to both materials and labor, and which accordingly is then
susceptible of low prices of sale to the consuming public, thereby
making such footwear economically available to the buying
public.
[0021] The present invention provides a footwear cushioning system
that can provide specific stability means to various locations of
the heel and forefoot areas.
[0022] The present invention provides an improved footwear
cushioning system that can be adapted to athletic shoes for court
sports as well as to running and walking shoes.
[0023] Lastly, the present invention provides a new and improved
cushioning for footwear made with numerous tubes and/or rods
inserted between two portions of the midsole to provide desired
cushioning and stability means in the heel and forefoot areas.
[0024] For a better understanding of the invention, its operating
advantages and the specific objects attained by its uses, reference
should be made to the accompanying drawings and descriptive matter
in which there are illustrated preferred embodiments of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a front elevational view of the lateral side of an
article of footwear, constructed in accordance with the principles
of the present invention.
[0026] FIG. 2 is an exploded view showing the various individual
components of the footwear shown in FIG. 1.
[0027] FIG. 3 is an isometric view of the heel tubes.
[0028] FIG. 4 is an isometric view of the forefoot tubes.
[0029] FIGS. 5a-d are detailed views showing the tubes varying in
diameter along their length.
[0030] FIGS. 6a-d are detailed views of the tubes showing the
variance of wall thickness along their length.
[0031] FIGS. 7a-b are detailed views showing the tubes being solid
for at least a portion of their length.
[0032] FIGS. 8a-b are detailed views showing the option of inserts
being placed inside the tubes.
[0033] FIGS. 9a-c are isometric views of various alternatives of
tube orientations to achieve different cushioning and stability
means.
[0034] The same reference numerals refer to the same parts
throughout the various Figures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] With reference now to the drawings, and in particular to
FIGS. 1 through 9 thereof, the preferred embodiments of footwear
according to the invention, generally designated by the reference
numeral 10, will be described.
[0036] The present invention uses pre-molded hollow tubes whose
function is to vary the amount of cushioning of the shoe. The
tubes, being circular or oval in cross section, are preferably
fabricated using resilient plastic or elastomeric materials, and
act as arches or springs to absorb the force of impact. The amount
of cushioning desired depends on the material, geometry, location,
and orientation of each tube.
[0037] The material used for the tubes can vary the amount of
cushioning achieved. For example, if a high degree of cushioning is
desired, then the material should be an elastomeric grade material
with a Shore A hardness of 30-50 such as Thermoplastic
Polyurethane(TPU), or Thermoplastic Rubber(TPR), or Thermoplastic
Elastomer (TPE). An example would be GLS Dynaflex. If less
cushioning and more stability is needed, the material should be
stiffer with a Shore A hardness value between 50-90 such as Dupont
Hytrel series or BASF Elastollan series.
[0038] The geometry and dimension of the tubes can vary to provide
more or less cushioning. For example, if more cushioning is
desired, the diameter of the tube can be increased along with a
reduced wall thickness to increase flexibility to allow more
compression of the tube during impact. If less cushioning is
desired, the diameter of the tube can be decreased, or the wall
thickness of the tube increased in order to increase the stiffness
of the tube.
[0039] Where the tubes are located will also determine the amount
of cushioning. Within each of the heel and forefoot areas, there
are many options on where to locate each tube, as well as the
number of tubes, the spacing between the tubes, the vertical
positioning of the tubes, and the orientation of the tubes.
[0040] The orientation of the tubes will also affect the cushioning
and stability of the shoe. For example, the tubes can be positioned
90 degrees to the axis of the shoe to provide selective cushioning
along the length of the shoe by varying the size, dimension, and
stiffness of each tube. The tubes may also be oriented parallel to
the axis of the shoe, or be positioned in a radial fashion in order
to provide specific cushioning or stability in selected forefoot
and heel areas.
[0041] The tubes are manufactured in a separate molding operation,
prior to molding the shoe midsole. Preferably, each tube will be
injection molded separately in order to produce the exact geometry
and material properties desired. High pressure injection molding
can produce a very strong and reliable structure which can
withstand repeated impact loadings without breaking down and losing
integrity, which is common among typical foam materials used in
midsoles.
[0042] Once the tubes are molded, it can be positioned in the
midsole one of several ways. One option is to mold two separate
portions of the midsole, one above and one below the centerlines of
the tubes, each with a cavity molded in which is the exact shape of
the portion of the tubes to be placed in the respective part of the
midsole. In this example, the tubes are bonded to both the lower
and upper midsole portions as they are bonded to each other. This
option provides the alternative of using different foam materials
for each of the midsole portions. For example, using different
densities or even using different materials where one portion could
be made with a lighter weight ethyl vinyl acetate(EVA) foam and the
other portion comprised of a more dense and more durable
polyurethane(PU)foam.
[0043] A second option is to position the tubes in the opened
midsole mold, then pour the premixed foam in liquid form into the
mold, close the mold and the foam will expand and encapsulate the
tubes. This requires an accurate positioning of the tubes, for
example using pins to locate the tubes in place, and then when the
liquid foam is injected into the mold and begins to expand, the
locating pins are retracted leaving the tubes suspended and
accurately located within the midsole. With this method it is more
economical but does not allow different density midsole
portions.
[0044] Using either the two piece midsole concept or the one piece
midsole concept provides options on the vertical positioning of the
tubes within the midsole. The tubes do not need to be centered
within the vertical thickness of the midsole. The tubes can be
positioned higher or lower as desired within the midsole. In
addition, the tubes can be positioned at an angle, for example,
with the height of the tubes higher in the rear and lower toward
the front of the shoe. Another option is to have the tube height
vary from the medial side to the lateral side.
[0045] It is also possible to locate the tubes so they are outside
the midsole. This would be most common in the forefoot area where
the midsole is the thinnest, and there may not be space to embed
tubes inside the midsole. There also may be advantages to locating
the tubes on the upper side of the midsole in the heel area. When
done this way, attention must be given to the contour of the upper
surface of the tubes so they are not felt by the foot. In this
case, the tubes could have a flatter, horizontal top surface or the
sock liner and insole could have some relief designed in the
underneath side to accommodate the tubes.
[0046] The footwear cushioning system of the present invention
provides a unique solution to footwear cushioning because the tubes
act like springs to absorb the force of impact. For example, when
the heel strikes the ground, the force of impact tends to compress
the tubes, changing them from a circular cross section to an oval
cross section. In doing so, the outside walls of the tubes press
against the foam, which, depending on its density and resiliency,
can affect the amount of cushioning provided.
[0047] In addition, the tubes do not need to be circular in cross
section. The tubes can be oval, with the major axis oriented either
vertical or horizontal or at an angle, to provide unique cushioning
alternatives never before achieved. With this option, the tubes can
rotate as well as compress to achieve desirable cushioning
levels.
[0048] In addition, the tubes do not need to be cylindrical. The
tubes can be conical or parabolic, meaning that the diameter
changes in a nonlinear fashion along the length of the tubes. For
example, the tubes could have a large diameter with a thicker wall
near the outside of the shoe to provide more stability and a more
unique look to the shoe.
[0049] In addition, the tubes can accept inserts of various
hardnesses, which when placed in the tubes, can affect the amount
of cushioning and stability.
[0050] In addition, the tubes can be solid or a portion of the tube
be solid to provide specific cushioning or stability
characteristics as desired.
[0051] In addition, the tubes could be connected together, e.g., by
a web, to form a cartridge. This would facilitate the molding and
handling of the tubes, as well as positioning them in the midsole
mold.
[0052] Furthermore, the tubes could act as a continuous air
bladder, allowing flow between tubes to provide greater cushioning
where needed.
[0053] Another advantage of the tube concept is aesthetics. The
tubes can be open ended at the edge of the midsole to provide
maximum visibility, or enclosed inside a transparent material so
debris doesn't collect inside the tubes. The tubes can also be
positioned like an automobile's exhaust pipes, with two tubes
coming out of the rear portion of the shoe to give the shoe a
sports car look.
[0054] As mentioned before, the tubes can be molded individually
and located separately within the midsole of the shoe, or molded as
an interconnected cartridge. In either option, it is possible to
vary the material, hardness, and geometry of each tube and along
the length of each tube to achieve specific cushioning performance
characteristics.
[0055] The footwear cushioning system of the present invention is
not limited to court sports shoes. It can be applied to running
shoes, hiking shoes, walking shoes, and even dress shoes.
[0056] With greater reference to FIGS. 1 through 4 of the drawings,
a first embodiment of the present invention features elastomeric
tubes 10 connected by an optional web or strip 11 for improving the
cushioning of the midsole in the heel area, and similar but thinner
tubes 2 to improve the cushioning in the forefoot area. The midsole
is produced in two portions: an upper portion 3 and a lower portion
4. The lower midsole is bonded to the outsole 5.
[0057] FIG. 2 shows an exploded view of the individual components
of the midsole. The heel tubes 10 can comprise any number, and may
or may not be connected to one another. In the preferred
embodiment, the heel tubes 10 are comprised of four elastomeric
tubes 10, and each tube is the exact width of the midsole so they
are visible in the final product on both the lateral and medial
sides. The forefoot uses three solid tubes 12 in the preferred
embodiment. As used in the present specification, the term "tube"
includes solid rods as well as hollow tubes.
[0058] In this case, preferably only the lateral side of the tubes
12 is visible in the final product. Both the lower midsole portion
4 and upper midsole portion 3 have cavities molded in with the
exact shape of the portion of the embedded tubes. The assembly
procedure is to apply an adhesive to the tubes and the midsole
portions, then assemble together with compression to form a
complete midsole assembly.
[0059] FIG. 3 shows a detailed view of an alternative embodiment
with the heel tubes connected to form a cartridge 1. In this
embodiment, the wall thickness of the tubes is greater on the top
side than on the bottom side. The tubes are also oval in shape and
the major axis is oriented at an angle relative to vertical. In the
cartridge 1 of FIG. 3, outside air is allowed to enter and leave
the holes through the tubes 10. In addition, if desired, the strip
11 connecting the tubes can provide a passageway between adjacent
tubes 10, so that air can pass between tubes 10.
[0060] FIG. 4 shows a detailed view of an alternative embodiment of
the forefoot tubes connected to form a cartridge 2. In this
embodiment, the tubes 12 are solid forming rods to enhance the
stability of this area. In addition, the tubes 12 are oval in cross
section and their major axis is oriented at an angle similar to the
heel tube cartridge 1.
[0061] FIGS. 5a, 5b, 5c, and 5d show examples of variations in tube
diameters that are possible. It should be known that the amount of
options in tube diameters is numerous, and only limited by the
thickness of the midsole in that area.
[0062] FIGS. 6a, 6b, 6c, and 6d show examples of variations in wall
thickness that are possible, where the broken lines depict the
inner wall of the tube. It should be known that the amount of
options in wall thickness is numerous, and only limited by the
diameter of the tube in that area.
[0063] FIG. 7 shows 2 examples of how the tubes vary between a
hollow tube and solid portion along their lengths, where the broken
lines again depict the inner wall of the tubes in the hollow
portions. The amount of the tubular portion versus the solid
portion can vary depending on the cushioning or stability desired
in each area.
[0064] FIG. 8 shows examples of how inserts 14, 15 could be used to
change the amount of cushioning and stability in the tubes. FIG. 8a
shows a cylindrical insert 14 designed to insert into a cylindrical
hole in the tube. Another option is shown in FIG. 8b, where a
conical shaped insert 15 is designed to insert into a conical
shaped hole.
[0065] Finally, FIG. 9 shows some examples of variations of tube
orientation to achieve different cushioning amounts in different
areas. There are unlimited options on how the tubes 10a, 10b, 10c
can be oriented. For example, in FIG. 9c, the tubes 10c run
continuously the entire length of the midsole to provide cushioning
everywhere. This design would be best suited to a running or
walking shoe, where the motion is predominantly in a forward
direction. FIGS. 9a and 9b show tube orientations that would be
best suited for motions in all directions.
[0066] As to the manner of usage and operation of the present
invention, the same should be apparent from the above description.
Accordingly, no further discussion relating to the manner of usage
and operation will be provided.
[0067] With respect to the above description then, it is to be
realized that the optimum dimensional relationships for the parts
of the invention, to include variations in size, materials, shape,
form, function and manner of operation, assembly and use, would be
evident to one skilled in the art from the foregoing description,
and all equivalents to the examples illustrated in the drawings and
described in the specification are intended to be encompassed by
the present invention.
[0068] Therefore, the foregoing is considered as illustrative only
of the principles of the invention. Further, since numerous
modifications and changes will readily occur to those skilled in
the art, it is not desired to limit the invention to the exact
construction and operation shown and described, and accordingly,
all suitable modifications and equivalents may be resorted to,
falling within the scope of the invention.
* * * * *