U.S. patent application number 11/786359 was filed with the patent office on 2007-10-18 for chassis for footwear and method of making footwear.
This patent application is currently assigned to Deckers Outdoor Corporation. Invention is credited to Dindo Daquioag, Tuan Le, Angel Martinez, Barry McGeough.
Application Number | 20070240333 11/786359 |
Document ID | / |
Family ID | 38603484 |
Filed Date | 2007-10-18 |
United States Patent
Application |
20070240333 |
Kind Code |
A1 |
Le; Tuan ; et al. |
October 18, 2007 |
Chassis for footwear and method of making footwear
Abstract
An article of footwear comprises a chassis having an upper side
and a lower side. At least one outsole component is attached to the
lower side of the chassis, at least one midsole component is
attached to the upper side of the chassis, and an upper is attached
to the chassis. At least one opening extends through the chassis
from the upper side to the lower side which is unobstructed by the
outsole and midsole components. The openings allow for air
circulation and water drainage. The chassis is comprised of
multiple sub-frames that can be independently fastened to the other
footwear components.
Inventors: |
Le; Tuan; (Portland, OR)
; McGeough; Barry; (Piedmont, CA) ; Martinez;
Angel; (Montecito, CA) ; Daquioag; Dindo;
(Bacoor Cavite, PH) |
Correspondence
Address: |
GREER, BURNS & CRAIN
300 S WACKER DR
25TH FLOOR
CHICAGO
IL
60606
US
|
Assignee: |
Deckers Outdoor Corporation
|
Family ID: |
38603484 |
Appl. No.: |
11/786359 |
Filed: |
April 11, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60812287 |
Jun 9, 2006 |
|
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60791679 |
Apr 12, 2006 |
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Current U.S.
Class: |
36/30R ; 36/103;
36/25R; 36/3B |
Current CPC
Class: |
A43B 17/10 20130101;
A43B 13/20 20130101; A43B 5/08 20130101; A43B 13/141 20130101; A43B
7/08 20130101; A43B 13/189 20130101 |
Class at
Publication: |
036/030.00R ;
036/103; 036/025.00R; 036/003.00B |
International
Class: |
A43B 7/06 20060101
A43B007/06; A43B 13/14 20060101 A43B013/14; A43B 13/12 20060101
A43B013/12; A43B 13/00 20060101 A43B013/00 |
Claims
1. An article of footwear comprising: a non-planar chassis having
an upper side and a lower side; at least one outsole component
attached to said lower side of said chassis; at least one midsole
component attached to said upper side of said chassis; and an upper
attached to said chassis and defining a foot receiving space; at
least one opening extending through said chassis from said upper
side to said lower side and being unobstructed by said outsole
component and said midsole component, said opening adapted to
permit fluid flow into or out of said foot receiving space.
2. The article of footwear of claim 1 further comprising at least
two said outsole components.
3. The article of footwear of claim 2 wherein said upper is sewn to
said chassis.
4. The article of footwear of claim 1 wherein said upper comprises
at least one strap and said chassis has a midfoot channel disposed
generally transversely through said chassis for slidably receiving
said strap.
5. The article of footwear of claim 1 wherein said chassis has a
screen disposed over said opening.
6. The article of footwear of claim 1 wherein said midsole
component has at least one midsole port extending through said
midsole from an upper side thereof to a lower side thereof, wherein
said midsole port is aligned with said chassis opening.
7. The article of footwear of claim 1 wherein said chassis
comprises a plurality of sub-frames that are attached to each other
with a mechanical, interlocking connection.
8. The article of footwear of claim 7 wherein said plurality of
sub-frames comprise: a main sub-frame extending from a forefoot to
a heel portion of the article of footwear; and at least two minor
sub-frames, one said minor sub-frames being attached to the medial
side of said main sub-frame, and another said minor sub-frame being
attached to the lateral side of said main sub-frame, said upper
being attached to said minor sub-frame portions.
9. The article of footwear of claim 8 wherein there are at least
four said minor sub-frames, two of said minor sub-frames being
attached to the medial side of said main sub-frame, and another two
of said minor sub-frames being attached to the lateral side of said
main sub-frame, said upper comprising sandal straps that are
attached to said minor sub-frames.
10. A method of manufacturing an article of footwear comprising:
forming a main sub-frame; forming a plurality of minor sub-frames,
attaching at least one midsole component to an upper side of said
main sub-frame; and attaching an upper to said minor sub-frames in
an operation separate from the step of attaching said midsole
component to said main sub-frame; connecting said minor sub-frames
to said main sub-frame; and attaching at least one outsole
component to a lower side of said main sub-frame.
11. The method of claim 10 further comprising forming at least one
opening in said main sub-frame, said opening extending through said
main sub-frame from the upper side to the lower side thereof.
12. The method of claim 10 wherein the step of connecting the minor
sub-frames to the main sub-frame comprises joining said sub-frames
with a mechanical, interlocking connection.
13. The method of claim 10 wherein said plural minor sub-frames
include an extension portion extending generally perpendicular to
said main sub-frame.
14. The method of claim 13 wherein said step of attaching said
upper to said minor sub-frames comprises sewing said upper to the
extension portion of each of said minor sub-frames.
15. A framework structure for an article of footwear having an
upper, comprising: a main sub-frame extending substantially the
forefoot region to the heel region of the footwear; a plurality of
minor sub-frames mechanically connected to said main sub-frame to
form a chassis, said sub-frames having portions adapted for
connection to the upper.
16. The framework structure of claim 15 wherein at least one minor
sub-frame is attached to a medial side of said main sub-frame, and
at least one other minor sub-frame is attached to a lateral side of
said main sub-frame.
17. The framework structure of claim 15 wherein said chassis
comprises a lower side configured to receive one or more outsole
components, and an upper side configured to receive one or more
midsole components.
18. The framework structure of claim 15 further comprising a
midfoot channel disposed generally transversely through said main
sub-frame, generally from a medial side to a lateral side, and
configured for slidably receiving a strap.
19. The framework structure of claim 15 further comprising at least
one opening through said framework structure from an upper side to
a lower side thereof.
20. The framework structure of claim 19 further comprising a screen
over said opening.
Description
CROSS-REFERENCE
[0001] This application claims priority from co-pending U.S.
provisional patent application Ser. Nos. 60/791,679 filed Apr. 12,
2006 and 60/812,287 filed Jun. 9, 2006, which applications are
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to footwear, and
particularly to a framework support structure or chassis for
footwear.
BACKGROUND OF THE INVENTION
[0003] Conventional footwear includes a sole and an upper that is
sewn, tacked, cemented or otherwise attached to the sole.
Conventional shoe soles comprise one or more generally flat, planar
layers of leather, rubber or synthetic materials, e.g., ethyl vinyl
acetate. Sole structures for active footwear typically comprise
multiple sole layers, including an outsole having traction and wear
properties, a midsole having energy absorption properties, and an
insole or sockliner for providing cushioning for the wearer's
foot.
SUMMARY OF THE INVENTION
[0004] An article of footwear comprises a chassis having an upper
side and a lower side. At least one opening and preferably multiple
openings are defined in the chassis. The chassis forms a structural
framework for the article of footwear. At least one and preferably
multiple discrete outsole components are attached to the lower side
of the chassis. Openings or gaps are provided in the outsole
components or between outsole components. At least one midsole
component is provided for cushioning, and is attached to the upper
side of the chassis. Openings, gaps or spaces are provided within
and between the midsole components. The gaps or openings in the
chassis, outsole and midsole components are at least partially
aligned with one another to provide a fluid flow path for air
circulation and water drainage. At least one upper component, for
example sandal straps, is attached to the chassis. A toe guard may
also be attached to the chassis and extends up and over at least a
portion of the toes of the user.
[0005] A method of manufacturing the article of footwear comprises
forming the chassis of multiple sub-frame members, including a main
sub-frame and a plurality of minor sub-frames. The midsole
component(s) are attached to an upper side of the main sub-frame.
The upper components are attached to the minor sub-frames in an
operation separate from the step of attaching the midsole
components to the main sub-frame. Next, the minor sub-frames are
mechanically and adhesively joined to the main sub-frame. Finally,
the outsole component(s) are attached to a lower side of the main
sub-frame.
DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a top, front perspective view of an article of
footwear of the present invention;
[0007] FIG. 2 is a top, front perspective view of a chassis frame
of the article of footwear of FIG. 1;
[0008] FIG. 3 is a bottom, front perspective view of the chassis of
FIG. 2;
[0009] FIG. 4 is an exploded assembly view of a sole assembly of
the article of footwear of FIG. 1;
[0010] FIG. 5 is a bottom view of the article of footwear;
[0011] FIG. 6 is a cross-section view taken along line 6-6 of FIG.
5; and
[0012] FIG. 7 is a cross-section view taken along line 7-7 of FIG.
5.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0013] In contrast to conventional footwear having one or more
generally flat, planar layers, the present disclosure provides a
structural framework, i.e., a chassis, onto which selected
components are attached. The framework is preferably
three-dimensional, i.e., non-planar (not flat), and provides the
structural support for other components of the footwear.
[0014] Turning now to FIGS. 1-3, one preferred embodiment of a
chassis 10 for an article of footwear 22 is illustrated. Chassis 10
comprises a plurality of sub-frame structures 11, and numbered 13,
15, 17, 19, 21, which are joined together to form the support
structure for the article of footwear 22. The chassis 10 is
preferably three-dimensional, having (in a top plan view) an
exterior outline generally corresponding to a human foot. Each
sub-frame may be comprised of one or more frame members that are
integrally molded together, or alternatively, separately formed and
secured together to form the sub-frame. Because the chassis
comprises sub-frames each of which is comprised of one or more
frame members, each frame member can be designed, sized and located
to provide desired structural and/or biomechanical functions.
[0015] The chassis 10 performs multiple functions in the article of
footwear 22. Similar to an automobile chassis, chassis 10 is the
structural framework upon which the footwear 22 is constructed. It
lends structural integrity to the footwear 22. As will be described
with respect to FIG. 4, the chassis 10 provides the structure upon
which the other footwear components are mounted, including for
example, outsole components, an upper, straps, arch support pads,
cushions, toe guard and other footwear components. The chassis
provides bio-mechanical properties such as a propulsive energy
return, pronation and supination control, and otherwise stabilizes
the foot during one's gait. Chassis 10 preferably has an open
structure or otherwise comprises one or more openings which provide
for fluid flow into and out of the foot receiving interior 22 of
the footwear, thereby increasing airflow to the wearer's foot and
allowing for drainage of water from the interior. The open
structure also decreases the weight of the footwear. Although the
preferred embodiment of the invention illustrated and described
herein includes these features, other embodiments within the scope
of the appended claims may have less than all features.
[0016] The chassis 10 includes a forefoot portion 14, a heel
portion 16, a medial side 18 and a lateral side 20 corresponding to
the forefoot, heel, medial and lateral sides of the wearer's foot.
As best seen in FIG. 2, a main sub-frame 13 extends a majority of
the length of the chassis 10, from the forefoot portion 14 to the
heel portion 16. In the preferred embodiment, the main sub-frame 13
does not extend the full length of the article of footwear 22, but
extends substantially into the forefoot and heel regions of the
footwear. However, it is contemplated that the chassis 10 can
extend the full length of the article of footwear 22.
[0017] Preferably, minor sub-frames 15 and 17 are located at the
medial side 18 and the lateral side 20 of the forefoot portion 14,
respectively, and minor sub-frames 19, 21 are located at the medial
side and the lateral side of the heel portion 16, respectively.
While the preferred embodiment has four minor sub-frames 15, 17,
19, 21 at the four specified locations, alternative numbers and
arrangements of sub-frames are contemplated. The sub-frames 15, 17,
19, 21 are preferably adapted for attachment of straps that
comprise the upper portion of the footwear, as described below.
[0018] Referring to FIGS. 5 and 6, the sub-frame structures 11 may
include discrete frame members or ribs 12, which may be separately
or integrally formed with the other portions of the sub-frame.
Preferably, the main sub-frame 13 extends between the forefoot 14
and heel portions 16 of the footwear. The frame members or ribs 12
provide structural support to the sub-frame. Relatively thinner
planar members 25 may extend between frame members 12. Further, the
relatively thinner and more flexible planar members 25 preferably
extend from the frame members 12 towards the forefoot portion 14
and the heel portions 16.
[0019] The main sub-frame 13 is preferably made of a strong,
light-weight resilient material, such as thermoplastic urethane
(TPU), however other materials can be used. A TPU material with a
durometer of about 64 Shore D has been successfully used for the
main sub-frame. The ribs 12 and the planar members 25 are
preferably made of the same material having the same durometer,
however it is contemplated that different materials can be used.
Preferably, the main sub-frame 13 differs in flexibility from one
area to another area to provide a specific structural and/or
biomechanical function. In the preferred embodiment, stiffer ribs
12 are disposed at the arch, and thinner, more flexible planar
members 25 are disposed at the forefoot 14 and heel portions 16.
The ribs 12 provide arch support while the flexible planar members
25 allow flex at the forefoot 14 and heel portions 16.
[0020] The minor sub-frames 15, 17, 19, 21 are preferably formed
from the same material as the main sub-frame. However, in some
applications, it may be preferable to fabricate the minor
sub-frames 15, 17, 19, 21 from different materials (or the same
material of different hardness) to provide selected strength,
resilience, flexibility and other properties. Additionally, the
individual sub-frames 11 and/or the combinations of frame
structures may provide specific biomechanical functions. For
example, the forefoot portion 14 of the sub-frames 11 may be
provided with different biomechanical properties than the heel
portion 16.
[0021] The sub-frames 11 are mechanically connected to each other
with interlocking, snap-together puzzle-piece shaped connectors.
The minor sub-frames 15, 17, 19, 21 have a connection portion 28
for connecting to the main sub-frame 13, and an extension portion
30 extending generally perpendicular to the main sub-frame. In
addition, the sub-frames 11 are cemented to the main sub-frame. The
puzzle-piece connectors provide a positive mechanical connection
that resists pull-out. Although the cemented and mechanical
connection is preferred, alternatively, sub-frames 11 can be
connected to each other ways, including joints that permit relative
movement of one sub-frame relative to another, such as flexible,
hinged or pivotal connections. For example, the medial, forefoot
sub-frame 15 could be pivotally connected so that it can pivot with
respect to the main sub-frame 13.
[0022] Preferably one or more of the sub-frames 11 includes at
least one opening 56 to permit fluid, including air and water, to
flow through the footwear. More preferably, multiple openings 56
are located at the forefoot 14 and heel portions 16. The openings
56 are preferably covered with a mesh screen 29 to minimize the
entry of unwanted debris into the interior of the footwear 22.
Preferably, the mesh screen 29 is disposed on an upper side 31 of
the chassis; however, other locations are contemplated. Further, it
is contemplated that the mesh screen 29 can be located on an upper
side 33 of the outsole components 24 or on the midsole components
36.
[0023] Turning now to FIG. 4, various footwear components are
attached to the chassis 10. While particular footwear components
will be described herein, it is contemplated that any number and
arrangement of components can be incorporated with the chassis
10.
[0024] At least one and preferably multiple outsole components 24
are attached to a lower side 26 of the chassis 10. In the preferred
embodiment, multiple outsole components 24 are attached to the
lower side 26 of the chassis 10 in a spaced-apart relationship,
preferably at the contact points of the footwear to the ground.
FIG. 5 shows two discrete outsole components 24, namely forefoot
and heel outsole components. The outsole components are positioned
so that one or more of the chassis openings are unobstructed by the
outsole components.
[0025] The sub-frames 11 preferably include at least one protrusion
37 on the lower side 26 of the chassis 10 (see FIG. 3). The
protrusions 37 are received in openings 39 in the outsole
components 24 so as to locate and properly align the outsole
components on the chassis. It is contemplated that the protrusions
37 can be located on any of the sub-frames 11, and on more than one
sub-frame. The outsole components 24 are preferably cemented to the
chassis with adhesive.
[0026] As seen in FIGS. 3 and 5, lugs 41 project from the exterior
surface of the chassis 10, preferably from the main sub-frame 13.
The lugs 41 preferably span the channels and are configured to
extend through the channels in the outsole components 24. The lugs
41 are preferably triangular in shape and function to properly
locate and register the outsole components during assembly, and to
minimize the entry of debris into the channel within or between
outsole components 24 when the footwear is in use. Additionally,
the lugs 41 stabilize and strengthen the forefoot portion 14 of the
main sub-frame 13. Because the outsole components 24 are discrete
components, each may be different materials and/or may have
different properties, e.g., hardness, coefficient of friction, wear
resistance, designed to maximize performance of each component. The
outsole components 24 are not structural components inasmuch as
they primarily function to provide traction and wear. Thus, the
design and material options for the outsole 24 are more flexible
since they are not required to provide structural integrity to the
footwear.
[0027] The chassis 10 preferably comprises plural components for
support, shock absorption and cushioning, which are referred to
herein collectively as midsole components 36A, 36B. See FIG. 4. The
midsole component 36A is cradled inside the chassis 10, and
preferably is cemented to the upper side 31 of the chassis. The
midsole component 36B is preferably cradled inside the midsole
component 36A and has an upper side 38 which is preferably
contoured to the foot. Preferably made of an elastomeric material,
rubber or foam (such as ethyl vinyl acetate), the midsole
components 36 are compressible and cushion the foot from impacts
associated with movement. Alternatively, one of more midsole
components 36 can comprise one or more bags filled with gel, gas,
liquid, foam or a combination of materials. The midsole components
36A, 36B can be individually designed for specific performance
criteria. Alternatively, a single midsole component 36 can be
used.
[0028] Midsole components 36A, 36B preferably include ports 23 as
shown in FIGS. 4 and 7. Preferably at least some of the midsole
ports 23 are in alignment with openings 56 in the chassis 10 so
that the midsole does not obstruct the chassis openings. Further,
at least one but preferably several channels 60 are formed in the
midsole components 36, or alternatively, between multiple midsole
components. As seen in FIG. 7, at least one midsole port 23 is at
least partially aligned with openings 35 in outsole components 24.
With this construction, water can drain out of and air can
circulate within the article of footwear 22. While the channels 60
and ports 23 are shown in a generally vertical orientation, it is
contemplated that other alignments may be used as long as the
channels and ports permit fluid flow.
[0029] Referring back to FIG. 1, upper components 40 are connected
to the chassis 10. The upper may be enclosed as in a shoe or boot,
or may be open as in a sandal. In the illustrated embodiment, the
upper components 40 comprise a plurality of sandal straps 42. As
seen in FIGS. 5 and 6, the main sub-frame includes a midfoot
channel 27 for receiving an adjustable strap, as disclosed in
commonly owned U.S. Pat. No. 6,606,803, which is incorporated
herein by reference. Further, the sandal structure may have a
strapping system such as that disclosed in commonly owned U.S. Pat.
No. 4,793,075, which is also incorporated herein by reference.
[0030] The straps 42 are connected to the chassis 10, preferably at
the minor sub-frames 15, 17, 19, 21. The straps 42 are sewn to the
minor sub-frames 15, 17, 19, 21. The minor sub-frames 15, 17, 19,
21 preferably include an attachment portion 46, which is preferably
an opening or an area having material properties that enable the
straps 42 to be directly attached. In the preferred embodiment, the
attachment portion 46 is recess for receiving an end portion of a
strap. Alternative means for attaching the upper to the chassis can
be used, in addition to or in lieu of stitching, including
adhesives and rivets, for example.
[0031] The upper components 40 are preferrably attached to the
sub-frame structures 15, 17, 19, 21 independently of the
construction of the other footwear components to the main sub-frame
13. This allows greater flexibility in the manufacturing process.
It also reduces the risk of damage to the upper components 40
during assembly. The midsole components 36 can be cemented to the
main sub-frame 13, while in a separate operation, the upper
components 40 can be attached to the sub-frames 15, 17, 19, 21.
Because these operations are separate, the upper components 40 are
not exposed to the cement used to secure the midsole components 36
and thus cannot be damaged by the same.
[0032] The upper further preferably includes a liner 43. The liner
provides cushioning between the sandal straps and the foot.
Although the liner may be made in multiple pieces, it is preferably
a single sock. The liner may comprise a composite foam and nylon
fabric or other relatively material. The liner is attached at
multiple locations to other upper components and/or the midsole by
sewing and/or adhesive. The liner may, but need not register with
the straps 42.
[0033] Another optional upper component incorporated on the article
of footwear 22 is a toe guard 44. Having a generally cupped-shape,
the toe guard 44 extends up over the top of the user's toes. The
toe guard 44 is disposed at the medial side 18, preferably to cover
at least a portion of at least the first digit. The toe guard 44
preferably extends to the upper 40. Preferably the toe guard is
formed separately from the other footwear components. It is
attached to the chassis by any conventional means, e.g., by
adhesive. The toe guard can be independent of the other upper
components, however the liner or a portion thereof is preferable
secured to the inner surface of the toe guard.
[0034] Other components can be incorporated on the chassis 10, such
as a shank, or a shock pad. Additionally, the chassis 10 may have
sub-frames 11 that run the entire length of the article of footwear
22, may extend across selected portions of the footwear.
Preferably, when the chassis 10 is assembled in the article of
footwear 22, the chassis 10 is exposed from both the inside of the
upper 40 and the outside of the footwear.
[0035] While the preferred embodiments of the present invention
have been shown and described, it is to be understood that these
are merely examples for practicing the invention that the inventor
foresees at the present time, and that various modifications and
changes could be made thereto. In particular, various other chassis
assemblies could be designed by persons skilled in the art.
* * * * *