U.S. patent application number 12/128079 was filed with the patent office on 2009-12-03 for heat moldable sport shoes.
Invention is credited to Louis GARNEAU, Denis GINGRAS, Rene PLOURDE.
Application Number | 20090293318 12/128079 |
Document ID | / |
Family ID | 41377980 |
Filed Date | 2009-12-03 |
United States Patent
Application |
20090293318 |
Kind Code |
A1 |
GARNEAU; Louis ; et
al. |
December 3, 2009 |
HEAT MOLDABLE SPORT SHOES
Abstract
A sport shoe comprises a sole and an upper portion attached to
the sole and defining an inner space with the sole, and having an
entrance opening for receiving a user's foot therethrough, into the
inner space, and an attachment system to secure the user's foot
therein, the sport shoe having, in longitudinal succession, a heel
cage, a middle section, and a toe box, the middle section having at
least four generally transversally-oriented strips in the upper
portion, including tightening strips receiving the attachment
system externally and having a heat-moldable layer internally, and
flexibility strips, the tightening strips and flexibility strips
being in longitudinally alternating succession, at least a section
of the flexibility strips being heat moldable layer free.
Inventors: |
GARNEAU; Louis;
(Saint-Augustin-de-Desmaures, CA) ; PLOURDE; Rene;
(Quebec, CA) ; GINGRAS; Denis; (Saint-Nicolas,
CA) |
Correspondence
Address: |
OGILVY RENAULT LLP
1, Place Ville Marie, SUITE 2500
MONTREAL
QC
H3B 1R1
CA
|
Family ID: |
41377980 |
Appl. No.: |
12/128079 |
Filed: |
May 28, 2008 |
Current U.S.
Class: |
36/131 ; 12/142P;
36/115; 36/93 |
Current CPC
Class: |
A43B 23/16 20130101;
A43B 5/14 20130101 |
Class at
Publication: |
36/131 ; 36/115;
36/93; 12/142.P |
International
Class: |
A43B 5/00 20060101
A43B005/00; A43B 23/00 20060101 A43B023/00 |
Claims
1. A sport shoe comprising: a sole; an upper portion having a heat
moldable layer, a bottom outer edge on an outer side of the shoe
and a bottom arch edge on an arch side of the shoe, opposed to the
bottom outer edge, and defining an entrance aperture, the bottom
outer and arch edges being attached to the sole; at least two shoe
tighteners mounted to the upper portion, frontwardly of the
entrance aperture, the shoe tighteners defining tightening segments
extending from the bottom outer edge to the bottom arch edge, the
heat moldable layer extending on the outer side and the arch side
of the tightening segments, at least two of the shoe tighteners
being spaced apart and defining therebetween a flexibility segment
extending from the bottom outer edge to the bottom arch edge, at
least a section of the flexibility segment being heat moldable
layer free.
2. A sport shoe as claimed in claim 1, wherein at least a section
of the tightening segments overlapped externally by one of the shoe
tighteners comprises a section of the heat moldable layer.
3. A sport shoe as claimed in claim 1, wherein the heat moldable
free section has a closed shape figure surrounded by the heat
moldable layer.
4. A sport shoe as claimed in claim 1, wherein heat moldable layer
extends upwardly from the bottom arch edge and from the bottom
outer edge in the tightening segments.
5. A sport shoe as claimed in claim 1, wherein each of the
tightening segments have an area and more than 50% of the
tightening segment area comprises a section of the heat moldable
layer.
6. A sport shoe as claimed in claim 1, wherein the upper portion
has a fastening section, extending between the arch side and the
outer side, and the fastening section comprises a heat moldable
layer free section extending along a longitudinal axis of the sport
shoe.
7. A sport shoe as claimed in claim 1, wherein the upper portion
has a fastening section, extending between the arch and the outer
sides, the flexibility segment comprises a heat moldable layer free
section located having a first portion extending in the outer side
and a second portion extending in the fastening section.
8. A sport shoe as claimed in claim 1, wherein the heat moldable
layer free section is a tetragon narrower than the shoe
tighteners.
9. A sport shoe as claimed in claim 1, wherein the heat moldable
layer free section has an area ranging between 300 and 15000 square
millimeters.
10. A sport shoe as claimed in claim 1, comprising at least one of
the heat moldable layer free sections located on the arch side and
at least one heat moldable layer free sections located on the outer
side.
11. A sport shoe as claimed in claim 1, comprising at least one
heat moldable layer free section between each of the shoe
tighteners.
12. A sport shoe as claimed in claim 1, wherein the shoe tighteners
have two opposed edges spaced-apart from the bottom outer edge and
the bottom arch edge.
13. A cycling shoe comprising: an upper portion defining an inner
space sized and shaped to receive a foot of a rider therein, the
upper portion having a toe box, a heel cage and a middle section
extending between the toe box and the heel cage, the middle section
having an inner layer, an outer layer, and a discontinuous heat
moldable layer extending between the inner and the outer layers,
the cycling shoe having a longitudinal axis extending from the heel
cage to the toe box; and tightening straps mounted to the upper
portion, in the middle section, and defining tightening strips
extending from an arch end of the upper portion to an outer end of
the upper portion, the heat moldable layer extending upwardly from
the arch end and from the outer end in the tightening strips, the
tightening straps being spaced apart from one another along the
longitudinal axis and defining tightening discontinuity strips in
between the tightening strips, the tightening discontinuity strips
extending from the arch end of the upper portion to the outer end
of the upper portion, the heat moldable layer being discontinuous
over a flexibility area located in at least one of the tightening
discontinuity strips.
14. A sport shoe as claimed in claim 13, wherein at least a section
of the tightening strips overlapped externally by one of the
tightening straps comprises a section of the heat moldable
layer.
15. A sport shoe as claimed in claim 13, wherein the flexibility
area has a closed shape figure surrounded by the heat moldable
layer.
16. A sport shoe as claimed in claim 13, wherein each of the
tightening strips have an area and more than 50% of the tightening
strip area comprises a section of the heat moldable layer.
17. A sport shoe as claimed in claim 13, wherein the upper portion
has a fastening section, extending between an arch side and an
outer side, and the fastening section comprises a flexibility area
extending along the longitudinal axis, the flexibility area being
heat moldable layer free.
18. A cycling shoe as claimed in claim 13, wherein the upper
portion has an arch side, extending upwardly from the arch end, an
outer side, extending upwardly from the outer end and opposed to
the arch side, and a fastening section, extending between the arch
and the outer sides, at least one flexibility area having a first
portion extending in the outer side and a second portion extending
in the fastening section.
19. A cycling shoe as claimed in claim 13, wherein the flexibility
area has an area ranging between 300 and 1500 square
millimeters.
20. A cycling shoe as claimed in claim 13, comprising at least one
flexibility area between each of the tightening straps.
21. A method for manufacturing a cycling shoe, comprising:
assembling an inner layer, an outer layer, and a discontinuous heat
moldable layer extending between the inner and the outer layers to
define a middle section of a cycling shoe upper portion having an
arch side and an opposed outer side; mounting at least two shoe
tighteners to the upper portion of the cycling shoe in the middle
section, spaced-apart from one another for defining tightening
strips and tightening discontinuity strips in between the
tightening strips, the tightening strips and the tightening
discontinuity strips extending from a lower arch edge of the upper
portion to a lower outer edge of the upper portion; and aligning at
least one discontinuity of the heat moldable layer in at least one
of the tightening discontinuity strips to provide flexibility to
the middle section; aligning a section of the heat moldable layer
with the arch side of the tightening strips; and aligning a section
of the heat moldable layer with the outer side of the tightening
strips.
22. A method as claimed in claim 21, comprising aligning at least
one heat moldable layer discontinuity in the arch side.
23. A method as claimed in claim 21, comprising aligning at least
one heat moldable layer discontinuity between each of the shoe
tighteners.
24. A sport shoe comprising a sole and an upper portion attached to
the sole and defining an inner space with the sole, and having an
entrance opening for receiving a user's foot therethrough, into the
inner space, and an attachment system to secure the user's foot
therein, the sport shoe having, in longitudinal succession, a heel
cage, a middle section, and a toe box, the middle section having at
least four generally transversally-oriented strips in the upper
portion, including tightening strips receiving the attachment
system externally and having a heat-moldable layer internally, and
flexibility strips, the tightening strips and flexibility strips
being in longitudinally alternating succession, at least a section
of the flexibility strips being heat moldable layer free.
25. A cycling shoe as claimed in claim 24, comprising at least one
heat moldable layer free section located between the toe box and a
first one of the tightening strips in the longitudinal
succession.
26. A sport shoe comprising a sole and an upper portion attached to
the sole and defining an inner space with the sole, and having an
entrance opening for receiving a user's foot therethrough, into the
inner space, and, in longitudinal succession, a heel cage, a middle
section, and a toe box, the middle section having an arch side
extending upwardly from a lower arch edge, an opposed outer side
extending upwardly from a lower outer edge, and a fastening section
extending between the arch side and the outer side, the middle
section including internally a heat-moldable layer extending
upwardly from the lower arch edge and from the lower outer edge
towards the fastening section, the middle section having at least
four generally transversally-oriented strips including tightening
strips receiving an attachment system externally to secure the
user's foot therein and flexibility strips, the tightening strips
and flexibility strips being in longitudinally alternating
succession, at least a longitudinally extending area of the
fastening section extending along the four transversally-oriented
strips being heat moldable layer free.
27. A sport shoe as claimed in claim 26, wherein the attachment
system overlaps externally the heat moldable free longitudinally
extending area of the fastening section.
28. A sport shoe as claimed in claim 26, wherein at least a section
of each of the flexible strips located on one of the arch side and
the outer side being heat moldable layer free.
29. A sport shoe comprising a sole and an upper portion attached to
the sole and defining an inner space with the sole, and having an
entrance opening for receiving a user's foot therethrough, into the
inner space, and, in longitudinal succession, a heel cage, a middle
section, and a toe box, the middle section having an arch side
extending upwardly from a lower arch edge and an opposed outer side
extending upwardly from a lower outer edge, the middle section
including a first flap extending upwardly from one of the lower
arch edge and the lower outer edge towards the opposite one of the
lower arch edge and the lower outer edge and secured to the
opposite one through a resilient band, the resilient band extending
from a front end of the middle section, proximate to the toe box,
to approximately an opposite end of the first flap, the resilient
band preventing formation of improper folds of the first flap when
the user's foot is inserted in the inner space.
30. A sport shoe as claimed in claim 29, wherein the resilient band
is made of a relatively thin elastic material.
31. A sport shoe as claimed in claim 30, wherein the relatively
thin elastic material comprises Lycra.RTM..
32. A sport shoe as claimed in claim 29, wherein the first flap is
an outer flap extending from the lower outer edge.
33. A sport shoe as claimed in claim 29, comprising a second flap
extending upwardly from the opposite one of the lower edges,
overlapping a section of the first flap, and secured to the first
flap.
34. A sport shoe as claimed in claim 33, comprising a fastening
section extending between the arch side and the outer side and
wherein the second flap is secured to the first flap in the
fastening section via shoe tighteners.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to sport shoes and, more
particularly, it relates to a sport shoe having a thermoformable
upper portion.
DESCRIPTION OF PRIOR ART
[0002] In relatively high performance sport shoes, such as cycling
shoes for instance, a layer of a heat moldable polymer is added to
provide a custom fit around the athlete's feet. Heat molding is
known to improve comfort and thereby lower fatigue of the feet.
[0003] However, the heat moldable layer rigidities the sport shoes
and rigid shoes are harder to tighten to the feet and obtain the
desired tightening adjustment. Consequently, sport shoes are
conceived with only particular sections of the shoe that are heat
moldable and thus custom fit.
[0004] For instance, for cycling shoes, a layer of a heat moldable
material has been applied to the outer side of the upper portion,
opposed to the arch side, and the heel. Thus, the arch side and the
fastening section, extending between the outer and the arch sides,
are heat moldable layer free and provide flexibility to the
resulting shoe for tightening purposes. However, they are not
custom fit around the athlete's feet.
SUMMARY OF THE INVENTION
[0005] It is therefore an aim to address the above mentioned
issues.
[0006] According to a general aspect, there is provided a sport
shoe comprising: a sole; an upper portion having a heat moldable
layer, a bottom outer edge on an outer side of the shoe and a
bottom arch edge on an arch side of the shoe, opposed to the bottom
outer edge, and defining an entrance aperture, the bottom outer and
arch edges being attached to the sole; at least two shoe tighteners
mounted to the upper portion, frontwardly of the entrance aperture,
the shoe tighteners defining tightening segments extending from the
bottom outer edge to the bottom arch edge, the heat moldable layer
extending on the outer side and the arch side of the tightening
segments, at least two of the shoe tighteners being spaced apart
and defining therebetween a flexibility segment extending from the
bottom outer edge to the bottom arch edge, at least a section of
the flexibility segment being heat moldable layer free.
[0007] According to a general aspect, there is provided a cycling
shoe comprising: an upper portion defining an inner space sized and
shaped to receive a foot of a rider therein, the upper portion
having a toe box, a heel cage and a middle section extending
between the toe box and the heel cage, the middle section having an
inner layer, an outer layer, and a discontinuous heat moldable
layer extending between the inner and the outer layers, the cycling
shoe having a longitudinal axis extending from the heel cage to the
toe box; and tightening straps mounted to the upper portion, in the
middle section, and defining tightening strips extending from an
arch end of the upper portion to an outer end of the upper portion,
the heat moldable layer extending upwardly from the arch end and
from the outer end in the tightening strips, the tightening straps
being spaced apart from one another along the longitudinal axis and
defining tightening discontinuity strips in between the tightening
strips, the tightening discontinuity strips extending from the arch
end of the upper portion to the outer end of the upper portion, the
heat moldable layer being discontinuous over a flexibility area
located in at least one of the tightening discontinuity strips.
[0008] According to another general aspect, there is provided a
method for manufacturing a cycling shoe. The method comprises:
assembling an inner layer, an outer layer, and a discontinuous heat
moldable layer extending between the inner and the outer layers to
define a middle section of a cycling shoe upper portion having an
arch side and an opposed outer side; mounting at least two shoe
tighteners to the upper portion of the cycling shoe in the middle
section, spaced-apart from one another for defining tightening
strips and tightening discontinuity strips in between the
tightening strips, the tightening strips and the tightening
discontinuity strips extending from a lower arch edge of the upper
portion to a lower outer edge of the upper portion; and aligning at
least one discontinuity of the heat moldable layer in at least one
of the tightening discontinuity strips to provide flexibility to
the middle section; aligning a section of the heat moldable layer
with the arch side of the tightening strips; and aligning a section
of the heat moldable layer with the outer side of the tightening
strips.
[0009] According to another general aspect, there is provided a
sport shoe comprising a sole and an upper portion attached to the
sole and defining an inner space with the sole, and having an
entrance opening for receiving a user's foot therethrough, into the
inner space, and an attachment system to secure the user's foot
therein, the sport shoe having, in longitudinal succession, a heel
cage, a middle section, and a toe box, the middle section having at
least four generally transversally-oriented strips in the upper
portion, including tightening strips receiving the attachment
system externally and having a heat-moldable layer internally, and
flexibility strips, the tightening strips and flexibility strips
being in longitudinally alternating succession, at least a section
of the flexibility strips being heat moldable layer free.
[0010] According to still another general aspect, there is provided
a sport shoe comprising a sole and an upper portion attached to the
sole and defining an inner space with the sole, and having an
entrance opening for receiving a user's foot therethrough, into the
inner space, and, in longitudinal succession, a heel cage, a middle
section, and a toe box, the middle section having an arch side
extending upwardly from a lower arch edge, an opposed outer side
extending upwardly from a lower outer edge, and a fastening section
extending between the arch side and the outer side, the middle
section including internally a heat-moldable layer extending
upwardly from the lower arch edge and from the lower outer edge
towards the fastening section, the middle section having at least
four generally transversally-oriented strips including tightening
strips receiving an attachment system externally to secure the
user's foot therein and flexibility strips, the tightening strips
and flexibility strips being in longitudinally alternating
succession, at least a longitudinally extending area of the
fastening section extending along the four transversally-oriented
strips being heat moldable layer free.
[0011] According to a further general aspect, there is provided a
sport shoe comprising a sole and an upper portion attached to the
sole and defining an inner space with the sole, and having an
entrance opening for receiving a user's foot therethrough, into the
inner space, and, in longitudinal succession, a heel cage, a middle
section, and a toe box, the middle section having an arch side
extending upwardly from a lower arch edge and an opposed outer side
extending upwardly from a lower outer edge, the middle section
including a first flap extending upwardly from one of the lower
arch edge and the lower outer edge towards the opposite one of the
lower arch edge and the lower outer edge and secured to the
opposite one through a resilient band, the resilient band extending
from a front end of the middle section, proximate to the toe box,
to approximately an opposite end of the first flap, the resilient
band preventing formation of improper folds of the first flap when
the user's foot is inserted in the inner space.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is a front elevation view of a cycling shoe in
accordance with an embodiment;
[0013] FIG. 2 is a perspective view of the cycling shoe shown in
FIG. 1, showing the outer side of the shoe;
[0014] FIG. 3 is a cross-sectional view of the cycling shoe shown
in FIG. 1
[0015] FIG. 4 is a top plan view of the cycling shoe shown in FIG.
1 wherein the upper layer is partially removed;
[0016] FIG. 5 is an outer side perspective view of the cycling shoe
shown in FIG. 1 wherein the upper layer is partially removed;
[0017] FIG. 6 is an arch side perspective view of the cycling shoe
shown in FIG. 1, wherein the upper layer is partially removed;
[0018] FIG. 7 is a top plan view of a cycling shoe in accordance
with another embodiment wherein the upper layer is partially
removed and the heat moldable layer discontinuity sections are
divided in several sub-sections;
[0019] FIG. 8 is a top plan view of the cycling shoe in accordance
with another embodiment wherein the upper layer is partially
removed and having an alternate heat moldable layer discontinuity
pattern;
[0020] FIG. 9 is an outer side perspective view of the cycling shoe
shown in FIG. 8 wherein the upper layer is partially removed;
[0021] FIG. 10 is an arch side perspective view of the cycling shoe
shown in FIG. 8, wherein the upper layer is partially removed;
and
[0022] FIG. 11 is a rear perspective view, partly sectioned, of the
cycling show shown in FIG. 1, wherein a section of the arch side is
removed.
[0023] It will be noted that throughout the appended drawings, like
features are identified by like reference numerals.
DETAILED DESCRIPTION
[0024] Now referring to the drawings and, more particularly,
referring to FIGS. 1 and 2, there is shown a cycling shoe 10 having
a sole 12 and an upper portion 14 extending upwardly from the sole
12 and mounted thereto with conventional techniques.
[0025] The upper portion 14 defines an inner space 16 (FIG. 3) and
an entrance opening 18 sized and shaped to receive a foot of a
rider therein. The upper portion 14 has an arch side 20, an
opposite outer side 22, and a fastening section 23 extending
between the arch side 20 and the outer side 22.
[0026] The upper portion 14 extends longitudinally from a toe box
24, i.e. the front of the shoe containing the rider's toes, and a
heel cage 26, which wraps around the back or the rider's heel. A
shoe longitudinal axis 28 is defined and extends between the toe
box 24 and the heel cage 26. A middle section 30 of the upper
portion 14 extends between the toe box 24 and the heel cage 26.
[0027] The middle section 30 includes a tightening section 32,
frontwardly of the entrance opening 18. The tightening section 32
extends between the arch and the outer sides 20, 22 of the shoe
10.
[0028] In the tightening section 32, an outer flap 33 extends from
a lower outer edge 46 to approximately the middle of the arch side
20 and is secured to a lower arch edge 44 through an elastic band
34 (FIG. 11), as it will be described in more details below in
reference to FIG. 11. An arch flap 35 extends from the lower arch
edge 44 towards the outer side 22 to approximately the middle of
the tightening section 32. The arch flap 35 overlaps a section of
the outer flap 33 extending in the arch side 20 and the fastening
section 23. The outer flap 33 and the arch flap 35 are secured
together via shoe tighteners, as it will be described in more
details below.
[0029] It is appreciated that, in an alternate embodiment, the arch
flap 35 can extend from the lower arch edge to approximately the
middle of the outer side 22 and the outer flap 33 can extend from
the lower outer edge 46 towards the arch side 20 and overlap a
section of the arch flap 35. In this embodiment, the arch flap 35
can be secured to the lower outer edge 46 through an elastic band
34. It is also appreciated that, in an alternate embodiment, the
shoe 10 can include a shoe tongue 34 extending over the tightening
section 32.
[0030] Three tightening straps 36, as shoe tighteners, and, more
particularly, an upper tightening strap 36a, a middle tightening
strap 36b, and a lower tightening strap 36c, are mounted to the
upper portion 14 in the tightening section 32. Complementary
portions of each tightening straps 36 are respectively mounted to
the outer flap 33 and the arch flap 35. Each tightening strap 36
extends from the arch side 20 to the outer side 22. As shown in
FIG. 2, in an embodiment, the tightening straps 36b and 36c have a
fixed end 38 pivotally mounted to the outer flap 33, extends
towards the arch side 20, engage an elliptic free ring 40 mounted
to the arch flap 35, which has a pair of opposing, linear catching
portions, and folds back towards the outer side 22. Each tightening
strap 36b and 36c includes a pair of hook-and-loop type gripping
elements, such as "VELCRO.RTM." for securing the upper portion 14
in a selected tightened configuration.
[0031] The upper tightening strap 36a includes a buckle 37 and,
more particularly, a ratchet buckle to securely stabilize the
rider's foot in the inner space 16 and allow subtle tightening
adjustments. It is appreciated that the rachet buckle 37 can be
replaced by any buckle that offers precise adjustments or that the
upper tightener 36a can be buckle free.
[0032] In alternate embodiments, the three tighteners 36 can be
similar, different or any combination thereof. Each tightener 36
can include a buckle 37 or a pair of hook-and-loop type gripping
elements.
[0033] In alternate embodiments, the shoe tighteners can extend in
the opposite direction, i.e. their fixed end 38 is mounted to the
arch flap 35, the shoe 10 can include more or less shoe tighteners
in the tightening section 32, and the shoe tighteners can differ
from the ones described above in reference with FIGS. 1 and 2. The
shoe 10 can include a combination of various types of shoe
tighteners. Moreover, the fixed ends of the straps can be offset
from one another to prevent pressure points. It is thus appreciated
that alternate attachment system can be used.
[0034] The tightening straps 36 are spaced apart from one another
along the shoe longitudinal axis 28. They define tightening strips
42 (or segments), transversally oriented, which extend from a lower
arch edge 44 (inner end), located at the junction of the sole 12
and the arch side 20 of the upper portion 14, to a lower outer edge
46 (outer end), located at the junction of the sole 12 and the
outer side 22 of the upper portion 14.
[0035] The tightening strips 42 are aligned with the tightening
straps 36, i.e. the attachment system is externally received in the
tightening strips. In the embodiment shown, the shoe tighteners 36
have two opposed tightener edges 43 (shown in dashed lines),
substantially parallel to one another, extending along a shoe
tightening curved axis 50, which is substantially perpendicular to
the shoe longitudinal axis 28. The tightener edges 43 and their
extensions define the boundaries of the tightening segments 42
along the shoe longitudinal axis 28.
[0036] Tightening discontinuity strips 48 (or flexibility segments
or strips) are defined between the tightening strips 42, since the
tightening straps 36 are spaced apart from one another along the
shoe longitudinal axis 28. The tightening strips 42 and the
tightening discontinuity strips 48 are in a longitudinally
alternating succession. Consequently, the tightening discontinuity
strips 48 are also spaced apart from one another along the shoe
longitudinal axis 28. Their boundaries along the shoe longitudinal
axis 28 correspond to the boundaries of the tightening segments
42.
[0037] The tightening strips 42 and the tightening discontinuity
strips 48 extend substantially parallel to one another, in a
longitudinally alternating succession, and along the shoe
tightening curved axis 50. The tightening strips 42 are the
sections that compress the rider's foot in the inner space 16 and
prevent or at least minimize relative movement of the foot in the
inner space 16. On the opposite, the tightening discontinuity
strips 48 are sections that provide flexibility to the upper
portion 14 of the shoe 10.
[0038] In the embodiment shown, the tightener edges 43 extend
parallel to one another. Therefore, the tightening segments 42 have
substantially a uniform width along their entire length. However,
in an alternate embodiment, it is appreciated that the tightener
edges 43 can either be convergent or divergent and the tightening
segments 42 can have a variable width along their length.
[0039] Referring now to FIG. 3, there is shown that the upper
portion 14 has an outer layer 52, an inner layer 54, opposed to the
outer layer 52, and a discontinuous heat moldable layer 56
extending between the outer and the inner layers 52, 54. As it will
be described in more details below, the outer layer 52 and the heat
moldable layer 56 are discontinuous over flexibility areas of the
middle section 30, i.e. in these heat moldable layer discontinuity
sections 58, the upper portion 14 is heat moldable layer free and
outer layer free and includes solely the inner layer 54. It is
appreciated that, in an alternate embodiment, in the heat moldable
layer discontinuity sections 58, the inner layer 54 can be directly
juxtaposed to the outer layer 52, i.e. the upper portion 14 is
solely heat moldable layer free.
[0040] It is appreciated that the upper portion 14 can include more
material layers. For instance and without being limitative, it can
include a synthetic or natural leather layer, a PVC layer, a
polyester microfiber layer, a polyurethane layer or any combination
thereof.
[0041] The heat moldable layer 56 is located between at least two
material layers, i.e. the inner and the outer layers. The heat
modable layer 56 is laminated on both faces.
[0042] The outer layer 52 is the outer layer of the shoe 10. In
embodiments, it is made from leather, synthetic or natural. In a
particular embodiment, it is made from synthetic micro-fibre
leather, made from 100% wt polyester, for its lightweight,
durability, breathability, water resistance, and relatively easy
care. It can also be made of other materials such as, and without
being limitative, any appropriate thermal insulative material or
impervious membranes. The thickness of the outer layer 52 can vary
between 1.5 to 3 mm.
[0043] The inner layer 54 is the inner lining of the shoe 10. In
embodiments, it is made from superposed layers of nylon mesh
fabric, which can be made from 100 wt % polyester, for its high
breathability and lightness, and foam material for its padding
properties. For example, the foam material layer can be sandwiched
between two nylon mesh fabric layers. It can also be made of other
materials such as and without being limitative any appropriate
padding material, foam, mesh, polyurethane, a foam and mesh
laminate, or any combination thereof. The thickness of the inner
layer can vary between 1.5 to 5 mm.
[0044] The heat moldable layer 56 extends between the outer layer
52 and the inner layer 54. It is made of a thermoformable material
and, in an embodiment, a thermoformable polymer. Therefore, the
upper portion 14 of the shoe can be formed to the rider's foot for
a custom fit, as it will be described in more details below.
[0045] In an embodiment, the heat mouldable layer 56 is made of EVA
(Ethylene vinyl-Acetate), urethane or Teflon.TM., for instance.
[0046] The thickness of layer 56 can range between 0.4 mm and 0.8
mm (16 to 32 mils). A thicker thermoformable layer 56 is heavier,
less flexible for tightening purposes but harder to deform once
thermoform. On the opposite, a thinner thermoformable layer 56 is
lighter, more flexible for tightening purposes but easier to deform
once thermoform.
[0047] The upper portion 14 of the shoe 10, including or not the
sole 12, can be anatomically fitted to the rider's foot by heat
molding means such as a conventional or specialized oven. The upper
portion 14 is heated to a temperature to cause the heat moldable
layer 12 to become pliable. It is appreciated that the temperature
and heating time varies in accordance with the heat moldable layer
material and its thickness. In an embodiment, for an urethane heat
moldable layer having 0.6 mm (24 mils), the shoe, including the
heat moldable layer, can be heated at a temperature ranging between
65 and 135.degree. C. for 5 and 30 minutes. The upper portion 14
can be anatomically fitted to the rider's foot by placing the foot
in the inner space 16 and allowing the heat moldable layer 56 to
cool and harden in a shape conforming to the rider's foot. If a
thermoplastic polymer is used as heat moldable material, the same
molding process can be repeated several times.
[0048] Referring now to FIGS. 4-6, there is shown the shoe 10
wherein the outer layer 52 is partially removed, i.e. it is removed
over the middle section to show the heat moldable layer
discontinuity sections 58 but the tightening straps 36 are shown to
show the tightening segments 42 and the tightening discontinuity
strips 48.
[0049] As mentioned above, the heat moldable layer 56 is
discontinuous over heat moldable layer discontinuity sections 58 or
flexibility areas. Most of the heat moldable layer discontinuity
sections 58 are located in the tightening discontinuity strips 48
of the middle section 30. Therefore, a section of the tightening
discontinuity strips 48 is heat moldable layer free and outer layer
free.
[0050] In an embodiment, the heat moldable layer discontinuity
sections 58 can extend in the tightening segments 42. The heat
moldable layer discontinuity sections 58 in the tightening segments
42 can be continuous with the heat moldable layer discontinuity
sections 58 in the tightening discontinuity strips 48 as shown in
FIGS. 4 and 5. The heat moldable layer discontinuity sections 58 in
the tightening discontinuity strips 48 are shown in dashed lines
since they are covered by the shoe tighteners.
[0051] These discontinuities of the heat moldable layer 56
increases the flexibility of the shoe upper portion 14 for
tightening purposes. The heat moldable layer 56 rigidities the
outer portion 14 and makes it harder for the rider to tighten the
shoe 10 over its foot. Subtle tightening adjustments are thus
prevented.
[0052] By creating flexibility areas in the tightening
discontinuity strips 48, i.e. heat moldable layer free sections 58,
more flexibility is provided for tightening purposes. Moreover, the
middle section 30 of the shoe upper portion 14 can still be formed
to the rider's foot for a custom fit.
[0053] Furthermore, providing a heat moldable layer discontinuity
section 58 along the longitudinal axis 28 of the shoe 10 and
partially covered by the shoe tighteners provides more flexibility
for tightening purposes since this section can be compressed, if
needed.
[0054] In an embodiment, the heat moldable layer discontinuity
sections 58 are substantially elongated areas aligned along the
shoe tightening curved axis 50. In the embodiment shown in
reference to FIGS. 4-6, one heat moldable layer discontinuity
section 58, having a tetragon shape such as a substantially
rectangular shape, is provided on one side 20, 22 of the shoe 10 in
one tightening discontinuity strip 48. In an alternate embodiment,
several smaller heat moldable layer discontinuity sections 58 can
be provided on one side 20, 22 of the shoe 10 in one tightening
discontinuity strip 48, as it will be described in more details
below in reference to FIG. 7.
[0055] In an embodiment, the heat moldable layer discontinuity
sections 58 are narrower than the tightening strips 46. Similarly,
in an embodiment, the tightening discontinuity strips 48 are
narrower than the tightening strips 46. In an embodiment, the heat
moldable layer discontinuity sections 58 do not extend to either
the lower arch edge 44 or the lower outer edge 46. In an
embodiment, the width of the heat moldable layer discontinuity
sections 58 is substantially similar to the width of the tightening
discontinuity strips 48, i.e. they extend over substantially the
entire tightening discontinuity strip width.
[0056] It is appreciated that a relative narrow section of the heat
moldable layer discontinuity section 58 can partially extend over
in the tightening strip 46.
[0057] The heat moldable layer discontinuity sections 58 can be
located either on the arch side 20, the outer side 22 or centrally
in the tightening section 32. They can also extend partially over
two or three sections. For instance and without being limitative, a
section of one heat moldable layer discontinuity section 58 can
extend over the outer side 22 and the remaining section can extend
over the tightening section 32.
[0058] As mentioned above, the middle section 30 can include other
heat moldable layer discontinuity sections 58 than the one located
in the tightening discontinuity strips 48. In the embodiment shown
in reference to FIGS. 4-6, two heat moldable layer discontinuity
sections 58 are located in the middle section 30, frontwardly of
the tightening section 32.
[0059] In an embodiment, at least a section of the tightening
segments 42, overlapped externally by one of the shoe tighteners
36, includes heat moldable material. The heat moldable layer
discontinuity sections can have a closed shape figure surrounded by
the heat moldable material.
[0060] In an embodiment, the heat moldable layer 56 extends
upwardly from the bottom arch edge and from the bottom outer edge
in the tightening segments 42 and each of the tightening segments
42 have an area and more than 50% of the tightening segment area
includes the heat moldable material.
[0061] Referring back to FIGS. 5 and 6, there is shown that, to
provide aeration between the inner space 16 and the exterior of the
shoe 10, through holes 60 extend continuously through the outer
layer 52, the inner layer 54 and the middle heat moldable layer 56,
i.e. they are free of outer, inner and middle layers 52, 54, 56.
They have a first port opening on the inner space 16 and a second
port, opposite to the first port, opening on the exterior of the
shoe 10. Through holes 60 increase the breathability of the upper
portion 14 of the shoe 10.
[0062] In an embodiment, the heat moldable layer discontinuity
sections 58 are located between the shoe tighteners and have a
length ranging between 2 mm to 12 mm. In another embodiment, the
length of the heat moldable layer discontinuity sections 58 ranges
between 5 and 1200 mm and, in another alternate embodiment, its
length ranges between 10 and 1100 mm. The width of the heat
moldable layer discontinuity sections 58 ranges between 5 and 500
mm and, in another alternate embodiment, its length ranges between
10 and 50 mm. It is appreciated that the heat moldable layer
discontinuity section 58 extending along the longitudinal axis 28
is typically longer than the heat moldable layer discontinuity
section 58 extending along the shoe tightening curved axis 50. In
an embodiment, its length can range between 500 mm to 1200 mm and,
in an alternate embodiment, between 700 and 1000 mm.
[0063] Referring now to FIG. 7, there is shown an alternate
configuration for the heat moldable layer discontinuity sections.
As for FIGS. 4-6, the outer layer is partially removed. The
features are numbered with reference numerals which correspond to
the reference numerals of the previous embodiment in the 100
series. In this alternate embodiment, several smaller heat moldable
layer discontinuity sections 158 are provided on one side 120, 122
of the shoe 110 in one tightening discontinuity strip 148, as shown
in FIG. 7. Thus, each heat moldable layer discontinuity section 158
has a smaller area.
[0064] Referring now to FIGS. 8-10, there is shown another
alternate configuration for the heat moldable layer discontinuity
sections. As for FIGS. 4-7, the outer layer is partially removed.
The features are numbered with reference numerals which correspond
to the reference numerals of the previous embodiment in the 200
series. In this alternate embodiment, the heat moldable layer
discontinuity sections 258 are provided on each side 120, 122 of
the shoe 210. On the opposite of shoe 10, the heat moldable layer
discontinuity sections 258 do not extend in the tightening section
32.
[0065] Referring now to FIG. 11, there is shown that the outer flap
33, which extends from the lower outer edge 46 to approximately the
middle of the arch side 20, is secured to a lower arch edge 44
through an elastic band 34. The elastic band 34 extends from
approximately the beginning of the middle section 30, proximate to
the toe box 24 to approximately the opposite end of the outer flap
33. The elastic band 34 prevents the formation of improper folds of
the outer flap 33 when the rider's foot is inserted in the inner
space 16. The elastic band 34 can be made of any relatively thin
elastic/resilient material such as stretch fabrics (Lycra.RTM., for
instance).
[0066] As mentioned above, in an alternate embodiment, the arch
flap 35 can extend from the lower arch edge to approximately the
middle of the outer side 22 and the outer flap 33 can extend from
the lower outer edge 46 towards the arch side 20 and overlap a
section of the arch flap 35. In this embodiment, the arch flap 35
can be secured to the lower outer edge 46 through an elastic band
34.
[0067] In an embodiment, the elastic band has a similar width than
the flap 33, 35 to minimize improper fold formation.
[0068] The embodiments of the invention described above are
intended to be exemplary only.
[0069] It is appreciated that the heat moldable layer
discontinuities can be applied to other sport shoes than cycling
shoes.
[0070] It is appreciated that, in an alternate embodiment, a
substitute material layer can extend between the outer layer and
the inner layer in the heat moldable layer discontinuity
sections.
[0071] In an embodiment, the heat moldable layer discontinuity
sections can be wider than the tightening strips or the tightening
discontinuity strips can be wider than the tightening strips.
Similarly, in an embodiment, the heat moldable layer discontinuity
sections can extend to the lower arch edge and/or the lower outer
edge. In an embodiment, the width of the heat moldable layer
discontinuity sections can be different than the width of the
tightening discontinuity strips.
[0072] The scope of the invention is therefore intended to be
limited solely by the scope of the appended claims.
* * * * *