U.S. patent application number 12/908596 was filed with the patent office on 2011-06-23 for integral spine structure for footwear.
This patent application is currently assigned to RED WING SHOE COMPANY, INC.. Invention is credited to Kenton D. Geer.
Application Number | 20110146110 12/908596 |
Document ID | / |
Family ID | 34102765 |
Filed Date | 2011-06-23 |
United States Patent
Application |
20110146110 |
Kind Code |
A1 |
Geer; Kenton D. |
June 23, 2011 |
INTEGRAL SPINE STRUCTURE FOR FOOTWEAR
Abstract
A support structure for footwear includes a longitudinally
extending member to which a plurality of laterally extending
supports members are secured at spaced apart locations along a
length of the longitudinal member. The support structure may extend
along the entire length of a footwear or may be specifically
designed for the forefoot, midfoot, or hindfoot areas of a
footwear. The support structure may be combined with plate-like
structures or may include a plurality of longitudinally extending
members. The lateral supports may extend in a generally horizontal
plane or may extend in an upward or downward direction out of the
horizontal plane. Furthermore, the longitudinal and lateral members
may be made of different materials, or each may be made of a
plurality of different materials to provide the desired
characteristics of the support structure at a given location in the
footwear. Different portions of the longitudinal member may be more
or less flexible than the lateral supports.
Inventors: |
Geer; Kenton D.; (Red Wing,
MN) |
Assignee: |
RED WING SHOE COMPANY, INC.
Red Wing
MN
|
Family ID: |
34102765 |
Appl. No.: |
12/908596 |
Filed: |
October 20, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12204274 |
Sep 4, 2008 |
7818897 |
|
|
12908596 |
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|
|
|
10893114 |
Jul 16, 2004 |
7421805 |
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12204274 |
|
|
|
|
60488476 |
Jul 17, 2003 |
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Current U.S.
Class: |
36/25R ;
264/244 |
Current CPC
Class: |
B29D 35/061 20130101;
A43B 3/0036 20130101; A43B 13/10 20130101; A43B 7/14 20130101; A43B
23/22 20130101; A43B 3/0057 20130101; A43B 13/141 20130101; A43B
13/12 20130101; A43B 13/026 20130101; A43B 13/41 20130101; A43B
13/181 20130101; A43B 13/125 20130101; A43B 3/0052 20130101 |
Class at
Publication: |
36/25.R ;
264/244 |
International
Class: |
A43B 13/00 20060101
A43B013/00; B29D 35/02 20100101 B29D035/02 |
Claims
1-26. (canceled)
27. A method of manufacturing a footwear, the footwear including an
upper, a sole, and a spine support structure that includes an
elongate spine member and a plurality of transverse supports, the
method comprising: positioning the spine support structure in a
mold and positioning the upper adjacent to the mold; filling the
mold with a moldable material to form the sole; and curing the
moldable material to secure the sole and the spine support
structure to the upper.
28. The method of claim 27, wherein filling the mold with a
moldable material includes filling the mold with a first moldable
material to form a first portion of the sole, and filling the mold
with a second moldable material to form a second portion of the
sole.
29. The method of claim 27, wherein the footwear further includes a
welt member secured to the upper and positioned between the upper
and the mold.
30. The method of claim 27, wherein the footwear further includes a
lasting insole secured to the upper and positioned between the
upper and the mold.
31-58. (canceled)
59. A footwear support structure, comprising: an elongate member
extending along a first axis; and a plurality of laterally
extending supports secured to the elongate member, at least a
portion of one of the lateral supports extending out of a
horizontal plane.
60. A footwear support structure, comprising: an elongate spine
extending along a first axis; and a plurality of laterally
extending support ribs secured to the elongate spine at spaced
apart locations along a length of the spine.
61. The support structure of claim 60, wherein the spine includes
segments along the length of the spine that have different
properties.
62. The support structure of claim 60, wherein the supports have a
width, a height and a depth, and at least one of the width, height
or depth varies for supports along a length of the spine.
63. The support structure of claim 60, wherein the spine has
greater flexibility than the ribs.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Pat. No.
7,818,897 which issued from U.S. patent application Ser. No.
12/204,274, filed Sep. 4, 2008, which claims priority to U.S.
patent application Ser. No. 10/893,114, filed Jul. 16, 2004, which
claims benefit of U.S. Provisional Application Ser. No. 60/488,476,
filed on Jul. 17, 2003, which applications are hereby incorporated
by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention generally relates to footwear, and
more specifically relates to structures for supporting a
footwear.
[0004] 2. Related Art
[0005] A common objective for most types of footwear designs is to
address at least one of the following three biomechanical issues:
shock attenuation, stability, and support. Shock attenuation
involves the absorption of shock, shock diffusion and pressure
distribution. The ability of a footwear to attenuate shock forces
can greatly reduce the pain and discomfort to a user of the
footwear for any given application. Shock absorption may be
addressed by the type of materials that are used in the footwear.
Various types of materials have excellent shock absorption
properties, especially for the thin layers that are typically
required for a footwear. Shock diffusion relates to dampening of
shock forces to reduce how much of the shock force is transferred
to the user. Again, the type of material as well as the structure
of the footwear may significantly affect shock diffusion by a
footwear. Pressure distribution relates to the distribution or
spreading out of a point force or pressure point such as, for
example, a heel strike pressure point at the heel of a footwear
when walking or running. Pressure distribution is often
accomplished using a plate-like structure wherein the amount of
pressure distribution is controlled by the type and thickness of
the plate material.
[0006] The stability of a footwear is a another important
biomechanical issue and may be controlled by the material
properties and structure of various features of a footwear. For
example, a footwear with a very thick sole that raises an
individual's center of gravity beyond a natural position may
provide a very unstable scenario. Further, some types of materials
used in footwear are very flexible and if used alone without any
other support features may create an unstable footwear. Some types
of material that do not allow flexibility may effect the natural
motion of the foot and further create instability.
[0007] The support provided by a footwear is also important. A
common objective for a footwear is to obstruct as little as
possible the natural movements of the foot while supporting the
foot where it is necessary for a given footwear application. In
some applications such as sports like soccer and tennis, lateral
support is extremely important, while arch support and support
along the longitudinal axis of the footwear may be a greater
consideration for applications such as running and walking. Other
applications that require standing for long periods of time may
require the type of support which reduces the amount of work the
users foot muscles must exert in order to maintain proper posture
and balance while standing.
[0008] A further biomechanical consideration for footwear is the
flexibility of the forefoot, midfoot and hindfoot portions of the
footwear. A natural motion of the foot requires significant flexing
and bending in a longitudinal direction as well as some complex
lateral and torsional motion. While some types of inflexibility may
be important for certain performance enhancement objectives, most
footwear applications require a range of flexibility in each major
section of the footwear. For example, undue amounts of torsional
flexibility about a transverse axis of the footwear in the area of
the arch of the foot may result in inadequate guiding and holding
of the foot if the footwear bottom also provides too much
longitudinal flexibility in that region of the footwear.
[0009] One known attempt at an "all day comfort" footwear that
addresses shock attenuation, stability, support and flexibility
includes a firm lasting insole that is layered in the footwear just
above the midsole and extends along the hind of the footwear up to
the midfoot of the footwear. This plate-like structure provides
support and diffuses forces in the heel. In an effort to attenuate
shock forces, the footwear may include a gel or other type of
insert material at the outsole or within the midsole of the
footwear. Although the plate structure may distribute pressure, the
heel strike and other significant shock forces are not dissipated
very well. Furthermore, because there is no support structure in
the forefoot of the footwear, the footwear may be entirely too
flexible for a given application and fails to provide the torsional
rigidity that is necessary for support and stability of the
footwear.
[0010] Another known footwear design that attempts to address the
biomechanical issues described above includes a sole structure that
has multiple horizontal and/or vertical layers of foam materials
that each have different properties. The outsole may also include
certain structures that provide some lateral support. This type of
design is difficult to alter for the support, stability and shock
attenuation needs of different applications while concurrently
providing necessary flexibility along the length of the
footwear.
[0011] The cost and feasibility of a footwear design is a further
consideration when designing a footwear that addresses the
above-mentioned biomechanical issues. Some footwear designs may
include materials or structures that are not conducive to cost
effective manufacturing and assembly of the footwear.
SUMMARY OF THE INVENTION
[0012] The present invention relates to a support structure for use
in a footwear that can be altered to meet the shock attenuation,
stability, support and flexibility needs for a given footwear
application. One aspect of the invention relates to a footwear
support structure that includes an elongate member and a plurality
of lateral supports coupled to the elongate member. In some
embodiments, the elongate member may be more flexible than the
lateral supports by using, for example, different materials or
different cross-sectional shapes for the elongate member verses the
lateral supports. In other embodiments, the support structure may
have different flexibility properties in the forefoot, midfoot and
hindfoot sections of the support structure. The support structure
may be positioned at various locations within a footwear sole
assembly between various layers of the sole assembly. The support
structure may also be coupled to a carrier or base member and used
as an insert piece in the sole assembly.
[0013] Another aspect of the invention relates to a footwear sole
structure that includes a sole member having a heel portion
defining a void, and a spine structure that includes an elongate
spine extending along a first axis and a plurality of laterally
extending support ribs secured to the elongate spine at spaced
apart locations along a length of the spine. The spine structure is
at least partially positioned over the void and supported by the
heel portion of the midsole member, and a portion of the spine
structure is movable into the void. In other embodiments, the void
is positioned in other portions of the midsole or another sole
member of a footwear sole assembly. The void may be filled with a
material different properties from the material that defines the
void.
[0014] Another aspect of the invention relates to a footwear
construction that includes a midsole member having a heel section
that includes first and second portions having different
properties, an upper member coupled to the midsole, and a spine
support structure that includes an elongate spine member and a
plurality of laterally extending supports coupled to the elongate
spine member. The first portion of the heel section supports the
laterally extending supports and the second portion of the heel
section supports the elongate spine member.
[0015] A further aspect of the invention relates to a method of
manufacturing a footwear that includes an upper, a sole, and a
spine support structure that includes an elongate spine member and
a plurality of transverse supports. The method includes positioning
the spine support structure in a mold and positioning the upper
adjacent to the mold, filling the mold with a moldable material to
form the sole, and curing the moldable material to secure the sole
and the spine support structure to the upper.
[0016] Another aspect of the invention relates to a method of
forming a footwear support structure that includes forming an
elongate member along a first axis, and forming a plurality of
support members that are secured to the elongate member and that
extend in a lateral direction relative to the first axis.
[0017] Another aspect of the invention relates to a method of
assembling a footwear support structure that includes an elongate
member extending along a first axis and a support member. The
method may include the steps of securing the support member to the
elongate member, and aligning the support members in a
substantially lateral direction relative to the first axis.
[0018] A further aspect of the invention relates to a footwear
support structure that includes a longitudinal spine structure and
a plurality of support members secured to the spine and that extend
in a generally lateral direction relative to a direction of
extension of the spine structure. The support structure may include
separate segments having different stiffening properties unique for
certain areas of the footwear.
[0019] Another aspect of the invention relates to a footwear that
includes a midsole, an outsole, a lasting insole, an upper, and a
support structure positioned between lasting insole and the
outsole. The support structure may include an elongate member and a
plurality of spaced apart laterally extending supports.
[0020] A further aspect of the invention relates to a method of
supporting a footwear that includes an upper, a midsole, an
outsole, and a support structure having a longitudinally extending
spine and a plurality of laterally extending supports secured to
the spine at spaced apart locations along a length of the spine.
The steps of the method may include positioning the support
structure in the midsole and securing the midsole to the upper and
the outsole.
[0021] A further aspect of the invention relates to a method of
supporting a footwear having a outsole, a midsole, an upper, and a
support structure having an elongate spine and a plurality of
laterally extending supports secured to the spine at spaced apart
locations along a length of the spine. The method may include
positioning the support structure within the upper and above the
outsole, and resisting lateral movement in the footwear with the
support structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a side cross-sectional view of a footwear known in
the art.
[0023] FIG. 2 is a side cross-sectional view of a footwear having
an embedded support structure according to principles of the
invention.
[0024] FIG. 3 is a bottom plan view of the footwear of FIG. 2.
[0025] FIG. 4 is a lateral cross-sectional view of the footwear of
FIG. 3 taken along cross-sectional indicators 4-4.
[0026] FIG. 5 is a lateral cross-sectional view of the footwear of
FIG. 3 taken along cross-sectional indicators 5-5.
[0027] FIG. 6 is a lateral cross-sectional view of the footwear of
FIG. 3 taken along cross-sectional indicators 6-6.
[0028] FIG. 7 is a top view illustrating one example longitudinal
member according to principles of the invention that follows a
centerline a footwear through the toe and heel centerlines.
[0029] FIG. 8 is a top view illustrating another example
longitudinal member according to principles of the invention that
follows a pressure line for a footwear.
[0030] FIG. 9 is a top view illustrating a further example
longitudinal member according to principles of the invention that
follows a random line in a footwear.
[0031] FIG. 10 is a perspective view of a portion of one example
support structure according to principles of the invention.
[0032] FIG. 11 is a lateral cross-sectional view taken along
cross-sectional indicator 11-11 shown in FIG. 10.
[0033] FIG. 12 is a top view of one example support structure that
includes the longitudinal member of FIG. 7.
[0034] FIG. 13 is a top view of another example support structure
that includes the longitudinal member of FIG. 8.
[0035] FIG. 14 is a top view of anther example support structure
that includes lateral supports with a single flared end.
[0036] FIG. 15 is a top view of anther example support structure
that includes lateral supports with two flared ends.
[0037] FIG. 16 is a top view of anther example support structure
that includes a longitudinal support that is exposed where attached
to the lateral supports.
[0038] FIG. 17 is a top view of anther example support structure
that includes lateral supports at a mid section that act as shank
for a footwear.
[0039] FIG. 18 is a top view of anther example support structure
that includes multiple longitudinal supports.
[0040] FIG. 19 is a top view of anther example support structure
that includes webbing material that extends between some of the
lateral supports.
[0041] FIG. 20 is a top view of anther example support structure
that includes a heel plate.
[0042] FIG. 21 is a top view of anther example support structure
that is configured as a blocker unit with connecting webbing
between lateral supports of the support structure.
[0043] FIG. 21A is a side view of the blocker unit configuration
shown in FIG. 21.
[0044] FIG. 21B is a side view of another example blocker unit
configuration that includes a layer of connecting webbing above and
below the support structure.
[0045] FIG. 22 is a side cross-sectional view of one example
support structure according to principles of the present invention
mounted in a footwear having a continuous flat outsole.
[0046] FIG. 23 is a side cross-sectional view of one example
support structure according to principles of the present invention
mounted in a footwear having a cut out arch section of the
footwear.
[0047] FIG. 24 is a side cross-sectional view of one example
support structure according to principles of the present invention
mounted in a footwear having a partial cut out arch section of the
footwear.
[0048] FIG. 25 is a side cross-sectional view of one example
support structure wherein the mid section of the support structure
is a continuous piece of material and acts as a shank for the
footwear.
[0049] FIG. 26 is a side cross-sectional view of another example
support structure wherein the mid section of the support structure
is exposed at the outsole of the footwear.
[0050] FIG. 27 is a side cross-sectional view of another example
support structure wherein the hindfoot section of the support
structure extends through a midsection of the midsole.
[0051] FIG. 28 is a side cross-sectional view of one example
support structure wherein the mid section of the support structure
includes a continuous piece of material having a longitudinal
support with an increased cross-section.
[0052] FIG. 28A is a top perspective view of the support structure
shown in FIG. 28.
[0053] FIG. 28B is a lateral cross-sectional view taken along
cross-sectional indicator 28B-28B shown in FIG. 28A.
[0054] FIG. 29 is a side cross-sectional view of one example
support structure wherein the support structure extends along the
outsole of the footwear.
[0055] FIG. 29A is a top perspective view of the support structure
shown in FIG. 29.
[0056] FIG. 29B is an lateral cross-sectional view of the footwear
shown in FIG. 29 taken along cross-sectional indicators
29B-29B.
[0057] FIG. 30 a side cross-sectional view of one example support
structure wherein the support structure extends in the middle of
the midsole of the footwear.
[0058] FIG. 31 a side cross-sectional view of one example support
structure wherein the support structure includes lateral supports
in the toe section and a plate support in the mid section and heel
section.
[0059] FIG. 31A is a top perspective view of the support structure
shown in FIG. 31.
[0060] FIG. 32 is a lateral cross-sectional view of an example
footwear that includes a support structure that includes upward and
downward extending lateral supports.
[0061] FIG. 32A is a top perspective view of support structure
shown in FIG. 32.
[0062] FIG. 33 is a top perspective view of another example support
structure that includes upward, downward and horizontally extending
lateral supports.
[0063] FIG. 33A is an end view of the support structure shown in
FIG. 33.
[0064] FIG. 34 is a top perspective view of a portion of the
support structure shown in FIG. 16.
[0065] FIG. 35 is lateral cross-sectional view of another support
structure in which the longitudinal support and the lateral support
have a coplanar top surface and the longitudinal support includes a
curved cross-section.
[0066] FIG. 36 is lateral cross-sectional view of another support
structure in which the longitudinal support and the lateral support
have a coplanar top surface and the longitudinal support includes a
rectangular cross-section.
[0067] FIG. 37 is lateral cross-sectional view of another support
structure in which the longitudinal support extends above a top
surface of the lateral support and the longitudinal support has a
circular cross-section.
[0068] FIG. 38 is lateral cross-sectional view of another support
structure in which the longitudinal support extends across a top
surface of the lateral support.
[0069] FIG. 39 is a side view of a portion of an example support
structure in which the lateral support extends continuously along
the longitudinal axis and the longitudinal support extends between
the lateral supports.
[0070] FIG. 39A is a side cross-sectional view of the support
structure shown in FIG. 39 taken along cross-sectional indicator
39A-39A.
[0071] FIG. 40 is a side view of a portion of another example
support structure in which the longitudinal support extends
continuously along the longitudinal axis and the lateral supports
are mounted to the longitudinal support.
[0072] FIG. 40A is a cross-sectional view of the support structure
shown in FIG. 40 taken along cross-sectional indicator 40A-40A and
further supported in a mold.
[0073] FIG. 41 is a perspective view of one example support
structure according to principles of the invention integrated into
a padded footwear insert.
[0074] FIG. 42A is a top view of forefoot or toe portion of a
support structure according to principles of the invention.
[0075] FIG. 42B is a top view of midfoot portion of a support
structure according to principles of the invention.
[0076] FIG. 42C is a top view of hindfoot or heel portion of a
support structure according to principles of the invention.
[0077] FIG. 43 is a top view of another example support structure
according to principles of the invention that supports midfoot and
hindfoot portions of a footwear.
[0078] FIG. 44 is a top view of another example support structure
according to principles of the invention that supports forefoot and
midfoot portions of a footwear.
[0079] FIG. 45 is a top view of a footwear that includes another
example support structure according to principles of the invention
that extends the entire length of the footwear.
[0080] FIG. 46 is a side cross-sectional view of the footwear shown
in FIG. 45 taken along cross-sectional indicators 46-46.
[0081] FIG. 47 is a lateral cross-sectional view of the footwear
shown in FIG. 45 taken along cross-sectional indicators 47-47.
[0082] FIG. 48 is a lateral cross-sectional view of the footwear
shown in FIG. 45 taken along cross-sectional indicators 48-48
[0083] FIG. 49 is a top view of a footwear that includes another
example support structure according to principles of the invention
that extends along a partial length of the footwear.
[0084] FIG. 50 is a side cross-sectional view of the footwear shown
in FIG. 45 taken along cross-sectional indicators 50-50.
[0085] FIG. 51 is a lateral cross-sectional view of the footwear
shown in FIG. 45 taken along cross-sectional indicators 51-51.
[0086] FIG. 52 is a lateral cross-sectional view of the footwear
shown in FIG. 45 taken along cross-sectional indicators 52-52.
[0087] FIG. 53 a lateral cross-sectional view of the footwear shown
in FIG. 45 taken along cross-sectional indicators 53-53.
[0088] FIG. 54 is a top perspective view of an example footwear
sole insert according to principles of the present invention.
[0089] FIG. 55 is a side cross-sectional view of an example
footwear sole that includes the insert member shown in FIG. 54.
[0090] FIG. 55A is lateral cross-sectional view of the footwear
sole shown in FIG. 55.
[0091] FIG. 56 is a side cross-sectional view of an example
footwear sole that includes separate forefoot and heel sections of
the insert member shown in FIG. 54 positioned as outsole
members.
[0092] FIG. 56A is a lateral cross-sectional view of the footwear
sole shown in FIG. 56.
[0093] FIG. 57 is a side cross-sectional view of an example
footwear sole that includes separate forefoot and heel sections of
the insert member shown in FIG. 54 positioned respectively adjacent
to a midsole and as a portion of the outsole.
[0094] FIG. 58 is a side cross-sectional view of an example
footwear sole that includes separate forefoot and heel sections of
the insert member shown in FIG. 54 positioned adjacent to a midsole
of the footwear sole.
[0095] FIG. 59 is a side cross-sectional view of an example
footwear sole that includes a support structure secured to an
underside of a midsole of a welt sole construction.
[0096] FIG. 59A is a lateral cross-sectional view of the footwear
sole shown in FIG. 59.
[0097] FIG. 60 is a side cross-sectional view of an example
footwear sole that includes a support structure secured to an
underside of a lasting insole of lasting sole construction.
[0098] FIG. 61 is a side cross-sectional view of an example
footwear sole that includes a support structure completely embedded
in an sole insert member that is positioned as a portion of the
footwear outsole.
[0099] FIG. 61A is a lateral cross-sectional view of the footwear
sole shown in FIG. 61.
[0100] FIG. 62 is a side cross-sectional view of example footwear
sole that includes a support structure molded in the footwear sole
in a welt sole construction.
[0101] FIG. 62A is a lateral cross-sectional view of the footwear
sole shown in FIG. 62.
[0102] FIG. 63 is a lateral cross-sectional view of another example
footwear sole that includes a support structure with lateral
supports that extend vertically downward.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0103] The present invention generally relates to a support
structure for footwear. The support structure includes a
longitudinally extending member to which a plurality of laterally
extending supports members are secured at spaced apart locations
along a length of the longitudinal member. The support structure
may extend along the entire length of a footwear or may be
specifically designed for the forefoot, midfoot, or hindfoot areas
of a footwear. The support structure may be combined with
plate-like structures or may include a plurality of longitudinally
extending members. The lateral supports may extend in a generally
horizontal plane or may extend in an upward or downward direction,
or combination of upward, downward, horizontal or generally curved
upward or downward directions. Furthermore, the longitudinal and
lateral members may be made of different materials, or each may be
made of a plurality of different materials to provide the desired
characteristics of the support structure at a given location in the
footwear. In some embodiments, the longitudinal member is more
flexible than the lateral supports. The term "flexible" or
"flexibility" is defined as the ability of a member to flex in
various direction under different loads, such as flexibility in
bending or in torsion, wherein the member at least temporarily
changes shape or size. The invention may be more completely
understood with reference to the above descriptions and the
following examples. The examples included herein are given for
illustrative purposes only and should not be construed as limiting
the scope of the invention to what is illustrated and described
herein.
[0104] An example footwear 10 known in the art is shown in FIG. 1.
Footwear 10 includes a forefoot section 12, a midfoot section 14,
and a hindfoot section 16, and further includes an upper 18, a
lasting insole 20, a midsole 22, an upper midsole 23, an outsole
24, and a padded insert 26. The outsole 24 may include a variety of
different materials, but is typically made from rubber or a rubber
composite material compression molded into a given shape. The
outsole 24 may be cupped upward, as shown in FIG. 1, so as to
extend upward at edges of the outsole to cover those parts of the
footwear that may otherwise contact the ground. The midsoles 22, 23
are typically the primary cushioning and shock attenuation
components of the footwear and may be one of two types of
construction. A first type of construction includes a molded EDA
material or polyurethane (typically known as foam or a foam
product), as shown in FIG. 1. This type of construction is common
in athletic and casual footwear but also has a wide variety of
other uses. The second type of construction is a masting design in
which the midsole is hard and relatively thin. This type of
construction is common for dress footwear and some types of boots
and other work footwear. A padded insole 26 may be removable from
the footwear, or in other instances may be bonded to the lasting
insole 20.
[0105] Footwear 10 is generally orientated along an XYZ coordinate
system wherein the direction along a length of the footwear is the
Y direction, the direction transverse across a width of the
footwear is the X direction, and a direction vertical upward
relative to the outsole 24 is the Z direction. The same or similar
reference numbers used to describe features of footwear 10 will be
used for like components in the following examples.
[0106] An example footwear 100 having a support structure 30
according to principles of the invention is illustrated with
reference to FIGS. 2-6. Footwear 100 includes forefoot, midfoot and
hindfoot sections 12, 14, 16; an upper 118, a lasting insole 120, a
midsole 122, an outsole 124 and a padded insert 126. The support
structure 30 may include a longitudinally extending support 32
(referred to herein as a "spine", "elongate spine", "longitudinal
spine", or "longitudinal member") and a plurality of laterally
extending supports 34 (referred to herein as "ribs", "support
ribs", "rib supports", "lateral supports", or "lateral ribs"), and
may further include a window 38 that provides viewing into a void
39 in midsole 122 and outsole 124. The window 38 provides viewing
of a portion of support structure 30 after footwear 100 is
assembled. Spine 32 may extend along an axis 36 that defines a
spatial centerline or a pressure centerline of footwear 100.
[0107] Referring to FIGS. 4-6, a cross-section taken in each of
sections 12, 14, 16 of footwear 100 illustrate example shapes and
configurations for the spine 32 and ribs 34. The section of spine
32 that corresponds to the forefoot, midfoot and hindfoot sections
of footwear 100 are referred to as spine section 32a, 32b, 32c,
respectively. Likewise, groups of ribs 34 corresponding with the
forefoot, midfoot and hindfoot sections of footwear 100 are
referred to as ribs 34a, 34b, 34c, respectively. FIGS. 4-6
illustrate that the ribs and spine may have different shapes and
sizes at various locations along a length a support structure 30 in
order to provide the needed support, stability and shock
attenuation of footwear 100 at each section of the footwear. Some
of these variations will be described in the further example that
follows.
[0108] Spine 32 may include first and second ends 48, 50 and extend
along different "centerlines" of a footwear. In one example
embodiment shown in FIG. 7, first end 48 is aligned with a toe
centerline 42 and second end 50 is aligned with a heel centerline
40. The axis 36 of spine 32 may change direction in the midfoot
section 32b. Another example embodiment shown in FIG. 8 includes a
spine 32 that follows an axis 36 that corresponds to a pressure
centerline of a footwear. In this configuration, first end 48
aligns with a centerline 46 of toe push off pressure and second end
50 aligns with a centerline 44 of heel strike pressure. The
curvature of axis 36 shown in FIG. 8 may be altered for different
footwear designs depending on the footwear structure and the
intended use of the footwear.
[0109] A further example embodiment shown in FIG. 9 includes a
spine 32 that follows a complex centerline pattern. First end 48 in
this configuration aligns with a centerline 42 of a footwear toe
while the second end 50 aligns with a centerline 44 of heel strike
pressure. In other embodiments, the first and second ends 48, 50
may be aligned differently or in different combinations of pressure
centerlines and feature centerlines of a footwear than shown in
FIG. 7-9. Furthermore, spine 32 may extend along an axis that is
offset from the axis 36 shown in FIG. 7-9, or there may be two or
more spine members that extend along different portions of a
footwear or that extend across only certain sections of the
footwear.
[0110] FIG. 10 provides an example support structure 30 that
illustrates some of the features and benefits of a support
structure disclosed herein. Support structure 30 includes spine 32
and a plurality of ribs 34. Each rib 34 includes first and second
sides 52, 54, a mid section 56 and a cut-out portion 58 sized to
engage spine 32. Rib 34 may also include a turned-up portion 60 or
a turned-down portion 61 at ends of the ribs. Spine 32 and ribs 34
may be made of the same or different materials depending on the
application for the support structure 30. In one example
embodiment, ribs 34 are made from a material having less
flexibility than the material of spine 32. In other embodiments,
the structure of spine 32 compared to that of the ribs 34 alone may
provide greater flexibility in the spine than in the ribs. In some
applications it is preferred to have greater flexibility in the
spine than in the ribs so as to allow flexibility along a length of
the footwear at certain areas of the footwear while providing
desired amounts of lateral support with the ribs. In other
embodiments it is desired to have a spine that has the same
flexibility characteristics or being less flexible than ribs 34 if
the intended purpose is to reduce longitudinal flexibility at
certain sections in the footwear.
[0111] The support structure 30 shown in FIG. 10 illustrates
direction of motion of ribs 34 about the X, Y and Z-axis. Arrow 66
illustrates rotational motion about the Y-axis, which generally
corresponds to an axis of spine 32, arrow 68 illustrates rotational
motion of rib 34 about the Z-axis, and arrow 70 illustrates
rotational motion about the X-axis, which axis is generally aligned
in a lateral direction across a width of the footwear. The amount
of movement of ribs 34 about the X, Y and Z-axis may be controlled
by both the structure and materials used for ribs 34 and spine 32.
For example, spine 32 may include different materials in different
"zones" of support structure 30 to provide varying amounts of
movement of ribs 34 in each zone. In other embodiments, the
cross-section of spine 32 may be such that there is little
flexibility for a given material that would otherwise provide
greater flexibility if using a smaller cross-section.
[0112] FIGS. 10 and 11 further illustrate features related to an
optional method of mounting ribs 34 to spine 32. Although support
structure 30 may be most easily generated using a co-molding
process in which the spine and ribs are secured together during the
molding process, the spine 32 and ribs 34 may be separately formed
and then individually mounted to each other. One example of such a
separate mounting includes the use of position fins 72, 74 that
extend outward from spine 32 and corresponding locking recesses 76,
78 formed in rib 34. In this configuration, spine 32 may be
inserted into opening 58 in the rib until position fin 72, 74
engage locking recesses 76, 78 to hold the rib 34 in a fixed
position relative to spine 32. In other embodiments (not shown),
spine 32 may include at least one recess formed around a
circumference of the spine and the rib may include positioning fins
extending radially inward from aperture 58 of the rib so that the
positioning fins of the rib engage the recesses formed in the spine
to lock the rib into a predetermined position.
[0113] FIG. 12 illustrates another support structure 130 that
includes a spine 132 corresponding to the spine arrangement shown
in FIG. 7. First and second ends 148, 150 of spine 132 are aligned
with respective toe and heel centerlines 142, 140. An axis 136 of
spine 132 changes direction in an area corresponding to a midfoot
of a footwear and includes generally linear sections between the
first and second ends 148, 150 and the point at which direction
changes. Spine 132 includes forefoot, midfoot and hindfoot sections
132a, 132b, 132c that correspond to groups of ribs 134a, 134b,
134c. Support structure 130 may also include a heel plate 162
secured at second end 150.
[0114] FIG. 13 illustrates a support structure 230 that includes a
spine 232 extending along an axis 236 that is similar to the
configuration shown in FIG. 8. First and second ends 248, 250 of
spine 232 align with respective centerlines of toe push-off
pressure and heel strike pressure 246, 244, and axis 236 follows a
pressure centerline of a given footwear. Ribs 234 are separated
into groups 234a, 234b, 234c corresponding to the forefoot, midfoot
and hindfoot sections of a footwear. Spine 232 includes
corresponding zones 232a, 232b, 232c. Support structure 230 may
also include a heel plate 262 secured at end 250 and a toe plate
264 secured at first end 248.
[0115] FIG. 14 illustrates another example support structure 330
that is a variation of support structure 230. The first side 352 of
some of the ribs in zones 334b, 334c include a flared, wider top
profile than the second side 354 of those same ribs. In addition,
the second side 354 of some of the ribs 334a, 334b are flared so as
to have a wider top profile than the first side 352 of those same
ribs. In other embodiments, different combinations of ribs in
various sections of the support structure may include flared ends
at the first or second sides, or both the first and second sides
may include flared ends as shown by support structure 430 in FIG.
15. The first and second sides 452, 454 of support structure 430
are flared in a generally oval shape, but may, in other
embodiments, have other shapes and different sizes from those
flares shown in FIGS. 14 and 15.
[0116] FIGS. 14 and 15 illustrate support structures 330, 430 in
which the spine 332, 432 extends through an internal cavity of each
of the ribs 334, 434. Support structure 530 shown in FIG. 16
includes a connection between spine 532 and ribs 534 in which the
spine 532 is exposed as it passes through and connects to each of
ribs 534. Spine 532 includes a pair of position fins 572, 574 at
the location where each rib 534 is to be secured to spine 532, and
a corresponding recess 558 is formed in midsection 556 of each rib.
In one embodiment shown in FIG. 34, a top surface of spine 532 is
coplanar with a top primary surface of rib 534. This type of flush
mounting of the top surfaces of the spine and ribs may be
advantageous for supporting the lasting insole directly or for
directly engaging an outsole of a footwear (if the support
structure 530 is turned upside down). A similar configuration may
be useful for securing the toe plate 564 and heel plate 562 to the
spine 532 at respective first and second ends 548, 550. Further
example configurations for securing the spine and ribs are shown
and described with reference to FIGS. 34-38.
[0117] FIG. 17 illustrates a variation of support structure 530 in
which the spine 532b associated with ribs 534b is formed of the
same material as the ribs of that section. Thus, if ribs 534c
include a material that has little flexibility and spine 532b
includes the same low flexibility material, the section of support
structure 530 associated with the midfoot of a footwear would have
less flexibility than those sections of support structure 530 at
the forefoot and the hindfoot areas of the footwear. As a result,
the midfoot "zone" of the support structure 530 has a low
flexibility, which may be useful for replacing a shank element that
would otherwise be required in the footwear.
[0118] FIG. 18 illustrates a yet further variation of support
structure 530 that includes multiple longitudinally extending spine
members 532a, 532b, 532c in addition to spine 532. Each of the
additional spine members 532a, 532b, 532c may have a different
curvature and may extend along different sections of support
structure 530. For example, spine member 532c is secured at a first
side 552 of ribs 534 between the ribs 534a, while spine member 532a
is secured at second side 554 and connects ribs along all sections
532a, 532b, 532c. The additional spine members 532a, 532b, 532c may
be made of the same material as spine 532, or may be made of
different materials having different properties from spine 532, and
may in some instances completely eliminate the need for spine
532.
[0119] A yet further variation of support structure 530 is shown in
FIG. 19 and includes a webbing material 580 interposed between and
connecting various ribs 534 in sections 532a, 532b, 532c. Such a
webbing member may limit movement of the ribs 534 about the Z-axis
while still permitting movement of the ribs about the X and Y-axis.
In some embodiments, webbing 580 may extend between only the second
sides of ribs 534, while in other embodiments webbing 580 may
extend between only the first sides of the ribs 534. A yet further
embodiment may include the configuration shown in FIG. 38 in which
webbing 580 further extends across a top or a bottom, or both a top
and a bottom surface of each of the ribs 534.
[0120] FIG. 20 illustrates another support structure 630 that
includes a greater number of ribs in zones 634a, 634b than in those
embodiments shown previously. Support structure 630 includes a heel
plate 662 that takes the place of ribs 634c. Heel plate 662
includes recesses 682a-d to increase the flexibility in the heel
plate 662. Support structure 630 also includes a toe plate 664. In
yet further embodiments, rib 634a and 634b may be even narrower and
closely spaced apart than the configuration shown in FIG. 20, or
such ribs may replace the heel plate 662 within zone 634c and plate
662 may replace ribs 634a or ribs 634b.
[0121] Another example support structure 730 shown in FIG. 21 may
be used as a blocker unit that can be cut or otherwise formed for
use in multiple footwear sizes. For example, an outer periphery 784
of support structure 730 may be used for one footwear size, or the
support structure 730 may be cut or otherwise formed to have the
smaller outer periphery 786 such that support structure 730 may fit
in a smaller footwear size. The relatively simple design of spine
732 and ribs 734 may be advantageous for providing consistent
performance of support structure 730 in any of several sizes.
[0122] FIGS. 21A and 21B illustrate side views of possible
configurations for support structure 730 when using a webbing 780
between and/or around ribs 734. FIG. 21A illustrates rib 734
encapsulated between layers of webbing 780 and connected together
with spine 32. As discussed above, webbing 780 may be made of the
same or different materials from spine 732. FIG. 21b shows webbing
780 between ribs 734. In some embodiments, the webbing and spine
may be colored differently than each other and different from ribs
734 so that a side view of the footwear provides a visual indicator
of certain features of support structure 730.
[0123] FIGS. 22-31 are cross-sectional views taken along a length
of an example footwear and illustrate various example footwear and
support structure embodiments. In any of these examples or other
embodiments using the principles disclosed herein, the support
structure may be secured to a footwear in a number of ways. One
example securing method includes molding a portion of the footwear
around the support structure and then securing that portion of the
footwear to the remaining portions of the footwear. Another method
may include forming a portion of the footwear with recessed areas
sized to receive the support structure such that the support
structure may be "dropped in" to the recess. In a yet further
method, the support structure may be configured as a complete layer
that can be added as a separate layer during construction of a
footwear.
[0124] Each of the examples shown in FIGS. 22-31 include forefoot,
midfoot and hindfoot sections 12, 14, 16, an upper 18, a lasting
insole 20, a midsole 22, an outsole 24, and a support structure 30
having a spine 32 and ribs 34. Some of the examples further include
an upper midsole 23. These features have been referenced in each
figure. Of further note, many of the layers and features shown in
FIGS. 22-31 are not shown with complete cross-section hatching so
as to more clearly illustrate the various features shown in those
figures.
[0125] An example footwear 200 having a generally flat outsole 24
is shown in FIG. 22. Outsole 24 is generally flat and extends along
forefoot, midfoot and hindfoot sections 12, 14, 16. Support
structure 30 is mounted in midsole 22 along an upper portion of the
midsole 22 adjacent the lasting upper 20 and further includes toe
and heel plates 64, 62 at opposing first and second ends 48, 50 of
spine 32.
[0126] Another example footwear 300 having a heel breast 108 shown
in FIG. 23. Footwear 300 includes a support structure 30 that has a
longitudinally extending spine 32, lateral support structures or
ribs 34, at a heel plate 62. The outsole 24 and midsole 22 are
recessed in the area of midsole 14 so as to create a heel portion
of the footwear defined by heel breast 108. The upper midsole 23
may be co-molded with midsole 22 or may be a separate midsole
member made of a different material having different properties
than midsole 22. For example, upper midsole 23 may be a firm,
plate-like layer or a foam having little flexibility while midsole
22 includes a foam having greater flexibility. Support structure 30
is positioned along an upper part of midsole 22 adjacent to upper
midsole 23, but may in other embodiments be positioned above the
upper midsole 23 or within other areas of midsole 22.
[0127] Example footwear 400 shown in FIG. 24 includes a "fiddle"
shank 88. A fiddle shank is constructed such that the midfoot
region 14 includes recesses in the midsole and outsole portions,
but includes a shank-like feature made from the midsole and outsole
that extends downward to be supported by the ground in the area of
midfoot 14. In some embodiments, the recessed portion of the fiddle
shank area may be recessed completely in a vertical direction so as
to expose a portion of support structure 30, or may include a
window feature so as to view a portion of the support structure
either from a side or a bottom view of footwear 400.
[0128] A yet further example footwear 500 shown in FIG. 25 includes
a support structure 30 having a section of the support structure
acting as a shank. Support structure 30 includes a plurality of
ribs 34a and a spine 32a in the region of forefoot 12, ribs 34b and
spine 32b in the area of midfoot 14, and ribs 34c and spine 32c in
the area of hindfoot section 16. Another example support structure
having similar features is shown as support structure 530 in FIG.
17. Spine 32b and ribs 34b may be made of the same or similar
materials so as to have a reduced flexibility in the midfoot
section 14 where additional support is typically desired because of
the recesses in midsole 22 and outsole 24 that define the heel
breast 108. Footwear 500 may also include a window 38 through
outsole 24 for viewing a portion of support structure 30 from a
bottom side of the footwear.
[0129] A further example of footwear 600 having a portion of a
support structure 30 exposed at a bottom side of the footwear is
shown in FIG. 26. Support structure 30 includes separate zones or
sections along a length of the footwear, which include a spine 32a
and ribs 34a at the forefoot 12, spine 32b and ribs 34b at midfoot
14 and spine 32c and ribs 34c at hindfoot section 16. The spine 32b
and ribs 34b may have significantly larger cross-sectional sizes as
compared to the spine and ribs in other sections of the footwear,
and may be made of material that has a greater resistance to wear
and increased resistance to deformation because of its exposure
outside of the footwear. The material in this section of support
structure 32 may also have less flexibility, or may be the same
material as the other sections of the support structure, but have
less flexibility as a whole because of the larger cross-section of
that section. In other embodiments, there may be additional or
fewer layers that midsole 22 and upper midsole 23, or there may be
layers of midsole between the lasting insole 20 and the support
structure features 34b, 34b. The ribs 34b may be covered by a
protective coating such as a clear polyurethane material to protect
the ribs 34b from damage.
[0130] An example footwear 700 having a portion of the support
structure 30 that extends into a midsection of the midsole 22 is
shown in FIG. 27. Support structure 30 has at least three sections
or zones that align with the forefoot, midfoot or hindfoot sections
12, 14, 16. A forefoot section of support 30 includes spine 32a and
a plurality of ribs in 34a that extend along an upper portion of
midsole 22 adjacent the lasting insole. A second section or zone
includes a spine 32b and a plurality of ribs 34b that are enlarged
in comparison to features of the other support structure sections,
and extend along an upper area of midsole 22 adjacent the lasting
insole 20. A third section includes a spine 32c and a plurality of
ribs 34c at the hindfoot section of the footwear that extend into a
midsection of midsole 22 between the lasting insole 20 and outsole
24. Support structure 30 may also include a heel plate 62 and a toe
plate 64. Further, footwear 700 may include a window 38 in the
midfoot section 14 of the footwear for viewing the support
structure from a bottom side of the footwear.
[0131] An example footwear 800 that includes an alternative
shank-like feature in the support structure 30 is shown in FIGS.
28, 28a and 28B. Support structure 30 may include at least three
separate zones or sections that are align with the forefoot,
midfoot and hindfoot sections of the footwear. A forefoot section
of the support structure includes a spine 32a and a plurality of
ribs 34b along with a toe plate 64. A midfoot section of the
support structure may include a spine 32b with a substantial height
and width along with a plurality of ribs 34b. The size and
materials of spine 32b and ribs 34b they provide a shank-like
feature for footwear 800. A hindfoot section of the support
structure may include spine 32c and a plurality of ribs 34c have a
different cross-section and shape than the other sections of the
support structure. As with many of the other examples described
herein, the features of support structure 30 may be turned upside
down and mounted at a bottom side of midsole 22 so as to extend the
long outsole 24 rather than extending along lasting insole 20.
[0132] An example footwear 900 that includes a support structure 30
with features facing upward such that the support structure extends
along an outsole of footwear (as mentioned above) is shown in FIGS.
29, 29A and 29B. The support structure 30 extends along midsole 22
adjacent to outsole 24 and further includes upward extending
support structures 60 at opposing ends of the ribs 34a and 34c. The
spine 32b extends through midfoot section 14 and may be configured
to extend along the lasting insole 20 as well as the outsole 24.
The ribs 34b in midfoot section 14 may be a single plate as shown
in FIG. 29A or maybe a plurality of ribs similar to ribs 34a and
34c. Support structure 30 may also include a heel plate 62 and a
toe plate 64.
[0133] A further example of footwear 1000 that includes a support
structure extending through a midportion of midsole 22 is shown in
FIG. 30. The support structure 30 includes a spine 32 and a
plurality of ribs 34, and may further include a heel plate 62 and a
toe plate 64. A support structure 30 may extend through a mid
portion of midsole 22 so as to be spaced between the lasting insole
20 and the outsole 24 along the entire length of support structure
30 from a first end 48 to a second end 50, or may in other
embodiments extend along the outsole and the lasting insole, or
both the lasting insole and the outsole at various locations along
a length of the support structure.
[0134] An example footwear 1100 that includes a support structure
30 having an extended plate feature in combination with a spine and
plurality of ribs is shown in FIG. 31. The support structure 30
includes a plate-like structure similar to heel plate 62 that
extends along the hindfoot and midfoot sections 16, 14, and further
includes a forefoot section having a spine 32a and a plurality of
ribs 34a, including a toe plate 64. This particular embodiment may
be useful for providing lateral support and additional pressure
dissipation in high impact areas in the hindfoot and midfoot
sections of the footwear while providing necessary flexibility with
limited lateral support through the forefoot section of the
footwear. FIG. 31A illustrates one example support structure 30
that includes features illustrated in FIG. 31. The heel plate 62
may include a cupping fin or wall 63 that extend upward or downward
(not shown) that can be used to engage portions of the midsole 22,
outsole 24, upper 18, or other portions of the footwear 1100.
[0135] FIGS. 32-38 illustrate several further example support
structure embodiments, any of which may be included in the above
listed examples. One example support structure 830 that includes
upward and downward extending ribs 90, 92 is shown in FIGS. 32,
32A. Support structure 830 includes a longitudinally extending
spine member 32 and a plurality of upward extending lateral
supports or ribs 92 as well as a plurality of downward extending
lateral supports or ribs 90. Each of the ribs 90, 92 may further
include generally vertically extending tabs or supports 60 at ends
of the ribs. As shown in FIG. 32A, the vertical support 60 may
extend along an exterior side wall of the midsole or extend upward
to support a vertically extending portion of an upper 18 of a
footwear 1200. A footwear 1200 may include a window 38 that is
viewable through either lasting insole 20 and midsole 22 from a top
of the footwear, or from a bottom of the footwear through outsole
24 and midsole 22. In further embodiments, a window may be
positioned along a sidewall of the midsole so as to view the
support structure 30 from a side or back of the footwear.
[0136] The upward extending tabs 60 may be configured to extend
outside of the sole structure of footwear 1200 and around the upper
18 as a strap feature 65 in FIG. 32. The strap 65 may be integrally
coupled to one of the ribs 90, 92, or any other portion of the
support structure 830. The strap 65 may be detachable for optional
use, or may extend only partially around the upper 18 such that
strap 65 includes multiple pieces that are separately coupled to
portions of the upper 18.
[0137] Another support structure example embodiment 930 is shown in
FIGS. 33 and 33a. Support structure 930 includes a longitudinally
extending spine 32, at least one horizontally extending lateral
support or rib 34, at least one downward supporting lateral support
or rib 34, at least one downward extending lateral support or rib
90, and at least one upward extending lateral support or rib 92.
Each of ribs 34, 90, 92 may include a vertical tab or extension 60,
or a vertically downward extending tab, such as tab 61 shown in the
following FIG. 36.
[0138] FIG. 34 illustrates a close-up perspective view of a portion
of the support structure 530 shown in FIG. 16. As discussed above
related to FIG. 16, spine 32 includes a top surface that is
generally coplanar with a top surface of rib 34, and includes
position fins 72, 74 that engage rib 34 to hold rib 34 in position
relative to the spine 32. This type of configuration could be
either upward (as shown) or downward facing depending on whether
the support structure 530 is aligned adjacent a lasting insole of
the footwear or against the outsole of the footwear.
[0139] The spine 32 shown in FIG. 34 has a partial cylindrical
cross-section and rib 34 is generally flat between first and second
sides 52, 54. In other embodiments shown in FIGS. 35-38, spine 32
may have a parabolic, cylindrical, rectangular, or combination of
cylindrical and rectangular cross-sections. Furthermore, a top
surface of the rib 34 may have a generally upwardly sloping
curvature (to mirror the curvature of the lasting insole) that may
further include vertically upward or vertically downward extending
tabs 60, 61.
[0140] Support structure 1030 shown in FIG. 35 includes one example
spine 32 with a parabolic cross-section and a top surface that is
flush with a top surface of rib 34. A midsection 56 of rib 34 in
support structure 1030 generally outlines the parabolic shape of
the spine 32. Support structure 1130 shown in FIG. 36 includes a
spine with a rectangular cross-section and the midsection 56 has a
shape that is unrelated to the shape of the spine. The top surface
of spine 32 is coplanar with the top surface of the rib 34. Support
structure 1230 shown in FIG. 37 includes a spine with a cylindrical
cross-section that extends above an upper surface of rib 34. This
configuration may be useful when the support structure 1230 is
embedded in a midsole rather than being flush against an outsole or
a lasting insole of a footwear. Support structure 1330 shown in
FIG. 38 includes a spine 32 with a partial cylindrical
cross-section and further includes an extension 32d that extends
across at least a portion of rib 34 beyond midsection 56. In some
embodiments, the spine material 32d may extend across the entire
upper surface of rib 34 and may further extend in between a
plurality of ribs positioned along a length of the spine to act as
a webbing between the ribs.
[0141] The support structure shown in FIGS. 34-38 may be especially
useful for co-molding the support structure or for creating a
configuration in which the ribs 34 can be snap fit or otherwise
separately secured to spine 32 using methods other than
co-molding.
[0142] FIGS. 39-40 illustrate two examples of co-molding
arrangements. Support structure 1430 shown in FIGS. 39 and 39A
include a spine 32, ribs 34, and right and left flex sections 94,
96 of rib 34. Each rib 34 is connected via a longitudinal connector
98 such that the ribs 34 are connected together in a continuous
string. Once the string of ribs 34 is molded, the spine 32 may be
co-molded using around longitudinal connector 98 and to flex
sections 94, 96 using mold 100. This type of molding may provide
advantages of strength and performance when using the support
structure 1430, as well making it easier to handle the ribs during
manufacture of the support structure.
[0143] A support 1530 is shown in FIGS. 40 and 40A having a
continual longitudinal extending spine 32 that is held in a mold
101 and co-molded with ribs 34 having flex sections 94, 96 around
the spine 32. This type of construction may also provide certain
performance and manufacturing advantages over other support
structure designs. A molded structure manufactured using the
examples shown in FIGS. 39 and 40 may be very cost effective for
both initial tool and die preparation and ongoing production of
parts over time.
[0144] A support structure as disclosed herein may be integrated
into various portions of the sole of a footwear (described above),
or may be integrated into a padded insert 126 for a footwear, as
shown in FIG. 41. Insert 126 includes a support structure 30 that
includes a longitudinally extending spine 32 and a plurality of
laterally extending supports or ribs 34 that are secured to the
spine 32. Support structure 30 may also include a heel plate 62 and
a toe plate 64 and may also include vertically extending tabs 60
formed at ends of the ribs 34. Support structure 30 is encapsulated
within a padding 27 that provides a comfortable interface between
support structure 30 and a user foot, and further provide an proper
interface between the support structure 30 and a lasting insole or
other feature of the footwear.
[0145] Any of the above examples, including the padded insert 126
show in FIG. 1 may include one or multiple sections of a support
structure at various location along a length of a footwear. For
example, FIGS. 42A, 42B, 42C illustrate separate support structure
sections that may be used for certain forefoot, midfoot or hindfoot
sections of a footwear. Forefoot insert 102 shown in FIG. 42A
includes a spine 32a that extends along a pressure centerline and
further includes a plurality of laterally extending supports or
ribs 34a and a toe plate 64. Midfoot insert 103 includes a
longitudinally extending spine 32b and a plurality of laterally
extending supports or ribs 34b. Hindfoot insert 104 shown in FIG.
42C includes a longitudinally extending spine 32c and a plurality
of laterally extending support or ribs 34c as well as a heel plate
62. Spine sections 32a, 32b, 32c shown in FIGS. 42A-C may extend
along a pressure centerline of a footwear or may be aligned with an
actual centerline of the footwear. Furthermore, the ribs 34a, 34b,
34c may have a variety of different shapes and sizes and be aligned
relative to the respective spine member at a variety of different
angles.
[0146] A yet further example embodiment may include a combined
hindfoot and midfoot insert 105 shown in FIG. 43, or a combined
forefoot and midfoot insert 106 shown in FIG. 44. Insert 105
includes spine sections 32b and 32c as well as groups of ribs 34b
and 34c. Likewise, insert 106 includes spine sections 32a, 32b as
well as ribs 34a, 34b.
[0147] In addition to the separate "zones" or sections of the spine
or groups of ribs discussed above, the spine material between each
individual rib may also vary along the length of the support
structure. In one embodiment, the spine material between every rib
member may have a different composition or set of physical
characteristics. In another example, the spine material beginning
at the toe and heel areas is very flexible and the spine material
becomes less flexible between every rib or between every few ribs
leading toward the midfoot region of the support structure.
[0148] In a yet further embodiment, the support structure may
include a plurality of wire or hair-like laterally or vertically
extending support structures that extend from either the ribs or
the spine for specialized support in certain areas of a
footwear.
[0149] Referring now to FIGS. 45-48, an example footwear sole
assembly 1601 that includes a support structure 1630 is shown and
described. The support structure 1630 is shown extending along
substantially the entire length of the footwear sole assembly 1601.
The support structure includes a longitudinal spine 1632 and
lateral support 1634 that extend in only the midfoot section 1603
and hind foot section 1604. The forefoot section 1602 includes a
plate-like structure 1662 that may include a plurality of recesses
1635 to increase flexibility of the plate structure. Various
features of the support structure 1630 cooperate with features of
the midsole 1622 and outsole 1624 of the footwear sole assembly
1601, as described below.
[0150] The longitudinal spine 1632 and lateral supports 1634 may
have different configurations along the length of the footwear to
provide desired results in the footwear sole assembly 1601. In many
cases, it is preferable to provide high shock absorption and shock
attenuation in the hindfoot portion of a footwear. To address these
criteria, the hindfoot portion 1632c of the longitudinal spine is
relatively small in cross section and may include a recessed
portion to increase flexibility of the spine where the spine
attaches to the lateral supports 1634c in the hindfoot portion
1604. A spine insert piece 1633 may be inserted in the recessed
portion (see FIGS. 46 and 47), wherein the insert piece 1633 may
include different flexibility properties or other characteristics
to help "fine tune" the support structure characteristics for a
given footwear. The longitudinal spine 1632c may also include
different materials from the lateral supports 1634c that also
promotes increased flexibility spine and movement of the lateral
supports relative to the spine.
[0151] The lateral support 1634c may be relatively long and narrow
as shown in FIG. 45 or may be relatively short and wide depending
on the desired result. Ends of the lateral supports 1634c opposite
the longitudinal spine 1632c may be supported on a support shelf
1683 defined by a recess 1681 in the midsole 1622. A separate void
1685 formed in the midsole 1622 beneath the remaining portions of
the lateral support 1634c and the longitudinal spine portion 1632c
establish a trampoline-like design that provides the desired shock
attenuation and shock absorption benefits while still providing
sufficient support due to the remaining relatively firm midsole
material around a periphery of the hindfoot section of the footwear
sole assembly 1601.
[0152] A separate spine support member 1687 may be positioned
within the void 1685 in a further effort to "fine tune" overall
performance of the support structure 1630. This member 1687 may
either partially or completely fill the void 1685, and preferably
is position in alignment the longitudinal spine section 1632c (see
FIG. 47) to provide engagement of the spine when a load is applied
to the spine structure 1630.
[0153] The midfoot section of a footwear typically requires greater
stiffness to support the arch of a users foot. In many footwear
constructions, a shank member is required to bridge between the
forefoot of the footwear and the heel portion of the footwear
defined by a heel breast. The support structure 1630 may be
modified to include different materials or a different structure to
provide the desired support and stiffness. The longitudinal spine
portion 1632b includes a greater cross sectional area, which in
combination with the shorter length of lateral support 1632b and
the absence of a recess or void beneath the support structure in
the midfoot portion of the footwear, results in a shank-like
structure or effect. An alternative embodiment of a support
structure that includes a shank-like structure is shown with
reference to FIGS. 49-53.
[0154] In many types of footwear, the forefoot area is relatively
thin for purposes of aesthetics and styling. The preferred reduced
thickness in the forefoot is in conflict with another objective to
provide additional support, shock absorption, and shock attenuation
in the forefoot to balance toe off forces and the like when the
footwear is used for walking, which objective typically requires
additional thickness in the forefoot area. The support structure
1630 is modified in the forefoot area 1602 to eliminate the lateral
supports 1634 and a defined longitudinal spine 1632 and to include
a plate-like structure 1662 that is surrounded by first and second
forefoot padding layer 1689, 1691. The forefoot section 1602 may be
configured such that the first padding layer 1689 may be flush with
a top surface of the midfoot and hindfoot sections 1603, 1604 as
shown in FIG. 46. Other embodiments may use a single padding layer
in the forefoot or may replace the plate-like structure with a
material or member that includes more flexibility and/or
padding.
[0155] The footwear sole assembly 1601 may also include a viewing
window 1638 that is positioned vertically below the hindfoot
section 1604 to provide viewing of some of the support structure
features. The window 1638 may be embedded in the outsole 1634 and
may include a clear polymer material or other material that
provides the desired viewing. Multiple viewing windows may be
provided at different locations along a length of the support
structure 1630 (e.g., see viewing window 38 in FIGS. 27 and 28).
Preferably, the window 1638 is aligned with an open portion of the
void 1685, the materials of the midsole 1322 and support member
1687 between the window 1638 and the support structure 1630 must be
clear as well in order for viewing to occur. In other embodiments
in which the support structure is positioned at a bottom side of
the midsole rather than at a top side of the midsole, a window
through the outsole alone may provide viewing of the support
structure. Other embodiments may include a viewing window from a
top side of the support structure, such as through a lasting insole
or mast layer of the footwear sole assembly.
[0156] Referring now to FIGS. 49-53, another footwear sole assembly
1701 is shown and described. Assembly 1701 includes a support
structure 1730 having midfoot and hindfoot longitudinal spine
portions 1732b, 1732c and a plurality of lateral supports 1734, and
a midsole 1722. The midsole 1722 includes a void 1785, a recess
1781 that defines a shelf 1783, and a spine support member 1787
positioned in the void 1785. A midfoot section 1703 of the support
structure 1730 includes a longitudinal spine section 1732b having a
greater cross-sectional area than spine portion 1732c in the heel
section 1704 thereby providing a shank-like function. Because of
the relatively narrow width of the midsole 1722 as compared to
midsole 1622 shown in FIG. 45, the addition of lateral supports
small enough to fit with the relatively wide spine portion 1732c
within that width may not be as useful in providing additional
support, shock absorption, and shock attenuation.
[0157] The spine support member 1787 completely fills the void 1785
and maintains contact with the spine portion 1732c. Other
embodiments may include a reduced size spine support member or no
spine support member at all, wherein the void 1785 is left
completely open for free movement of the spine structure within the
void 1785 (movement of the spine structure in void 1785 being
restricted by at least the support of lateral supports 1743c on
shelf 1783).
[0158] In the embodiments shown and described with reference to
FIGS. 45-53, the hindfoot portion of the support structures may be
generally described as being able to move within a void portion in
the midsole when a load is applied to the support structure. More
specifically, the longitudinal spine portion in the hindfoot
section of the footwear sole assembly may be capable of moving
within the voided portion or against a compression or shock
absorbing member positioned within the void. The same or similar
structure may be added in other portions of a footwear sole
assembly such as in the forefoot of the assembly if sufficient
thickness is provided in the midsole to establish such a void and
movement of the support structure within the void or against a
material positioned in the void. Using a first material to support
ends of the lateral support members and a second material to
support at least a portion of the longitudinal spine or the
remaining portions of the lateral supports may be particularly
useful to meet the demands of shock absorption and shock
attenuation while providing desired support in a footwear
assembly.
[0159] FIG. 54 illustrates a footwear sole insert 1807 that
includes a support structure 1830 coupled to a base portion 1809.
The insert includes forefoot, midfoot and hindfoot sections 1802,
1803, 1804. The support structure 1830 includes a portion of the
longitudinal member 1832 and multiple lateral supports 1834 in each
of the forefoot, midfoot and hindfoot portions of the insert 1807.
The insert 1807 may be particularly useful when assembling a
footwear sole assembly such as the sole assembly shown in FIGS. 55
and 55A. When the base portion 1809 is configured as an outsole
member, the insert 1807 may be secured to an under side of an
outsole portion 1824, which is in turn coupled to a midsole 1822
and further coupled to an upper of a footwear (not shown). The base
portion 1809 may include any desired material with any desired
shape, such as, for example, a material having slip resistant
properties that is formed in shapes that enhance resistance to the
footwear slipping.
[0160] When using molding processes to generate a footwear assembly
such as assembly 1801, the insert 1807 may first be separately
formed by coupling the base member 1809 to the support structure
1830 using such methods as, for example, molding, heat or sound
welding, or adhesives to provide a single insert member. The insert
may be placed within a mold cavity and the outsole 1824 and midsole
1822 are molded around the insert 1807 in separate steps. The
outsole and insole members 1824, 1822 may be separately molded or
formed and later coupled to other components of the footwear sole
assembly 1801 rather than using direct molding on top of the insert
1807.
[0161] The insert 1807 may have a width that is narrower than a
total width of the outsole 1824 as shown in FIG. 55A, or may extend
across an entire width of the footwear sole assembly as shown in
the embodiment illustrated in FIG. 56A. The insert 1807 may also
have a length that extends along an entire length of the footwear
sole assembly and may further extend upward to engage an upper of
the footwear if desired (see, for example, the dotted line numbered
99 in FIG. 55). Referring to FIGS. 59 and 59A, the footwear 2300
includes an outsole 2324 and a support structure 2330 that could be
formed as an insert member, a portion of which extends an entire
length of the footwear 2300 and engages the upper 2318.
[0162] The insert sections 1802, 1803, 1804 may be divided into
separate pieces that are individually insertable into different
portions of a footwear sole assembly. For example, FIG. 56
illustrates a footwear sole assembly 1901 that include forefoot and
hindfoot insert sections 1902, 1904 that are positioned in an
outsole 1924 at respective forefoot and hindfoot sections of the
assembly. The base member 1909 may be configured as an outsole
member wherein base member 1909 couples the support structure 1930
against the outsole 1924. A midsole 1922 may be molded or otherwise
coupled to the outsole 1924 to complete the footwear sole
assembly.
[0163] FIGS. 57 and 58 illustrate footwear sole assemblies 2001,
2101 that each include insert sections positioned at alternative
positions with respect to the outsole. Assembly 2001 includes a
forefoot section 2002 positioned between the outsole 2024 and the
midsole 2022, and a hindfoot section 2004 positioned at a bottom
side of the outsole 2024. Assembly 2101 includes forefoot and
hindfoot sections 2102, 2104 that are positioned at a top side of
the outsole 2124 along an underside of the midsole 2122. Other
embodiments may include insert segments at other locations within a
footwear sole assembly such as on a top side of a midsole or
completely embedded within an outsole or insole member.
[0164] Referring again to FIGS. 59 and 59A, the footwear 2300 may
be well suited for a welt type molding or forming process in one
method, the support structure 2330 is positioned in a mold cavity
with stand-off members (not shown) that hold the support structure
vertically above a floor of the mold cavity. The mold cavity is
then filled underneath and around the support structure using
injection molding, casting, or other methods in which a material
such as, for example, a polyurethane foam or a TPU elastomer, fills
a portion of the mold cavity to form the outsole 2324. The midsole
2322 is either directly molded on top of the support structure 2330
and outsole 2324, or is formed separately and then coupled to the
support structure 2330 and outsole 2324. In another method, the
outsole 2324 is formed in a mold cavity with a dummy support
structure in place to create a recess shaped like the actual
support, wherein the dummy support structure is later replaced with
the actual support structure 2330 before adding the midsole or
other layers of the footwear 2300. In a still further embodiment,
the support structure is combined with three or more sole layers as
shown in the footwear sole assembly 2601 shown in FIGS. 62 and 62A.
Assembly 2601 includes a support structure 2630 positioned between
an outsole 2624, a first midsole 2622, and a second midsole 2633.
The midsole layers 2622, 2633 (and any other midsole or outsole
described herein) may include gels, air pockets, or specialized
shock absorbing and shock attenuating materials that are sealed
within the assembly 2601 to enhance performance of the footwear
sole assembly.
[0165] These types of processes may be useful for interchanging
support structures with a variety of different designs. For
example, the midfoot portion 2303 of the support structure may
include a longitudinal member and lateral supports configured to
provide a shank-like function. Size and shape modifications to the
support structure can be accounted for easily when using molding
and related methods to form portions of a footwear sole as
described above.
[0166] Referring now to FIG. 60, another example footwear 2400 is
shown including an outsole 2424, a lasting insole 2422, and a
support structure 2430. The lasting insole 2422 may be separately
coupled to an upper 2418 before being secured to the outsole 2424
using any desired methods such as the molding methods described
above. In one example method, the combined lasting insole 2422 and
upper 2418 may be directly molded or otherwise coupled to the
outsole 2424 using, for example, adhesives, cements, or other
bonding materials.
[0167] Referring now to FIG. 61, another example footwear sole
assembly 2501 is shown in which the support structure 2530 is
completely embedded within the base member 2509 so as to provide an
insert 2507 in which none of the support structure is exposed.
Other embodiments may include exposed portions of the support
structure along sides of the insert 2507, but not at top and bottom
surfaces of the insert 2507. The insert 2507 may be combined within
an outsole 2524 and midsole 2522 using any of the methods described
above.
[0168] Any of the example inserts described above may be configured
as a blocker unit that can be trimmed to fit any size footwear
desired. When the insert is used as a blocker, end portions of the
lateral supports may be removed as part of the trimming
process.
[0169] In an additional embodiment illustrated in FIG. 63, a
footwear sole assembly 2701 includes a support structure 2730
having lateral supports 2734 that extend in a vertically downward
direction from the longitudinal member 2732. The support structure
2730 is positioned between an outsole 2724 and a midsole 2722. The
downward sloping lateral supports 2734 provide a configuration in
which the support structure 2730 acts as a spring-like member,
wherein ends of the lateral members 2734 at an outside edge of the
assembly 2701 maintain a relatively fixed position due to the
reduced amount of outsole material between the ground and the
lateral support, and the longitudinal member 2732 is vertically
movable due to compressibility of the larger amount of outsole
material between longitudinal member 2732 and the ground beneath
the outsole 2724. This type of configuration could also be modified
into a blocker style unit in which the lateral members extend out
to a further width as shown by the dash lines in FIG. 63, wherein
the lateral members are preferably always covered by material of
the outsole or insole 2722, 2724. With the lateral members at their
maximum width, it may be possible to obtain a maximum "spring"
effect, although a narrower configuration as shown by the solid
lines in FIG. 63 may still provide a desired amount of shock
absorption and shock attenuation while providing additional lateral
support that may not otherwise be present if the support structure
2730 were removed from the assembly 2701.
[0170] Materials for the spine and ribs of the support structure
may include, for example, metals and metal alloys, nylon,
polyurethane, polypropylene, or any of a variety of other polymer
and synthetic materials. The materials may include fillers such as
glass that increase the hardness and reduce flexibility of the
structures. In one example, the spine support structure material
includes at least about 10% glass, and preferably includes about
30% or more glass.
[0171] The above specification, examples and data provide a
complete description of the manufacture and use of the composition
of the invention. Since many embodiments of the invention can be
made without departing from the spirit and scope of the invention,
the invention resides in the claims hereinafter appended.
* * * * *