U.S. patent application number 12/696029 was filed with the patent office on 2011-07-28 for cushioning and shock absorbing midsole.
This patent application is currently assigned to BROWN SHOE COMPANY, INC.. Invention is credited to Brian Hanebrink, Cody Peterson.
Application Number | 20110179669 12/696029 |
Document ID | / |
Family ID | 44307845 |
Filed Date | 2011-07-28 |
United States Patent
Application |
20110179669 |
Kind Code |
A1 |
Hanebrink; Brian ; et
al. |
July 28, 2011 |
CUSHIONING AND SHOCK ABSORBING MIDSOLE
Abstract
A midsole adapted for attachment to a shoe having multiple
layers of varying materials each having a different hardness level.
More particularly, the present midsole includes a top, middle and
bottom layer wherein all three layers of material have a different
hardness range and wherein at least one of the layers is made from
thermoplastic rubber (TPR). In one embodiment, the thermoplastic
rubber (TPR) layer lies between the top and bottom layers and in
another embodiment, the thermoplastic rubber (TPR) layer is the
bottom layer. The thermoplastic rubber (TPR) layer may also have a
length shorter than the other two layers forming the midsole.
Inventors: |
Hanebrink; Brian; (O'Fallon,
MO) ; Peterson; Cody; (St. Louis, MO) |
Assignee: |
BROWN SHOE COMPANY, INC.
St. Louis
MO
|
Family ID: |
44307845 |
Appl. No.: |
12/696029 |
Filed: |
January 28, 2010 |
Current U.S.
Class: |
36/28 ;
36/30R |
Current CPC
Class: |
A43B 7/144 20130101;
A43B 13/127 20130101; A43B 21/265 20130101 |
Class at
Publication: |
36/28 ;
36/30.R |
International
Class: |
A43B 13/18 20060101
A43B013/18; A43B 13/12 20060101 A43B013/12 |
Claims
1. A midsole of a shoe comprising: a top layer; a middle layer
extending at least partially across the length of said top layer
and attachable to said top layer; and a bottom layer attachable to
said middle layer along at least a portion of its length; said top
layer having a hardness greater than said middle and bottom layers,
and said middle layer having a hardness greater than said bottom
layer.
2. The midsole of claim 1 wherein said middle layer extends across
the heel portion of said top and bottom layers.
3. The midsole of claim 2 wherein the heel portion of said bottom
layer is attached to said middle layer and the remaining portion of
said bottom layer is attached to said top layer.
4. The midsole of claim 1 wherein said top layer includes male
connecting portions and said middle layer includes corresponding
female connecting portions, said male connecting portions engaging
said female connecting portions when said middle layer is attached
to said top layer.
5. The midsole of claim 1 wherein said top layer is made of a
polyurethane material.
6. The midsole of claim 1 wherein said middle layer is made of a
thermoplastic rubber material.
7. The midsole of claim 1 wherein said bottom layer is made of a
polyurethane material.
8. The midsole of claim 1 wherein said top layer has a hardness in
the range of 60-90.degree. Asker C hardness.
9. The midsole of claim 1 wherein said middle layer has a hardness
in the range of 20-65.degree. Asker C hardness.
10. The midsole of claim 1 wherein said bottom layer has a hardness
in the range of 20-50.degree. Asker C hardness.
11. The midsole of claim 1 further including an outsole attachable
to the bottom layer of said midsole.
12. A midsole of a shoe comprising: a top layer made of a material
having a hardness in the range of 60-90.degree. Asker C hardness; a
middle layer extending at least partially across the length of said
top layer and attachable to said top layer, said middle layer being
made of a material having a hardness in the range of 40-60.degree.
Asker C hardness; and a bottom layer attachable to said middle
layer along at least a portion of its length, said bottom layer
being made of a material having a hardness in the range of
20-40.degree. Asker C hardness.
13. The midsole of claim 12 wherein said top layer is made of a
polyurethane material.
14. The midsole of claim 12 wherein said middle layer is made of a
thermoplastic rubber material.
15. The midsole of claim 12 wherein said bottom layer is made of a
polyurethane material.
16. The midsole of claim 12 wherein said middle layer extends
substantially across the length of said top layer.
17. A midsole of a shoe comprising: a top layer; a middle layer
attachable to said top layer; and a bottom layer extending at least
partially across the length of said middle layer and attachable to
said middle layer; said top layer having a hardness greater than
said middle and bottom layers, and said bottom layer have a
hardness greater than said middle layer.
18. The midsole of claim 17 wherein said bottom layer extends
across the heel portion of said middle layer.
19. The midsole of claim 18 wherein said bottom layer is attached
to the heel portion of said middle layer.
20. The midsole of claim 17 wherein said middle layer includes
female connecting portions and said bottom layer includes
corresponding male connecting portions, said male connecting
portions engaging said female connecting portions when said bottom
layer is attached to said middle layer.
21. The midsole of claim 17 wherein said top layer is made of a
polyurethane material.
22. The midsole of claim 17 wherein said middle layer is made of a
polyurethane material.
23. The midsole of claim 17 wherein said bottom layer is made of a
thermoplastic rubber material.
24. The midsole of claim 17 wherein said top layer has a hardness
in the range of 60-90.degree. Asker C hardness.
25. The midsole of claim 17 wherein said middle layer has a
hardness in the range of 20-50.degree. Asker C hardness.
26. The midsole of claim 17 wherein said bottom layer has a
hardness in the range of 20-65.degree. Asker C hardness.
27. The midsole of claim 17 further including an outsole attachable
to the bottom layer and to a portion of the middle layer of said
midsole.
28. A midsole of a shoe comprising: a top layer made of a material
having a hardness in the range of 60-90.degree. Asker C hardness; a
middle layer attachable to said top layer and being made of a
material having a hardness in the range of 20-40.degree. Asker C
hardness; and a bottom layer attachable to said middle layer along
at least a portion of its length, said bottom layer being made of a
material having a hardness in the range of 40-60.degree. Asker C
hardness.
29. The midsole of claim 28 wherein said top layer is made of a
polyurethane material.
30. The midsole of claim 28 wherein said middle layer is made of a
polyurethane material.
31. The midsole of claim 28 wherein said bottom layer is made of a
thermoplastic rubber material.
32. The midsole of claim 28 wherein said bottom layer extends
substantially across the heel area of said middle layer.
33. The midsole of claim 28 wherein said middle layer includes
connecting portions which are cooperatively engageable with
corresponding connecting portions associated with said bottom layer
when said bottom layer is attached to said middle layer.
34. The midsole of claim 33 wherein said bottom layer includes a
pair of flanges which are cooperatively receivable within a
corresponding pair of cut-offs associated with said middle layer.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the construction
of a shoe and, more particularly, to a midsole construction with
improved comfort and shock absorption to enhance the comfort of a
user's foot.
[0002] The footwear industry has seen numerous design features
introduced over the years in order to enhance the comfort,
cushioning, resiliency and shock absorption capabilities of a shoe.
Many of the technological advances have occurred in the sole,
particularly the midsole. In most footwear, the midsole often
provides both protective cushioning and shock absorption for the
user's foot. In an effort to provide improved performance, it is
often desirable to vary the support characteristics of the sole
from one region to another. A wide variety of soles have been
developed to provide variable support for the foot. These advances
include using air cushioning systems such as air cavities or air
bladders disposed within the sole of a shoe Although a marked
improvement over conventional uniform sole constructions has
occurred over the years, there still remains a need for a midsole
construction that can be adapted to provide additional comfort and
shock absorption to the wearer's foot.
[0003] It would therefore be desirable to provide an improved
midsole construction which is capable of providing increased
comfort and shock absorption for the foot without using air
cavities and/or air bladders to achieve the same.
SUMMARY OF THE INVENTION
[0004] A shoe is generally composed of an upper connected to a
sole. The sole of a shoe is generally comprised of an outsole, a
midsole, an insole, and on occasion, a sock liner. The present
invention is directed to an improved midsole construction having
multiple layers of varying materials, each layer of material having
a different hardness/softness level.
[0005] In one aspect of the present invention, a midsole is
provided which includes a three-layered construction, namely, a top
layer, a middle layer and a bottom layer. The top layer provides a
layer of material between the insole of the shoe and the second or
middle layer of the midsole; the middle layer provides cushioning
to the foot; and the bottom layer provides additional cushioning
and a contacting surface for the outsole. In one embodiment, the
top layer is made of a polyurethane material with a hardness in the
range of 60-90.degree. Asker C hardness, the middle layer is made
of a thermoplastic rubber material with a hardness in the range of
20-65.degree. Asker C hardness, and the bottom layer is made of a
polyurethane material with a hardness in the range of 20-50.degree.
Asker C hardness. In one embodiment, the middle layer spans the
heel portion of the shoe only and includes an upper surface which
mates with and attaches to a portion of the bottom surface of the
top layer and a bottom surface which mates with and attaches to a
portion of the upper surface of the bottom layer. As a result, in
the forefront area of the shoe, the bottom surface of the top layer
mates with and attaches directly to the upper surface of the bottom
layer. The bottom layer provides a layer of material between the
outsole of the shoe and the second or middle layer of the midsole
in the heel portion of the shoe and a layer of material between the
outsole of the shoe and the top layer of the midsole in the
forefront portion of the shoe. The three layers of the midsole have
varying hardness/softness levels with the top layer being harder
than the middle and bottom layers and with the middle layer being
harder than the bottom layer. These layers can be attached to each
other by any suitable means such as cement adhesion and/or
stitching.
[0006] In another embodiment, the three layers of material forming
the midsole are re-arranged such that the top layer is harder than
the middle and bottom layers but the middle layer is softer than
the bottom layer. In one embodiment, the bottom layer has an upper
surface which mates with and attaches to only a portion of the
bottom of the middle midsole layer and the bottom surface thereof
mates with and attaches to a portion of the upper surface of the
outsole in the heel portion of the shoe. In this particular
embodiment, the middle layer of the midsole attaches directly to
the upper surface of the outsole in the forefront portion of the
shoe.
[0007] It is an object of the present invention to provide a
midsole which provides enhanced comfort and shock absorption by
utilizing multiple layers of varying materials which are likewise
of varying hardness/softness levels.
[0008] Specific advantages and features of the present midsole
construction will be apparent from the accompanying drawings and
the description of the several embodiments of the present
invention.
DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of one embodiment of a shoe
constructed in accordance with the teachings of the present
invention.
[0010] FIG. 2 is an exploded view of the shoe of FIG. 1 showing
construction of the midsole.
[0011] FIG. 3 is an exploded view of the embodiment of the midsole
shown in FIG. 2.
[0012] FIG. 4 is an exploded view of another embodiment of the
midsole of the shoe shown in FIG. 1.
[0013] FIG. 5 is an exploded view of the embodiment of the midsole
shown in FIG. 4.
[0014] FIG. 6 is a rear elevational view of the bottom layer of the
midsole embodiment shown in FIGS. 4 and 5.
[0015] It should be understood that the drawings are not
necessarily to scale and that the embodiments disclosed herein are
sometimes illustrated by fragmentary views. In certain instances,
details which are not necessary for an understanding of the present
invention or which render other details difficult to perceive may
have been omitted. It should also be understood that the invention
is not necessarily limited to the particular embodiments
illustrated herein. Like numbers utilized throughout the various
figures designate like or similar parts or structure.
DETAILED DESCRIPTION
[0016] A shoe generally includes an upper and a sole assembly that
is affixed to the upper. The sole assembly generally includes an
insole, a midsole, and an outsole, each having a peripheral shape
designed to conform to the shape of a wearer's foot. To facilitate
disclosure of the present invention, reference will be made to
various general areas of the foot, such as the heel, arch and
forefoot areas. When used to refer to locations on the various sole
components, these terms should be interpreted to include those
areas of the midsole and outsole that are disposed generally (and
not necessarily directly) beneath the corresponding elements of the
foot. It should be understood, however, that the boundaries between
the heel, arch and forefoot areas are not precise and that these
terms should be interpreted loosely and with a great deal of
flexibility.
[0017] Referring now to the drawings and, in particular, FIGS. 1-3,
a first embodiment of a new and improved shoe midsole construction
having multiple layers embodying the principles and concepts of the
present invention and generally designated by the reference numeral
20 in FIGS. 2 and 3 will be described.
[0018] A shoe 12 (FIG. 1) generally includes an upper 14 and a sole
assembly 16 that is affixed to the upper 14. Sole assembly 16
typically includes an insole 18, a midsole 20, and an outsole 22
and is attached to the upper 14 using a conventional method of
attachment such as an adhesive, stitching or injection molding. In
the embodiment illustrated in FIG. 1, the insole 18 is formed as
part of the upper 14. The midsole 20 includes three layers, a top
layer 24, a middle layer 26 and a bottom layer 28. The midsole 20,
as shown in FIGS. 2 and 3, has an upper surface 30 and a bottom
surface 32. The top layer 24 of the midsole 20 can be attached via
conventional means to either an insole such as insole 18, or to the
upper 14, while the bottom surface 32 of bottom layer 28 is
attached to the outsole 22 using a conventional method of
attachment.
[0019] Top layer 24 of the midsole 20 is positioned below the
insole 18 and above the middle layer 26 of the midsole 20. The
specific material of the top layer 24 may be chosen depending upon
the nature and type of shoe in which it will be used. Top layer 24
may be made from a variety of materials including, but not limited
to, molded Polyurethane (PU), Polyvinyl Chloride (PVC),
Thermoplastic Urethane (TPU), Thermoplastic Rubber (TPR),
vulcanized rubber, ethyl vinyl acetate (EVA), rubberlon, or any
other synthetic or natural material. The material forming the top
layer 24 has a hardness factor greater than the middle and bottom
layers 26 and 28 and is generally in the range of 60-90.degree.
Asker C hardness. The material and hardness/softness ranges
selected will be determined by the type of footwear onto which
midsole 20 is intended to be placed.
[0020] Lying underneath top layer 24 of the midsole 20 is a middle
layer 26 having an upper surface 36 and a bottom surface 40. In the
embodiment illustrated in FIGS. 2 and 3, the middle layer 26 only
extends across the heel portion of top layer 24 and bottom layer 28
and may be made from a variety of materials including, but not
limited to, TPR. The upper surface 36 of middle layer 26 is
attached to the bottom surface 34 of the top layer 24 at the heel
portion of the sole 16 using a conventional method of attachment,
such as adhesive, while the bottom surface 40 of the middle layer
26 is attached to the upper surface 38 of the bottom layer 28 in
the heel portion of the sole 16. In contrast, the bottom surface 34
of the top layer 24 is attached directly to the upper surface 38 of
bottom layer 28 in the arch and forefoot areas of the sole 16. The
middle layer 26 may further be secured to the top layer 24 by
utilizing male connection portions, projections or components 42
associated with the bottom surface 34 of the top layer 24 which
portions 42 mate with and engage corresponding female connection
portions, openings or components 44 associated with the middle
layer 26 as best shown in FIG. 3. Regardless of the type of
material used for the middle layer 26, the middle layer 26 is
softer than the top layer 24 and is generally of a hardness in the
range of 20-65.degree. Asker C hardness, and preferably in the
range of 40-60.degree. Asker C hardness.
[0021] The bottom layer 28 of the present midsole 20 is positioned
below the middle layer 26 in the heel area of the sole 16 and below
the top layer 24 in the arch and forefront areas of the sole 16 and
above the outsole 22. The specific material of the bottom layer 28
may again be chosen depending upon the nature and type of shoe in
which it will be used. The bottom layer 28 may be made from a
variety of materials including, but not limited to, molded
Polyurethane (PU), Polyvinyl Chloride (PVC), Thermoplastic Urethane
(TPU), Thermoplastic Rubber (TPR), vulcanized rubber, EVA,
rubberlon, or any other synthetic or natural material. The material
forming the bottom layer 28 has a hardness factor which is softer
than both the top layer 24 and the middle layer 26 and is generally
in the range of a 20-50.degree. Asker C hardness, and preferably in
the range of 20-40.degree. Asker C hardness. The material and
hardness/softness ranges selected will again be determined by the
type of footwear onto which midsole 20 is intended to be placed.
The upper surface 38 of the bottom layer 28 of the midsole 20 is
attached to the bottom surface 40 of the middle layer 26 of the
midsole 20 in the heel portion of the sole 16 using a conventional
method of attachment, while the upper surface 38 of the bottom
layer 28 of the midsole 20 in the arch and forefront areas of the
shoe 16 is attached directly to the bottom surface 34 of the top
layer 24 of the midsole likewise using conventional means.
[0022] In the particular embodiment illustrated in FIGS. 2 and 3,
the middle layer 26 of midsole 20 is utilized to provide additional
comfort to the wearer of the shoe 12 in that the middle layer 26
acts as a cushioning means to further cushion the heel of the
wearer as the heel portion of the shoe 12 strikes the ground during
a normal gait. In some embodiments, the middle layer 26 may be
comprised of a gel type material which provides increased shock
absorption and energy return whereas the top and bottom layers 24
and 28 of the midsole 20 can be made of a dual density lightweight
material which likewise provide support and shock absorption. It is
also recognized and anticipated that in some embodiments, the
middle layer 26 of the midsole 20 may extend beyond the heel
portion of the sole 16 to include the arch area and/or forefoot
area of the sole 16 as well, or portions thereof. Regardless of the
types of materials used for each of the three separate layers 24,
26 and 28 associated with the present midsole construction 20,
improved comfort and cushioning is achieved in this particular
midsole construction due to the fact that the top layer 24 of the
midsole 20 is harder than the middle layer 26 of the midsole 20,
which, in turn, is harder than the bottom layer 28 of the midsole
20. Stated another way, the bottom layer 28 is softer than the
middle layer 26 which, in turn, is softer than the top layer 24 of
the midsole construction 20. This arrangement of layers and
hardness factors provides for improved comfort and cushioning to
the wearer of the shoe 12.
[0023] In another embodiment, referring now to the drawings and, in
particular, FIGS. 4-6, a second embodiment of a new and improved
shoe midsole construction having multiple layers embodying the
principles and concepts of the present invention and generally
designated by the reference numeral 46 in FIGS. 4 and 5 will be
described.
[0024] In the embodiment illustrated in FIG. 4, the insole 18 is
again formed as part of the upper 14. The midsole 46 includes three
layers, a top layer 48, a middle layer 50 and a bottom layer 52.
The midsole 46, as shown in FIGS. 4-6, has an upper surface 54 and
a bottom surface 56. The top layer 48 of the midsole 46 can be
attached via conventional means to either an insole such as insole
18, or to the upper 14, while the bottom surface 56 of bottom layer
52 is attached to the outsole 22 using a conventional method of
attachment.
[0025] Top layer 48 of the midsole 46 is positioned below the
insole 18 and above the middle layer 50 of the midsole 46. The
specific material of the top layer 48 may be chosen depending upon
the nature and type of shoe in which it will be used. Top layer 48
may be made from a variety of materials including, but not limited
to, molded Polyurethane (PU), Polyvinyl Chloride (PVC),
Thermoplastic Urethane (TPU), Thermoplastic Rubber (TPR),
vulcanized rubber, EVA, rubberlon, or any other synthetic or
natural material. The material forming the top layer 48 has a
hardness factor greater than the middle and bottom layers 50 and 52
and is generally in the range of 60-90.degree. Asker C hardness.
The material and hardness/softness ranges selected will be
determined by the type of footwear onto which midsole 46 is
intended to be placed.
[0026] Lying underneath top layer 48 of the midsole 46 is a middle
layer 50 having an upper surface 58 and a bottom surface 60. Middle
layer 50 of the midsole 46 is positioned below the top layer 48 and
above the bottom layer 52 of the midsole 46. The specific material
of the middle layer 50 may be chosen depending upon the nature and
type of shoe in which it will be used. Middle layer 50 may be made
from a variety of materials including, but not limited to, molded
Polyurethane (PU), Polyvinyl Chloride (PVC), Thermoplastic Urethane
(TPU), Thermoplastic Rubber (TPR), vulcanized rubber, EVA,
rubberlon, or any other synthetic or natural material. The material
forming the middle layer 50 has a hardness factor lesser than the
top and bottom layers 48 and 52 and is generally in the range of
20-50.degree. Asker C hardness, and preferably in the range of
20-40.degree. Asker C hardness. The material and hardness/softness
ranges selected will be determined by the type of footwear onto
which midsole 46 is intended to be placed.
[0027] In the embodiment illustrated in FIGS. 4 and 5, the middle
layer 50 extends across the entire length of the top layer 48. The
upper surface 58 of middle layer 50 is attached to the bottom
surface 62 of the top layer 48 using a conventional method of
attachment, such as adhesive, while the bottom surface 60 of the
middle layer 50 is attached to the upper surface 64 of the bottom
layer 52 in the heel portion of the sole 16 and to the upper
surface 66 of the outsole 22 in its remaining portion, namely, in
the arch and forefoot areas.
[0028] The bottom layer 52 of the present midsole 46 is positioned
below the middle layer 50 and above the outsole 22 and may be made
from a variety of materials including, but not limited to, TPR. The
upper surface 64 of bottom layer 52 is attached to the bottom
surface 60 of the middle layer 50 at the heel portion of the sole
16 using a conventional method of attachment, such as adhesive,
while the bottom surface 56 of the bottom layer 52 is attached to
the upper surface 66 of the outsole 22 in the heel portion of the
sole 16. In contrast, the bottom surface 60 of the middle layer 50
is attached directly to the upper surface 66 of the outsole 22 in
the arch and forefoot areas of the sole 16. The bottom layer 52 may
further be secured to the middle layer 50 by utilizing male
connection portions, projections, flanges or components 68
associated with the top surface 64 of the bottom layer 52 as best
shown in FIG. 6, which portions 68 mate with and engage
corresponding female connection portions, cut-outs, cavities,
notches or components 70 associated with the middle layer 50 as
best shown in FIGS. 4 and 5. The flanges 68 mate with and engage
the cut-outs 70 when the bottom layer 52 is attached to the middle
layer 58. Regardless of the type of material used for the bottom
layer 52, the bottom layer 52 is softer than the top layer 48 and
is generally of a hardness in the range of 20-65.degree. Asker C
hardness, and preferably in the range of 40-60.degree. Asker C
hardness.
[0029] In the particular embodiment illustrated in FIGS. 4, 5 and
6, the bottom layer 52 of midsole 46 is utilized to provide
additional shock absorption to the wearer of the shoe 12 in that
the bottom layer 52 acts as a shock absorption means to further
absorb shock to the heel of the wearer as the heel portion of the
shoe 12 strikes the ground during a normal gait. It is also
recognized and anticipated that in some embodiments, the bottom
layer 52 of the midsole 46 may extend beyond the heel portion of
the sole 16 to include the arch area and/or forefoot area of the
sole 16 as well, or portions thereof. Regardless of the types of
materials used for each of the three separate layers 48, 50 and 52
associated with the present midsole construction 46, improved shock
absorption is achieved in this particular midsole construction due
to the fact that the top layer 48 of the midsole 46 is harder than
the middle layer 50 and bottom layer 52 of the midsole 46 and the
bottom layer 52 is harder than the middle layer 50 of the midsole
56. Stated another way, the bottom layer 52 is softer than the top
layer 48, but is harder than the middle layer 50 of the midsole
construction 46. This arrangement of layers and hardness factors
provides for improved shock absorption to the wearer of the shoe
12.
[0030] Thus, there have been shown and described two embodiments of
a novel invention. As is evident from the foregoing description,
certain aspects of the present invention are not limited by the
particular details of the examples illustrated herein, and it is
therefore contemplated that other modifications and applications,
or equivalents thereof, will occur to those skilled in the art. The
terms "having" and "including" and similar terms as used in the
foregoing specification are used in the sense of "optional" or "may
include" and not as "required". Many changes, modifications,
variations and other uses and applications of the present invention
will, however, become apparent to those skilled in the art after
considering this specification and the accompanying drawings. All
such changes, modifications, variations and other uses and
applications which do not depart from the spirit and scope of the
invention are deemed to be covered by the invention which is
limited only by the claims which follow.
* * * * *