U.S. patent application number 12/281324 was filed with the patent office on 2012-04-12 for universal sole.
Invention is credited to Philippe Biesse.
Application Number | 20120084998 12/281324 |
Document ID | / |
Family ID | 37025136 |
Filed Date | 2012-04-12 |
United States Patent
Application |
20120084998 |
Kind Code |
A1 |
Biesse; Philippe |
April 12, 2012 |
Universal Sole
Abstract
Universal sole designed to help a user adapt his walking or
running gait to the surface over which he is moving or to the
peculiarities of his individual leg/foot System by individually
adjusting the hardness and thickness of several areas of the sole.
Each area consists of one or more layers of a flat coil of elastic
extensible airtight and optionally reinforced rubber tube which may
be flattened or inflated beyond its nominal diameter as a function
of the pressure introduced by the action, as the user walks, of a
small pump located inside the sole underneath the user's heel and
adjustments and isolations performed manually with a System of
valves built into the thickness of the sole. The coils, the valve
System and the pumping System are either located and bonded between
layers of foam containing the impression of the coils and filling
the spaces between laces or placed in a mould or in a sole in the
shape of a boat, a filling material then being introduced to fill
the empty spaces. The resulting soles or sole elements can be used
on ail kinds of shoes.
Inventors: |
Biesse; Philippe;
(Bellegarde, FR) |
Family ID: |
37025136 |
Appl. No.: |
12/281324 |
Filed: |
February 28, 2007 |
PCT Filed: |
February 28, 2007 |
PCT NO: |
PCT/FR2007/000359 |
371 Date: |
July 12, 2010 |
Current U.S.
Class: |
36/29 |
Current CPC
Class: |
A43B 13/203 20130101;
A43B 13/206 20130101 |
Class at
Publication: |
36/29 |
International
Class: |
A43B 13/20 20060101
A43B013/20 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 3, 2006 |
FR |
0602046 |
Claims
1. universal sole for shoes designed to help a wearer adapt his
walking or his running to the type of ground encountered or to the
particularities of his leg/foot system characterized in that the
sole is made of flat serpentine coils (3, 3.1, 3.2, 3.3, 3.4) made
of elastic tubes, extendable and air-tight and each one limiting a
zone defined by its location in front or back, and right or left
sides of the foot, each coil with a plugged extremity, being filled
independently with its quantity and pressure of air by transfers
from the outside toward the coil, from the coil toward the outside
and from one coil to another, according to multiple combinations
controlled by a valves system (5, 5.2a-d, 5.21, 5.22), connection
pipes (3.6 and 3.7), a manifold (5.1), a vent (5.2e) and a pumping
system (4), the whole system being controlled manually.
2. universal sole for shoes according to claim no 1 characterized
in that each zone can include several layers (3.1a, 3.1b, 3.2a,
3.2b) of the same continuous flat coil.
3. universal sole for shoes according to one of the previous claims
characterized in that the elastic tube of the coils (3.1 a) is made
of a rubber compound and is reinforced with extendable elastic
fibers (3.11) stiffer than the main pipe material and in the form
of a diamond mesh elongated in the tube direction.
4. universal sole for shoes according to one of the previous claims
characterized in that the coils tubes (3) are filled with foam.
5. universal sole for shoes according to one of the previous claims
characterized in that the parallel loops of the coil tubes are
maintained by bandages with the help of a large mesh canvas (2.6)
and that a large mesh canvas (2.6) is deployed between each layer
of the coils.
6. universal sole for shoes according to one of the previous claims
characterized in that the pumping system is made of a connecting
nozzle linked to the manifold via a valve fitted in the thickness
of the sole, this nozzle being temporarily connected to the
flexible hose of an outside air pump for the pumping operation.
7. universal sole for shoes according to one of the previous claims
no 1 to 5 characterized in that the pumping system is made of a
mini-pump (4) integrated into the sole and equipped with a
non-return valve (8.2) and a safety valve (8.3) on its discharge
toward the manifold, and on the suction side, a connection to the
air filter (7) via an isolation valve (5.2f or 5.23) and a
non-return valve (8.1), the outside contact surface area (4.1) of
the pump being bigger than the section of the compression chamber
(4.3) and being maintained at the level of the lower surface of the
sole due to its location and its support under the lower surface of
the tubes of the lower layer of the coils in the heel zone.
8. universal sole for shoes according to claim no 7 characterized
in that the pumping system is equipped with a safety valve at its
discharge (8.3).
9. universal sole for shoes according to claim no 7 characterized
in that the pumping system is equipped with a plunger pump whose
suction spring system (4.2) maintains the pump in its compressed
position when the suction valve is dosed.
10. universal sole for shoes according to one of the previous
claims characterized in that the transfer system includes a set of
two positions valves (5.2a-f), open and closed, controlled with
knobs (5.3a-f) located on the side in the sole's thickness, these
organs being maneuvered by the wearer to set the required
configuration, each valve isolating or connecting on the one hand,
and independently, the different zones of the sole (3.1, 3.2, 3.3,
3.4) with the manifold (5.1), and on the other hand, the manifold
(5.1) with the vent through the vent valve (5.2e), or isolating or
opening the pumping system (4) suction valve (5.2f)
11. universal sole for shoes according to one of the previous
claims no 1 to 9 characterized in that the transfer system (5)
includes the set of several four positions valves (5.21, 5.22,
5.23) with multiple ways controlled by knobs (5.211, 5.221, 5.231)
located on the side in the thickness of the shoe's sole, these
knobs being rotated by the wearer to set the required
configuration, the first valve (5.23) isolating or connecting the
manifold (5.1), the vent, the suction and the pump discharge (4),
the other valves (5.21 and 5.22) isolating or connecting
independently groups of the sole zones (3.1, 3.2 and 3.3, 3.4),
each valve being composed of an inside rotating cylinder (5.23 for
valve 5.23) bored with radial coplanar holes (5.234 and 5.235) at a
90.degree. angle and having their intersection on the axis of the
inside cylinder, the corresponding block of valve (5.1a and 5.2b)
being bored in the same plane by four holes distributed at
90.degree. angles, the first valve (5.23) having their bores (5.234
and 5.235) and block holes placed in two separate parallel
planes.
12. universal sole for shoes according to one of the previous
claims characterized in that the manifold is equipped with a
pressure gauge (not represented).
13. universal sole for shoes according to one of the previous
claims characterized in that the standard number of zones (3) for
each sole is between 1 and 8.
14. universal sole for shoes according to one of the previous
claims characterized in that the most standard number of zones for
each sole is four, right front (3.4 for left shoe), left front
(3.3), right heel (3.2), left heel (3.1).
15. universal sole for shoes according to one of the previous
claims characterized in that the elements of the coils (3), valves
block (5), pumping system (4), are inserted between foam layers (2,
2.1, 2.2, 2.3), ridged and pre-imprinted with the coil path, the
foam layers are pre-glued, the set forming after assembly a
pre-manufactured element of a shoe sole.
16. universal sole for shoes according to one of the previous
claims no 1 to 14 characterized in that the elements, coils (3),
valves block (5), pumping system (4), bandages and possible canvas
(2.6) are put in a mould and empty spaces are filled by a poured
material that will get desired characteristics after maturation,
the whole set forming a pre-manufactured element of a shoe
sole.
17. universal sole for shoes according to one of the previous
claims no 1 to 14 characterized in that the elements, coils (3),
block of valves (5), pumping system (4), bandages and possible
canvas (2.6) are put in a outsole with upward curved edges (6), the
empty spaces being filled by a poured filler that will get desired
characteristics after maturing, the whole set forming a
pre-manufactured completed sole.
Description
TECHNICAL FIELD
[0001] This invention relates to soles for shoes and concerns a
device designed to help the walker adapt his/her walking or running
to the type of ground encountered or to the particularities of
his/her leg/feet system. The ground's characteristics refer to its
hardness, its forward or descending, right or left incline. The
leg/feet system characteristics refer to leg shape such as bow
legs, a stance to correct, or joint or muscle pain to alleviate or
stimulate.
[0002] The invention also applies to the method of manufacturing
elements of the sole.
BACKGROUND ART
[0003] This kind of situation is usually dealt with by having
different pairs of shoes with soles of various degrees of
stiffness/thickness and even orthopedic soles in extreme cases.
[0004] The major drawback of existing solutions is the need for a
different pair of shoes to deal with each situation and that can't
adjust to the various kinds of ground and circumstances encountered
during an outing.
[0005] Although it is easy to find corrective shoes resembling
regular town shoes, it is not easy to find readymade and affordable
corrective shoes for sports. Moreover, in the long run, the wear
and tear of the sole modifies the corrective effect, and the
existing solutions only cover a small part of the invention's
possible applications.
[0006] Especially concerning sports, manufacturers offer models
adapted specifically to each athletic discipline or type of ground,
with the shoes being designed for optimal performance and not
adapted to the specificity of the individual using them. They have
also recently developed adaptable and even motorized shoes equipped
with sensors, microprocessors, actuators, electric batteries,
communication interfaces. These models address a particular market
and call on advanced technologies which are relatively expensive.
Moreover, their application is sports-orientated and focuses on the
comfort and shock absorption of the shoe. They are based either on
a mechanical element as in patent ep 1582 108, or on air-sealed
pneumatic elements as in U.S. Pat. No. 6,430,843, or on elements
that are inflated at atmospheric pressure while the sole is no
longer in contact with the ground as in U.S. Pat. No. 5,813,142,
and from which the air can escape through a controlled opening of
vents when the foot comes in contact with the ground.
[0007] Other non motorized models allow the adjustment of comfort
and height of the soles via a mechanical system of inserts that are
intrinsically adjustable or interchangeable such as in patent
ep1530913 or even the comfort and the hardness of the heel area in
patent wo 90.00866.
[0008] Other patents use the pneumatic system of a sole made out of
pre inflated pockets that are in most cases made by soldering or
gluing 2 sheets of elastomer, according to patterns defining the
contours of these pockets, or by soldering or gluing the 2
complementary half-shells, the pockets being interconnected or
isolated. U.S. Pat. No. 900,867 or U.S. Pat. No. 4,129,951 are two
examples of such constructions. U.S. Pat. No. 5,406,719 shows a
configuration with 4 chambers which can be isolated or connected
and, owing to the presence of reservoirs, the user can adjust by a
few percent the pressure of the chambers whose range of pressure is
set during the manufacture, by manipulating the vents and the
stroke of the piston reservoirs. The sole is made of two sheets of
elastomer soldered following the contour of the zones.
[0009] A configuration which uses a pump activated by the contact
of the foot on the floor is described in U.S. Pat. No. 6,785,985.
The pump, which is a bladder with a non return valve, has an effect
on the inflation of the shoe, including its sole, in order to wrap
the foot tightly with a comfortable pressure; the pressure is
limited to a relatively weak value by controlling a vent.
[0010] Finally, U.S. Pat. No. 5,179,792 describes a system where
the sole's pockets which, owing to a check valve, are filled with
atmospheric pressure each time contact with the ground is lost, are
in turn pseudo-randomly maintained at pressure and allowed to
deflate by a rotating mechanical valving system activated each time
a push button comes in contact with the ground. The objective of
this invention is to make the shoes comfortable for the wearer and
to stimulate blood circulation through exercise.
[0011] In the preceding inventions, there are problems linked to
production costs, to changes in the characteristics of the sole
over time, to the need to keep replacement inserts in stock for the
mechanical systems, to bursting or rupturing in the soldering, to a
lack of stability in the horizontal plane, sideways front-to-back
or diagonally, due to the lack of stiffness of the air pockets as
well as the bloating of the pockets' central zones and the twisting
of the wearer's ankles.
[0012] This risk is mainly due to the fact that a large air pocket
tends to collapse under the pressure exerted by the corner of the
heel while the remaining wider surface of the pocket tends to raise
the rest of the foot, thus aggravating a position which is
initially inclined. in order to remedy these drawbacks, a number of
modifications are required.
DISCLOSURE OF THE INVENTION
[0013] The device stated in this invention provides solutions to
the above stated drawbacks, it consists of inserting a universal
sole under the shoe be it a regular town, orthopedic, athletic or
hiking shoe and helps the wearer adapt his/her walking or running
to the type of ground encountered or to the particularities of
his/her leg/feet system.
[0014] It consists of, generally and for each shoe, a sole made of
flat serpentine coils made of tubes or elastic pipes, extendable
and air tight, and each one limiting a tight zone or pocket,
defined by its location in front or back and left or right sides of
the foot each coil with a plugged extremity, being filled
independently with its quantity and pressure of air, by transfers
from the outside toward the coil, from the coil toward the outside,
and from one coil to another, according to multiple combinations
controlled by a valve system, connecting pipes, a manifold, a vent
and a pumping system with possible protection from over-pressure,
the whole system being controlled manually. For example, there
could be 4 such zones: at the front right and left front of the
sole, the right back and the left back near the heel. These
transfers are useful because they adjust the height and the global
sturdiness of the sole to ensure its comfort, its bounce or shock
absorption according to the activity of the wearer, to compensate a
difference in the length of the individual's legs; and because they
adjust the height of each zone in relation to the others, in a
right and left axis to walk on the shoulder of a road, to alleviate
and stimulate the knee joints, to rehabilitate or correct bone
deformations, or in a front and back axis to let rest or activate
frontal or back muscles when climbing or descending. It can also
boost athletic performance by reacting to different sorts of
impulsions.
[0015] These controls and adjustments will be implemented according
to problems encountered by the wearer and the abilities of the
system operator who is the wearer him/herself, a coach or a doctor.
Moreover, these adjustments will made seldom in the case of
orthopedic corrections or frequently, up to many times per hour,
for an athlete covering different types of ground or different
activities. The durability of these adjustments is made possible by
the effective air tightness of the coils and of the valve systems.
In particular, a simple configuration of the pumping system
consists of a connecting nozzle linked to the manifold via a valve
fitted in the thickness of the sole, this nozzle being temporanly
connected to the flexible pipe of an outside air pump for the
pumping operation. This pump is therefore independent of the sole
and for example can be a manual piston pump of an electrical
compressor or any other compressed air production unit A mini pump
model can be manufactured and sold with the shoes without too much
extra cost; the pump can even be fitted with a pressure gauge when
used by an orthopedist or other professionals taking care of
multiple users.
[0016] The pumping system can also consist of a mini pump for
example a piston pump in the shape of a capsule, integrated into
the sole and equipped with a non-return valve, and optionally with
a safety valve, on its discharge toward the manifold and on the
suction side, a connection to the air filter which is generally
located in a safe part of the shoe, via an isolation valve and a
non-return valve.
[0017] The outside contact surface area of the pump is bigger than
the section of the compression chamber in order to deliver to the
coils of any zone an air pressure which is greater than that due to
the weight of the wearer on the whole contact surface with the
ground. On the other hand, in order to always remain in contact
with the ground, even when the surrounding sole is at its maximal
thickness, the outside contact surface area of the pump is
maintained at the level of the lower surface of the sole due to its
location and its support under the lower surface of the pipes of
the lower layer of the coils in the heel zone, allowing it to
follow an increase in the sole's thickness. The pumping action is
made for example during a normal walk of the wearer, the pump being
actuated by part of the wearers weight at every contact with the
ground. When the pumping action concludes and thanks to the suction
spring system, the pump maintains its compressed position when the
suction valve is closed.
[0018] One simple configuration of the transfer system includes a
set of two positions valves, open and closed, controlled with knobs
located on the side in the sole's thickness. Each valve corresponds
respectively to a zone, to the vent, to the pump's suction. The
organs are screws or rotating knobs being maneuvered by the wearer
to set the required configuration, each valve isolating or
connecting on the one hand, and independently, the different zones
of the sole with the manifold, and on the other hand, the manifold
with the vent through the vent valve, or isolating or opening the
pumping system suction valve.
[0019] For a sole including 4 zones, the right heel, left heel,
front right, and front left, there will be 6 valves, 4 of which
will be corresponding to these zones.
[0020] For example, to change from the state of a flat and thin
sole to the state of a thick sole raised on the outside side and on
the heel, one checks that the vent is closed, opens the suction
valve of the pump, and the valves of the 4 zones. It is then
necessary to walk a few meters in the case of the integrated pump
or to pump a little bit in the case of an outside pump. When the
sole is slightly thicker, one closes the valves of the inside
zones, and again walks a few meters or pumps a little bit Then one
closes the outside front valve, takes more steps or pumps rightly
and closes the outside heel zone valve. One will then close the
pump suction valve in order to prevent it from working during
walking and to ensure that it keeps its minimal thickness thanks to
the suction created in the pump. During pumping, the safety valve
limits the pressure in each of the organs to a safe value well
under the structural limits. This margin allows for over-pressure
due to shocks created when the shoe hits the ground.
[0021] For adjustments with small differences in thickness between
zones, one can simply implement the desired shape by inclining the
foot, opening the valves of the zones to allow air transfers and
then closing the valves.
[0022] Another configuration that allows for the same type of
adjustments consists of a transfer system with several 4-position
valves and several openings controlled from control organs located
on the side in the sole's thickness, these organs being maneuvered
by the wearer through rotation to set the required configuration,
the e valve isolating or connecting the manifold, the vent, the
suction, and the discharge of the pump, the other valves isolating
or connecting independently groups of zones. Each valve is composed
of a rotating inside cylinder pierced with 2 radial coplanar bores
forming a 90 degree angle and ending at the point of intersection
on the inside cylinder axis, the valves block having been pierced
with 4 holes at 90 degree angles in the same plane as the bores,
the 1.sup.st valve having bores and block holes placed in 2
different parallel planes.
[0023] There are therefore 3 valves for a 4 zone configuration. The
order of the holes in the block of the first valve being
manifold-vent-pump suction-pump discharge, manifold-manifold--left
front-right front, for the valve corresponding to the zones at the
front of the sole, and manifold-manifold-back left-back right, for
the valve corresponding to the zones at the back of the sole.
[0024] Whatever the chosen configuration, it is possible to verify
the pressure by probes located in all points of the circuit,
nevertheless, using a single probe at the common manifold is the
most economic way to verify the pressure at all these points. A
probe can be fitted permanently, for example a dial-pressure gauge
or a piezo-etectric gauge with electrical sockets available for
measurements on the outside of the sole.
[0025] There are many categories of coils, generally tube-like
structures of extendable air-tight elastic material from the rubber
family. Rubber meaning here: natural or synthetic, elastomers,
thermoplastics, neoprene, butyl, polyurethane, silicone, fluoro
elastomer, or any mixture of this type whether opaque or
transparent. The coils can also be reinforced with elastic and
extendable fibers that are stiffer than the main material, as for
example but not limited to fibers made of nylon, polyester, lycra
and other combinations of materials.
[0026] The main axis of the various reinforcements being the
longitudinal axis, as for example mesh in the shape of an elongated
diamond in the direction of the tube's axis.
[0027] This allows for an easy increase in diameter and stiffens
the tube in its long axis. In any case, the tube's lengthwise
stiffness is used, whether or not there is air pressure in the
coils, to stabilize the sole against lateral movements which are
thus controlled mainly by the portions of the coil whose axes are,
parallel to these movements.
[0028] The path of the coils provides in all possible directions a
minimum quantity of these portions. This is why one avoids a
mono-directional layout, and why the combination of squiggly-shaped
paths and coil-forming tubes with lengthwise stiffness gives
superior lateral stability in comparison to other types of
pneumatic soles.
[0029] It must be noted that if the lateral forces of shear and
flexion of the sole increase with its thickness, the effect of the
lateral stiffness due to the tube, increases along with the
increase in pressure, thus ensuring good results in all cases. The
pressure in the tubes varies between a vacuum of a few 10.sup.ths
of a bar and a pressure of a few bars until around 6 bars for the
reinforced tubes. The bursting pressure in this case being 10 bars
minimum.
[0030] The tubes can work in a vacuum area. They are in fact
assembled without air inside, flat inside the layer of foam located
between the shoe and the outsole, and without air pressure the foam
or the filling material keeps their shape flat.
[0031] The thickness is then minimum and equal to the thickness of
the outsole plus the thickness of the foam above and below the
coils plus twice the nominal thickness of the tube walls for a
configuration with one layer of coils.
[0032] Through inflation, the tubes will pass progressively from a
flat cross-section to a circular cross-section, the foam or filling
material ensuring a relatively weak resistance to an increase in
thickness, rendering this transition interval soft enough with big
changes in thickness for small increases in pressure. Then, when
the cross-section of the tube is circular, the tube walls with or
without reinforcements provide the main resistance to the increase
in diameter, giving the sole great stability, with small increases
in thickness of the sole for big increases in pressure.
[0033] This allows for a thickness of the sole that depends on the
inflation pressure and that is not significantly influenced by the
load. When the reinforced coil tube is inflated at the pressure
corresponding to its optimal dimensions when the long axis of the
diamond shape of the reinforcement changes from the axial to the
radial direction, resisting better to an increase of the diameter,
the thickness of the sole reaches its threshold and becomes very
stable no matter what the load.
[0034] A way to stabilize the thickness of the sole starting from a
slight pressure is to fill the tubes with a rubber or foam insert
With no air or under low pressure, the sole acts as multiple layers
of rubber and foam material. An increase in pressure increases the
thickness; however with this configuration one cannot exploit the
maximum range of thicknesses.
[0035] In any case, the use of a vent equipped with a no return
valve allows one to completely empty the tube so that it's possible
to exploit the functional zone for minimal thickness while keeping
it steady. When there is no insert in the tube, it is flattened and
acts as a rubber insert whose thickness is equal to twice the
thickness of its walls.
[0036] Some spaces are left within the path of coils. These spaces
are filled with foam sheets, cut out to envelop the coils and glued
and piled together, or with liquid filling material such as rubber
or foam, poured during the final phases of sole manufacturing. In
this document, the generic term "pouring" groups together all the
techniques using a material or a mix of materials being fluid at
the moment of manufacture which allows it to penetrate in the empty
spaces between coils or across wide mesh, whether the product is
liquid, viscous, gaseous, granular or locally viscous.
[0037] This fluidity can be due to temperature as for injection,
vulcanization, warm pressing techniques or equivalents, or due to
the nature of materials before maturation by polymerization,
hardening, drying, hardening, or any other physical or chemical
process that would give the materials the required properties after
manufacturing. This not only results in a compact and light sole
but also allows one to control its lateral expansion.
[0038] Indeed, for a configuration with a single layer of tubes,
there will be a natural tendency for the sole to increase its width
more than its height in the proportion equal to the number of loops
of the coil. The foam in the interstitial space is pulled during
the vertical expansion of tube. It will lengthen and thin out
between two tubes while exerting a lateral compression on them and
give them a slightly oval shape. Each zone can contain more than
one superimposed layers of the same coil; the use of a
configuration with several layers also Mows to limit the tendency
to lateral widening. Depending on the diameter of the tubes, it's
possible to use a configuration with two, three, or more
layers.
[0039] The choice of diameter, number of layers and possible
variations in diameter of the tubes for each zone of coils allows
for numerous combinations. The standard diameters are mainly
between 4 and 20 mm, the number of layers between 1 and 5.
Configurations with 2 mm micro-tubes and up to 10 layers mainly
concern strongly air tight materials.
[0040] It is also possible to limit the lateral expansion of the
sole by wrapping parallel coils by means of a large mesh canvas.
Moreover, another such canvas is laid between coil layers in order
to increase the lateral stiffness and to prevent the sole from
buckling under the effect the various constraints.
[0041] The objective of controlling the total lateral expansion is
to decrease the stress and the shearing constraints between the
different components of the sole, especially at the contact surface
with the shoe and at the contact surface with the outsole. On the
contrary, there are advantages to expanding the width near the
bottom of the sole if the outsole is expandable enough not to be
damaged or if its shape with upwards curved lateral extremities
help contain the expansion of the material.
[0042] Whatever layout is chosen, one must always ensure that a
rigid element remains on the outsides of the sole, so that the
supporting part of the sole is as wide as possible to laterally
support the foot
[0043] For the configuration with foam layers, one will choose foam
having good compression qualities and also good characteristics
against tearing and stretching. Indeed, this foam bears part of the
wearers weight, mainly between the zones of the tube's lower
generatrix and the outsole, or the tube's higher generatrix and the
shoe or between intermediate layers of foam.
[0044] It also helps transmit lateral forces and partially
compensates by its extension the forces produced by the tubes when
they tend to increase the thickness of the sole.
[0045] This compensation maintains an acceptable stiffness during
the use of the sole when there is little or no air pressure in the
flattened tubes. In order to help the foam transmit lateral forces
and compensate for tube extensions and to avoid the accumulation of
constraints in the glued zone between foam layers, on can use
lengthwise ridged foam layers with a good quantity of glue.
[0046] For the configurations where the filling between tubes is
done with poured material, this material will also possess good
compression, shearing, and stretching characteristics. For injected
or vulcanized material, the working temperature will always remain
below the maximum temperature of the material used for the coils,
their reinforcements, the valves blocks and the pump. The fluidity
during the filling phase will allow the pouring material to flow
between the tubes even of small diameter and between the canvas
mesh. In order to locally reduce the stiffness of the sole due to
the air pressure in the coils, it's possible to make extra loops at
the chosen place, as for example would be done under the arch of
the foot.
[0047] The interconnection of the tubes or their connection to the
valve system is made by inserting the tube ends into a hard metal
or plastic small nozzle with an outside circular groove and by
wrapping this assembly with a nylon flat ring. This layout allows
for a fast, economical and air tight assembly even when the
inflation pressure is high.
[0048] Special connecting nozzles allow the interconnection of
tubes of different diameters.
[0049] The number of sole zones varies normally between 1 and 8, 4
being the most standard configuration. The number of valves,
depending on the chosen valve system, will thus correspond to this
number of zones, the other characteristics remaining applicable to
all other configurations.
[0050] The explanations given for different characteristics of the
invention in this chapter or in any other chapter of this document,
including the drawings and their keys, aren't limiting and are
sufficient for somebody who has knowledge of the art to realize the
invention or to develop variations or extensions that would result
from the invention and be recognized as part of it. These
characteristics and configurations are not exclusive and on the
contrary can be complementary and can combine to form families of
variations. Dimensions, when they are mentioned, give a general
range and are not limiting.
BRIEF DESCRIPTION OF DRAWINGS
[0051] The drawings are not to scale, they give a range
corresponding to the average size of a foot (around 30 centimeters)
for general proportions, and they are sometimes magnified in
certain areas to show the details of smaller parts.
[0052] The item number for one part or for similar parts is kept
identical throughout the document A letter of the alphabet will be
added to this item number for variations or similar parts
fulfilling the same function.
[0053] The parts forming a given subassembly will be identified by
the same item number as the assembly followed by a point and a
number in the prescribed order.
[0054] FIG. 1: Exploded view of the different elements of a shoe.
The shoe (1) has a lower surface (1.1) on which a sole will be
assembled. The set of coils (3) is sandwiched between the upper
layer of foam (2.1) and the lower layer of foam (2.2) whose contact
faces are ridged and that have been imprinted with the coil's path
shape. The pump (4) and the valves block (5) are pre-assembled on
the coil (3). The outsole with upward curved sides (6) will host
the assembly which will be inserted and glued. The top of the
outsole's curved sides will be connected to the lower part of the
shoe by traditional means (glue, sewing . . . ). Some openings are
provided in the outsole for the pump and valve control buttons. A
very similar drawing would illustrate the case where the foam
layers (2.1 and 2.2) would be injected or vulcanized depending on
the fusion temperatures of the different materials; also the use of
a flat outsole would follow the same principal.
[0055] FIG. 2: Simplified view of a section at the heel describing
shoe models I and II, differentiated by the number and diameter of
the coil tubes, according to their different configurations:
[0056] A) sole with maximum thickness
[0057] B) sole with minimum thickness
[0058] C) sole with maximum incline
[0059] The example shows a type I sole with a tube of large
diameter on one layer, and type II with a medium sized diameter on
two layers.
[0060] FIG. 3: Simplified view of a section at the heel describing
shoe models of type I in configurations A (sole with maximum
thickness), B (sole with minimum thickness) and type D models (with
classic thick sole) and type E (with classic thin sole). The shoes
are shown in a position with vertical load in column III and with
inclined load in column IV. The oblique lines on the drawings in
column IV represent the maximum incline obtained (short line) in
relation to the better incline obtained with the type I shoe
configuration C (long line furthest to outside). The type D sole
provides the least stable result
[0061] FIG. 4: Simplified view of a section at the heel describing
shoe model type II with an average sized diameter on two layers of
coils with ridged foam layers glued. The upper drawing shows a
configuration with upper and lower tubes aligned, and the lower
drawing shows a configuration with offset upper and lower tubes.
The perfect alignment or offset of the coils in the transversal
planes is not possible given the sinuous path of the coils, but can
either be desired or not.
[0062] The lower foam layer (2.2) is glued to the outsole (6.1) its
upper imprint envelops the 1.sup.st layer of coils on the right
side (3.2a) and on the left side (3.1a) and the ridges will hold
the glue (2.5) which will fix it to the middle layer (2.3), itself
supporting the 2.sup.nd layer of coil on the right (3.2b) and on
the left (3.1b), its upper ridges holding the glue (2.4) that fixes
the middle layer (2.3) to the upper layer (2.1) which is directly
glued onto the lower part of the shoe (1.1), making for example a
lasting board. FIG. 5: General view of a coil assembly
[0063] The 4 zones are made up of a front right (3.4) and front
left (3.3) coil each having a loop (3.5) designed to reduce the
lengthwise stiffness of the sole, of the 1.sup.st and 2.sup.nd
layers of coil of the hears right zone (3.2a) and (3.2b), and of
the layers of coil of the heel's left zone (3.1a) and (3.1b).
[0064] A large mesh canvas (2.6) is located between the two layers
of coils at the back and above the layer of coils at the front The
valves block (5) is connected to the coil assembly.
[0065] FIG. 6: Cross section of a tube connection. The two parts of
the tubes (3.1) are locked onto a small rigid nozzle with an
outside circular groove (3.6) and then wrapped with a flexible and
non extendible flat ring (3.7), for example made of nylon.
[0066] FIG. 7: Cross section of a U-shaped connecting nozzle. The
two parts of the tube (3.1) are locked onto a small U-shaped rigid
nozzle with an outside circular groove (3.8) and then wrapped with
a flexible and non extendible flat ring (3.7), for example made of
nylon.
[0067] FIG. 8: main diagram of a universal sole assembly.
[0068] The 4 zones (3.1), (3.2), (3.3) and (3.4) are connected to
the manifold (5.1) of the valves block via their isolating valves
(5.2a), (5.2b), and (5.2c), (5.2d). The manifold (5.1) of the
valves block is connected to the filter (7) via the isolating valve
(5.2e). This filter (7) is also connected to the isolating valve of
the pump suction (5.2f), then to the suction non-return valve
(8.1), then to the pump (4), and to the discharge non-return valve
(8.2) that leads to the manifold (5.1). The pump discharge is also
connected to the safety valve (8.3).
[0069] FIG. 9: Cross section of the upper row of a simple valves
block according to FIG. 8.
[0070] Le valves block (5.1) contains tapped holes in which the
threaded parts of the valves (5.3a) to (5.3f) are screwed. The
needles of the valves (5.2a) to (5.2f) will tightly seal the
extremities of the tubes (5.6a) to (5.6f) which constitutes the
valves seats and on which the coil tubes will be connected. The
cylindrical parts of the valves, located between the threaded parts
and the needles, are smooth and go through O-rings (5.4 a) to
(5.4f) which are inserted in corresponding block grooves in order
to ensure tightness of the manifold towards the outside. The valves
(5.2a) to (5.2e) are housed in the same block cavity (5.1) which
constitutes the manifold. The manifold's air tightness doesn't need
to be as perfect as that of the valves given that the manifold is
subject to pressure only for small periods of time or is subject to
the pump pressure. Valve (5.2f) is housed individually in another
cavity which is connected to non-return valve (8.1).
[0071] FIGS. 10 and 11: Top and side cross sections of the lower
part of a valves block according to the diagram of FIG. 8.
[0072] Valves block (5.1) contains tapped holes in which the
threaded part of the valves (5.3a) to (5.3f) are screwed. These
threaded parts are extended by cylinders pushing plungers (5.2a) to
(5.2f) that will tightly seal the tubes (5.6a) to (5.6f) by
pinching, thus constituting the valve. The cylindrical parts of the
valves located between the threaded parts and the plungers are
smooth and go through O-rings (5.4a) to (5.4f) which are inserting
in corresponding block grooves in order to ensure tightness of the
manifold towards the outside. The extremities of the tubes (5.6a)
to (5.6e) are either connected to the same valves block cavity
(5.1) which constitutes the manifold, or are simply interconnected.
One extremity of tube (5.6f) is individually connected to the
non-return valve (8.1). The flexible blade (5.5a) holds together in
position several plungers without interfering with their
strokes.
[0073] FIG. 12: Main diagram of a universal sole assembly.
[0074] The 4 zones (3.1), (3.2), (3.3) and (3.5) are connected to
the manifold (5.1) of the block via their isolating valves (5.21)
and (5.22) each one with 4 positions. The 4-position valve (5.23)
connects, depending on its different positions and variations, the
block manifold (5.1) to the filter (7) or to the pump (4), the
filter (7) to the suction non-return valve (8.1) of pump (4) or the
discharge non-return valve (8.2) to the block manifold (5.1). The
pump discharge is also connected to the safety valve (8.3).
[0075] The holes drilled in the valves block (5.21) and (5.22) are
in the same plane as the elbowed openings drilled in the valves
rotating cylinders. The holes drilled in the valves block (5.23)
are located in different 2 parallel planes, each one coinciding
with a plane of the elbowed openings of the rotating cylinder of
the valve.
[0076] FIG. 13: schematic representation of connections realized by
valve (5.23).
[0077] 3 configurations (5.23a), (5.23b) and (5.23c) are shown
according to the 4 different positions: V for vent S1 for isolation
1, S2 for isolation 2, and P for pumping. The holes drilled in the
valves block are shown as straight segments on the outside of the
circle and the elbowed openings as circular arcs or straight
segments on the inside of the circle. The arcs and segments drawn
in a continuous line are located in the fore plane; those in
discontinued lines are located in the back plane. Venting through
the fitter is shown at the top of the circle, the pump suction to
the left, the pump discharge at the bottom, and the manifold to the
right.
[0078] Valve configuration (5.23a) connects the manifold to the
filter, the pump discharge to the filter and to its suction when in
V position; isolates the manifold and the filter and connects the
discharge and the suction of the pump when in position S1; isolates
the manifold and the suction of the pump, and connects the pump
discharge and the filter when in position S2; connects the pump
suction and the filter, and the pump discharge and the manifold
when in position P. This configuration allows to connect the
discharge of the pump to the vent in order to avoid the use of the
safety valve (8.3) during normal functioning in position S2.
[0079] Valve configuration (5.23a) connects the manifold to the
filter and isolates the pump discharge and the pump suction when in
position V; isolates the manifold, the filter, the pump discharge
and the pump suction when in position S1; isolates the filter, the
manifold, the pump suction, and the pump discharge when in position
s2; connects the pump suction and the filter, the pump discharge to
the manifold when in position P.
[0080] This variation permits putting to put the discharge of the
pump in the vent to avoid using the safety valve (8.3) when in a
normal functioning position.
[0081] Valve configuration (5.23b) connects the collection device
to the filter, isolates the outlet pump and its suction when in
position V; isolates the collection apparatus, the filter, isolates
the outlet pump an its suction when in position S2; connects the
suction pump with the filter, and the outlet pump with the
collection device when in position P.
[0082] Valve configuration (5.23c) connects the manifold to the
filter in the venting direction, isolates the filter, the pump
discharge and the pump suction when in position V; isolates the
manifold and the filter, the pump discharge and the pump suction,
when in position S1; isolates the filter, the manifold, the pump
discharge and the pump suction, when in position S2; connects the
pump suction and the filter, and the pump discharge to the manifold
when in position P. This configuration allows, due to the
non-return valve, to better drain the air from the coils to obtain
a thin sole.
[0083] FIGS. 14 and 15: Frontal and side cross sections of an
alternate valves block (5.21), (5.22) and (5.23). The side view is
a simplified representation according to section D-D, the view from
the front is a simplified view, where the part corresponding to
valve (5.21) is viewed in plane A-A, the part corresponding to
valve (5.22) is viewed in plane B-B, and the part corresponding to
valve (5.23) is viewed in plane C-C. Only the main dotted lines are
shown for easier understanding. Block (5.1) is made up of lower
part (5.1a) and upper parts (5.1b), assembled by gluing after
centering with the help of centering pins (5.10).
[0084] During manufacture, all the drillings and machining of the
semi-blocks are done before assembly, including the surfacing of
the supporting thrust of O-rings (5.41) and with the exception of
the finishing of the bores housing the rotating cylinders (5.21)
(,5.22) and (5.23) of the valves which is made lastly: The
cylindrical then conical part (5.236) at the end of the rotating
cylinders of the valves (5.21, 5.22, 5.23) allows the assembly in
the block already fitted with O-rings without them being released
from their supporting surface and favors the compression of these
O-rings for better tightness and slight friction on the rotating
cylinder. Here the manifold (5.1c) consists of a drilled hole in
connection with the 3 parts of the valves. It is sealed with the
plug (5.1d) after being drilled.
[0085] The pins (5.10) can be replaced or completed by pins (5.11)
which, lodged inside the groove (5.231) block the translation
movement of the valves. An O-ring (5.42) inserted in groove (5.233)
ensures the air-tightness towards the outside. The maneuvering knob
(5.232) of the rotating cylinders is equipped with a thumbwheel
that indicates the position. The elbowed openings in the rotating
cylinders (5.234) and (5.235) are located on the front or back
plane. The tubes are connected to inserted nozzles (5.6) at the
outlets of the orifices. Zone (5.1e) can be equipped with a
non-return valve for to execute valve configuration (5.23c) of FIG.
13.
[0086] FIGS. 16 and 17: Side cross section and exploded perspective
view of safety valves and non-return valves.
[0087] The ball of non-return valve (8d) is housed in a hole
drilled in the pump's (4) body, is stopped by the reduction in
diameter. Insert nozzle (8a), equipped with a cross-shaped piece
(8b) with a contact point (8c) is inserted and fixed in the hole of
larger diameter. The chosen flexibility of elements (8b) and 8c) as
well as their optional prestressing given during assembly, allows
the ball to function as a non-return or a safety valve.
[0088] FIG. 18: Side cross section of the pump (4).
[0089] The directions of the discharge non-return valve (8.2) and
discharge safety valve (8.3) and the nozzle (4.6) of the inlet of
the compression chamber are shown in the view to simplify the
drawing but in reality their axis is in the direction of the coil's
tubes.
[0090] The coils (3.1a) and (3.1b) are housed in the foam (2)
between the lasting board located under the shoe (1.1) and the
outsole (6). The latter is equipped with a hole which holds the
convex disk (4.1) between the pump and the ground. The pump body
(4.4) rests on the coil's tubes, thus moving as they inflate. The
pump plunger (4.3) slides in an air-tight manner in the chamber
thanks to an O-ring (4.5), the air goes through the suction nozzle
(4.6), then goes through the space between the pump body (4.4) and
spring washer (4.2) before entering the compression chamber via the
non-return suction valve (8.1). The spring washer (4.2) is elastic
and lifts the pump plunger during the suction phases; on the other
hand, the fact that the air goes through the space between (4.4)
and (4.2) allows, due to the large surface area which is then under
vacuum, to maintain the plunger at the bottom of the chamber to
maintain a minimum thickness of the pump when the air inlet side is
isolated during normal use of the shoe.
[0091] FIG. 19 : Variation of a membrane pump
[0092] Side cross section the pump (4). The directions of the
discharge non-return valve (8.2) and discharge safety valve (8.3)
and the nozzle (4.6) of the inlet of the compression chamber are
shown in the view to simplify the drawing.
[0093] The coils (3.1a) and (3.1b) are housed in the foam (2) under
the outsole (6). The pump body is split into two parts (4.4a) and
(4.4b). The pump plunger (4.3) slides in an air-tight manner in the
chamber thanks to a membrane (4.51); the convex disk (4.1) between
the pump and the ground, the inlet nozzle (4.6), the spring washer
(4.2), the suction non-return valve (8.1) can be of the same type
as in FIG. 18.
[0094] FIG. 20: Section of a coil's tube (3.1a) with a
diamond-shaped reinforcement mesh (3.11).
BEST MODES FOR CARRYING OUT INVENTION
[0095] The best standard method to carry out the invention consists
in manufacturing a sole assembly using a coil made of four zones,
front right, front left, right heel and left heel and made of a
nylon-reinforced rubber tube of diameter 8 mm and 2 mm wall
thickness. The diameter under maximum pressure is 14 mm. A single
layer of coil is used in the front zones two layers are used in the
heel zones. The valves block houses the six needle valves isolating
the four zones, the suction of a plunger-pump with a convex disk
located under the heel, the vent and its filter.
[0096] The spaces between the coil's tubes are filled by layers of
pre-cut foam, made of a type of vinyl acetate ethylene copolymer
(eva) for example, ridged and pre-imprinted with the coil path. One
thus has a lower foam layer whose upper face, ridged and imprinted
with the coil path, is pre-glued; a set composed of the coils,
valves block and pump is placed upon it, then an intermediary foam
plate whose lower face is ridged and imprinted with the coil's path
is placed on the front and back zones, so that the second layer of
coil will fit on it. Its upper face will be ridged and
pre-imprinted with the path of the second layer of coil in the heel
zones and will be smooth in the front zones. Finally, a layer of
foam whose lower face is ridged and pre-imprinted with the path of
the second layer of coil, will be put on the heel zone, this layer
will be of reduced length and its thickness will decrease from the
back of the heel up to the arch of the foot. Its upper face is
smooth and joins the upper face of the intermediate layer to form a
continuous surface. In order to house the valves block which is
around 30 mm long by 15 mm high and 20 mm deep under the arch of
the foot, a cut has already been made in the intermediate layer of
foam and an imprint has been left on the upper and lower layers.
The lower face of the lower layer and the outside part of the
convex contact disk of the pump are pre-glued and this assembly is
then laid and pressed onto the outsole. The product is ready to be
dispatched to a shoe manufacturer to be assembled, for example,
just under a lasting board. Height can vary around 20 mm for the
heel and 10 mm for the front of the shoe.
[0097] A more sophisticated way to carry out the invention is to
use tubes of diameter 6 mm with wall thickness 1.5 mm giving a
maximum diameter of 10 mm; with a single layer on the two front
zones, and three layers of this same type of tube on the two back
zones at the heel. The valves block consists of 3 multi-position
valves. One valve controls the connections between the manifold and
the right and left front zones, another valve controls the
connections between the manifold and the right and left back zones,
the third controls the connections between the manifold, vent, pump
suction and pump discharge. The valves are operated by the rotation
of their corresponding knobs on the front of the valves block. The
outlet of the manifold toward the vent is realized via a non-return
valve, the manifold is equipped with an electrical pressure gauge
with a socket accessible on the outside to use an independent
instrument The pump is a plunger pump with a convex contact disk on
the outside. This system is assembled in an upward curved outsole
whose edges extend to the height where the shoe will be attached,
and a filling material such as rubbery foam is poured almost up to
the top of the curved edges to fill the spaces between the tubes.
The sole is ready to be dispatched to a shoe manufacturer to be
assembled under a shoe. Height can vary around 20 mm for the heel
and 7 mm for the front of the shoe.
POSSIBLE INDUSTRIAL APPLICATIONS
[0098] The products derived from the invention can form six main
sole sub-products. All the sub-products have applications for
manufacturing all types of shoes: town, sports, hiking, orthopedic
shoes. They provide, for different zones of the foot, an adjustable
range of sole thicknesses and characteristics. Their manufacture
and their quality varies depending on the kind of sub-product
chosen, all being based on the concept of combining the use of
coils of elastic and extendable tubes, one or several layers of
such tubes, the division of the sole into several zones, and a
valves block, pumping system, connectors . . . .
[0099] a) Part of a sole which is composed of a coil, a valves
block and a pumping system. This system is then assembled and
depending on its complexity is possibly wrapped in bandages. The
sub-product is dispatched to a sole manufacturer who will use it as
a part of a sole.
[0100] b) Part of a sole which is composed of a coil, a valves
block and a pumping system and of pre-cut layers of foam. These
layers, in a quantity corresponding to the maximum number of coil
layers, will possibly be ridged and pre-imprinted with the coil
path. This system will be assembled with glue and the sub-product
will be dispatched to a sole manufacturer who will use it as a
middle part of the sole.
[0101] c) Part of a sole which is composed of a coil, a valves
block, a pumping system, pre-cut layers of foam and a regular flat
outsole or one with upward curved edges. These layers, in a
quantity corresponding to the maximum number of coil layers, will
possibly be ridged and pre-imprinted with the coil path. This
system will be assembled with glue and the sub-product is a
finished sole that will be dispatched to a shoe manufacturer.
[0102] d) Part of a sole which is composed of a coil, a valves
block, a pumping system, bandages or even a canvas, the part being
inserted into a mould and its empty spaces being filled with a
poured filling material, such as for example liquids prior to
maturation by polymerization or sizing, by injection,
vulcanization, warm pressing or any other process for which the
pouring temperature is lower enough than the maximum temperature
acceptable for the inserted parts; this poured material must meet
the desired characteristics after transformation. This assembled
system is dispatched to a sole manufacturer who will use it as a
part of a sole.
[0103] e) Part of a sole which is composed of a coil, a valves
block, a pumping system, bandages or even a canvas, the part being
inserted into a mould and its empty spaces being filled with a
poured filling material. This assembled system is applied to and
glued onto a flat outsole or one with upward curved edges and the
sub-product is a finished sole that will be dispatched to a shoe
manufacturer.
[0104] f) Part of a sole which is composed of a coil, a valves
block, a pumping system, bandages or even a canvas, the part being
inserted into an outsole with upward curved edges and whose empty
spaces are filled with a poured filling material. This assembled
system is a finished sole that will be dispatched to a shoe
manufacturer.
[0105] In terms of manufacturing costs, the tube used for the coils
is continuous and several meters long. It will be cut as required
into different lengths to form the sets of coils. The valves blocks
and pumping systems are standard parts used for various shoe sizes
and their manufacture doesn't require sophisticated machinery.
Coils and valves block sub-assemblies can therefore be cheaply
prefabricated and mass produced.
[0106] In the manufacturing of valves blocks, pumps and connectors,
hard plastics will be chosen over metal because plastic can pass
through metal detectors without setting off an alarm.
* * * * *