U.S. patent application number 13/487125 was filed with the patent office on 2012-12-06 for footwear having a sole assembly with a concave chassis for a welt construction and associated methods.
This patent application is currently assigned to Danner, Inc.. Invention is credited to Aaron Barker, Paul W. Brabson, John W. Ludermann, Christopher J. Wojnar.
Application Number | 20120304495 13/487125 |
Document ID | / |
Family ID | 47260586 |
Filed Date | 2012-12-06 |
United States Patent
Application |
20120304495 |
Kind Code |
A1 |
Brabson; Paul W. ; et
al. |
December 6, 2012 |
FOOTWEAR HAVING A SOLE ASSEMBLY WITH A CONCAVE CHASSIS FOR A WELT
CONSTRUCTION AND ASSOCIATED METHODS
Abstract
Footwear assemblies with a light weight sole assembly securely
attached to an upper and associated methods are described herein.
In one embodiment, a footwear assembly includes an upper connected
to a light weight sole assembly, wherein the sole assembly has a
durable outsole securely attached to a lightweight midsole, and a
lightweight cradle style chassis is attached to the midsole. The
chassis has a body and sidewalls extending upwardly from the
lateral and medial side portions of the body to define a concave
structure that receives a portion of the upper therein. At least a
portion of the upper is cemented to the chassis, and edge portions
of the upper are stitched to the sidewalls of the chassis.
Inventors: |
Brabson; Paul W.; (Portland,
OR) ; Ludermann; John W.; (Canby, OR) ;
Wojnar; Christopher J.; (Portland, OR) ; Barker;
Aaron; (Portland, OR) |
Assignee: |
Danner, Inc.
Portland
OR
|
Family ID: |
47260586 |
Appl. No.: |
13/487125 |
Filed: |
June 1, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61493568 |
Jun 6, 2011 |
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Current U.S.
Class: |
36/87 ; 12/142R;
36/103 |
Current CPC
Class: |
A43B 7/12 20130101; A43B
9/02 20130101; A43B 13/12 20130101 |
Class at
Publication: |
36/87 ; 36/103;
12/142.R |
International
Class: |
A43B 13/04 20060101
A43B013/04; A43D 8/00 20060101 A43D008/00; A43B 13/12 20060101
A43B013/12; A43B 1/10 20060101 A43B001/10 |
Claims
1. A footwear assembly, comprising: an upper with a top portion and
a bottom portion, the bottom portion has medial and lateral side
portions; and a multi-layer sole assembly connected to the upper,
the sole assembly comprises: an outsole defining a first layer and
having a top outsole surface; a midsole attached to the top outsole
surface and defining a second layer, the midsole being made of a
first material and having a top midsole surface; and a chassis
having a cradle configuration and defining a third layer, the
chassis being made of a second material different than the first
material, the chassis being attached to the top midsole surface
with the midsole intermediate the chassis and the outsole, the
chassis having a full-length body portion having a toe portion, a
heel portion, a medial side portion and a lateral side portion, the
body portion being supported atop the midsole, the chassis having a
medial sidewall projecting from the medial side portion and
extending between the toe and heel portions, and a lateral sidewall
projecting from the lateral side portion and extending between the
toe and heel portion, the medial and lateral sidewalls and the body
defining a concave receiving area that defines the cradle
configuration and that receives the bottom portion of the upper
therein, wherein the medial and lateral side portions of the upper
are stitched with stitching to interior surfaces of the medial and
lateral sidewalls, respectively, with a Welt construction.
2. The assembly of claim 1 wherein the bottom portion of the upper
is cemented to the body portion of the chassis.
3. The assembly of claim 1 wherein the bottom portion of the upper
has a toe portion connected to the medial and lateral side
portions, and wherein the lateral and medial sidewalls terminate at
forward end portions spaced apart from each other and proximate to
the toe portion of the body without extending fully around the toe
portion of the body, and the outsole has a toe bumper disposed
between the forward end portions and connected to the toe portion
of the upper.
4. The assembly of claim 3 wherein the forward end portions of the
medial and lateral sidewalls are immediately adjacent to edges of
the toe bumper and uncovered by the toe bumper.
5. The assembly of claim 3 wherein at least a portion of the medial
and lateral sidewalls is covered by the toe bumper.
6. The assembly of claim 1 wherein the bottom portion of the upper
has a heel portion connected to the medial and lateral portions,
and wherein the lateral and medial sidewalls terminate at rearward
end portions spaced apart from each other and proximate to the heel
portion of the body, and the outsole has a heel guard disposed
between the forward end portions and connected to the heel portion
of the upper.
7. The assembly of claim 6 wherein the rearward end portions of the
medial and lateral sidewalls are immediately adjacent to edges of
the heel guard and uncovered by the heel guard.
8. The assembly of claim 6 wherein at least a portion of the medial
and lateral sidewalls is covered by the heel guard.
9. The assembly of claim 3 wherein the bottom portion of the upper
has a heel portion connected to the medial and lateral portions,
and wherein the lateral and medial sidewalls terminate at rearward
end portions spaced apart from each other and proximate to the heel
portion of the body, and the outsole has a heel guard disposed
between the forward end portions and connected to the heel portion
of the upper.
10. The assembly of claim 1 wherein the midsole is a full length
midsole and the body portion of the chassis fully covers the top
midsole surface.
11. The assembly of claim 1 wherein the midsole is a full length
midsole and the body portion of the chassis has an opening that
exposes at least a portion of the top midsole surface.
12. The assembly of claim 1 wherein the upper has an exterior layer
that defines the medial and lateral side portions, and the upper
has a waterproof inner layer coupled to an inner surface of the
exterior layer, portions of the waterproof inner layer being
adjacent to the medial and lateral side portions of the exterior
layer, and wherein the stitching extends through the medial and
lateral sidewalls and through the medial and lateral side portions
of the exterior layer, and the stitching does not extend through
the waterproof inner layer.
13. The assembly of claim 12 wherein the waterproof inner layer is
a full-foot booty with an underfoot portion positioned atop the
body portion of the chassis.
14. The assembly of claim 13 wherein the underfoot portion is
cemented to the body portion.
15. The assembly of claim 1 wherein the medial and lateral
sidewalls are integrally connected to the body portion.
16. The assembly of claim 1 wherein the chassis has toe and heel
sidewalls connected to the medial and lateral sidewalls and that
wrap around the toe and heel portions, respectively of the body
portion, and the toe and heel portions of the upper are stitched to
the toe and heel sidewalls, respectively, in a Welt
construction.
17. The assembly of claim 1 wherein the upper includes an insole
board and the medial and lateral side portions of the upper are
wrapped around portions of the insole board.
18. The assembly of claim 17 wherein the insole board is cemented
to the body portion of the chassis.
19. The assembly of claim 1 wherein the body portion is a
full-length, one-piece layer integrally connected to the medial and
lateral sidewalls.
20. The assembly of claim 1 wherein the outsole is a one-piece,
full-length rubber outsole.
21. A waterproof footwear assembly, comprising: an upper having an
exterior layer and an interior waterproof layer, the exterior layer
having a bottom portion with medial and lateral side portions; and
a sole assembly connected to the upper, the sole assembly
comprises: an outsole made of a first material; a midsole connected
to a top of the outsole and made of a second material different
than the first material; and a chassis made of a third material
different than the second material, the chassis having a cradle
configuration and being attached to a top of the midsole
intermediate the chassis and the outsole, the chassis having a body
with a toe portion, a heel portion, a medial side portion and a
lateral side portion, the body being supported atop the midsole,
the chassis having a medial sidewall projecting from the medial
side portion and extending between the toe and heel portions, and a
lateral sidewall projecting from the lateral side portion and
extending between the toe and heel portion, the medial and lateral
sidewalls and the body defining a concave receiving area forming
the cradle configuration that receives a portion of the upper
therein between the medial and lateral sidewalls, wherein the
medial and lateral side portions of the exterior layer are stitched
with stitching to the medial and lateral sidewalls, respectively,
with a Welt construction, and wherein the stitching does not extend
through the interior waterproof layer.
22. The assembly of claim 21 wherein at least one of the exterior
layer or the interior waterproof layer is cemented to the body of
the chassis.
23. The assembly of claim 21 wherein the exterior layer has a toe
portion connected to the medial and lateral side portions, and
wherein the lateral and medial sidewalls terminate at forward end
portions spaced apart from each other and proximate to the toe
portion of the exterior layer, and the outsole has a toe bumper
disposed between the forward end portions and connected to the toe
portion of the exterior layer.
24. The assembly of claim 23 wherein the forward end portions of
the medial and lateral sidewalls are immediately adjacent to edges
of the toe bumper and are fully uncovered by the toe bumper.
25. The assembly of claim 21 wherein the exterior layer has a heel
portion connected to the medial and lateral side portions, and
wherein the lateral and medial sidewalls terminate at rearward end
portions spaced apart from each other and proximate to the heel
portion of the exterior layer, and the outsole has a heel guard
disposed between the forward end portions and connected to the heel
portion of the exterior layer.
26. The assembly of claim 21 wherein the body is a full-length
member that fully covers a top surface of the midsole.
27. The assembly of claim 21 wherein the waterproof inner layer is
a full-foot booty with an underfoot portion positioned atop the
body of the chassis.
28. The assembly of claim 21 wherein the medial and lateral
sidewalls wrap around the toe and heel portions of the body and are
integrally connected to each other, and the medial and lateral side
portions of the exterior layer are stitched to the medial and
lateral sidewalls around the toe and heel portions in a Welt
construction.
29. A method of manufacturing a footwear assembly having an upper
and a sole assembly, wherein the sole assembly has an outsole
layer, a midsole layer attached to a top portion of the outsole
layer, and a chassis layer, the method comprising: attaching the
chassis layer to a top portion of the midsole layer wherein the
midsole layer is intermediate the chassis and the outsole;
positioning the upper on the chassis, wherein the upper has a
bottom portion with medial and lateral side portions, and the
chassis has a body with a toe portion, a heel portion, a medial
side portion and a lateral side portion, the body being supported
atop the midsole, the chassis having a medial sidewall projecting
from the medial side portion and extending between the toe and heel
portions, and a lateral sidewall projecting from the lateral side
portion and extending between the toe and heel portion, the medial
and lateral sidewalls and the body defining a cradle configuration
with a concave receiving area that receives a portion of the upper
therein between the medial and lateral sidewalls, the upper being
positioned with the medial side portion of the upper adjacent to
the medial sidewall of the chassis and the lateral side portion of
the upper adjacent to the lateral sidewall of the chassis;
stitching the medial side portion of the upper directly to the
medial sidewall of the chassis in a Welt construction; and
stitching the lateral side portion of the upper directly to the
lateral sidewall of the chassis in a Welt construction.
30. The method of claim 29, further comprising cementing a portion
of the upper's bottom portion to the body of the chassis.
31. The method of claim 29 wherein the chassis has a toe sidewall
extending between the medial and lateral sidewalls, and further
comprising stitching a toe portion of the upper to the toe
sidewall.
32. The method of claim 29 wherein the chassis has a heel sidewall
extending between the medial and lateral sidewalls, and further
comprising stitching a heel portion of the upper to the heel
sidewall.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of U.S.
Provisional Patent Application No. 61/493,568, titled "Footwear
Having Sole Assembly with a Concave Chassis for a Welt Construction
and Associated Methods", filed Jun. 6, 2011, which is incorporated
herein in its entirety by reference thereto.
TECHNICAL FIELD
[0002] The present disclosure is directed generally to footwear
having lightweight sole assemblies securely attached to an upper
using a welt construction.
BACKGROUND
[0003] Articles of footwear have been designed for a wide variety
of physical activities including walking, running, hiking,
trekking, hunting, backpacking, and indoor and outdoor activities.
For example, hiking and work boots are typically designed to
provide a wearer with suitable comfort and support for hiking or
walking on uneven or rough terrain. Conventional hiking or work
boots, however, can be relatively heavy. Every time a wearer takes
a step, such as while walking or hiking, the wearer must lift the
weight of the boot. After hundreds or thousands of steps, that
additional weight can be fatiguing on the wearer's legs.
Accordingly, it is highly desirable to minimize the weight of the
footwear without overly compromising the stability and support of
the footwear.
SUMMARY
[0004] Embodiments of the current invention are directed to
footwear assemblies that overcome drawbacks of the prior art and
provide other benefits. In one embodiment, footwear assemblies are
provided that have an upper with a top portion and a bottom
portion. The bottom portion has medial and lateral side portions
along medial and lateral sides of the upper. A sole assembly is
connected to the upper. The sole assembly comprises an outsole
having a top outsole surface, and a midsole attached to the top
outsole surface. A chassis having a cradle configuration is
attached to a top midsole surface with the midsole intermediate the
chassis and the outsole. The chassis has a full-length body portion
with a toe portion, a heel portion, a medial side portion and a
lateral side portion. The body portion is supported atop the
midsole. The chassis has a medial sidewall projecting from the
medial side portion and extending between the toe and heel
portions. The chassis has a lateral sidewall projecting from the
lateral side portion and extending between the toe and heel
portion. The medial and lateral sidewalls and the body define a
concave receiving area that receives the bottom portion of the
upper therein, wherein the medial and lateral side portions of the
upper are stitched to interior surfaces of the medial and lateral
sidewalls, respectively, with a Welt construction.
[0005] In another embodiment, a waterproof footwear assembly is
provided that comprises an upper having an exterior layer and an
interior waterproof layer. The exterior layer has a bottom portion
with medial and lateral side portions. A sole assembly is connected
to the upper. The sole assembly comprises an outsole and a midsole
connected to a top of the outsole. A chassis having a cradle
configuration is attached to a top of the midsole intermediate the
chassis and the outsole. The chassis has a body with a toe portion,
a heel portion, a medial side portion and a lateral side portion.
The body is supported atop the midsole. The chassis has a medial
sidewall projecting from the medial side portion and extending
between the toe and heel portions. The chassis has a lateral
sidewall projecting from the lateral side portion and extending
between the toe and heel portion. The medial and lateral sidewalls
and the body define a concave receiving area that receives a
portion of the upper therein between the medial and lateral
sidewalls. The medial and lateral side portions of the exterior
layer are stitched with stitching to the medial and lateral
sidewalls, respectively, with a Welt construction. The stitching
does not extend through the interior waterproof layer.
[0006] Another embodiment provides a method of manufacturing a
footwear assembly having an upper and a sole assembly, wherein the
sole assembly has an outsole layer, a midsole layer attached to a
top portion of the outsole layer, and a chassis layer. The method
comprises attaching the chassis layer to a top portion of the
midsole layer, wherein the midsole layer is intermediate the
chassis and the outsole. The upper is positioned on the chassis,
wherein the upper has a bottom portion with medial and lateral side
portions, and the chassis has a body with a toe portion, a heel
portion, a medial side portion and a lateral side portion. The body
is supported atop the midsole. The chassis has a medial sidewall
projecting from the medial side portion and extending between the
toe and heel portions. A lateral sidewall projects from the lateral
side portion and extends between the toe and heel portion. The
medial and lateral sidewalls and the body define a cradle
configuration with a concave receiving area that receives a portion
of the upper therein between the medial and lateral sidewalls. The
upper is positioned with the medial side portion of the upper
adjacent to the medial sidewall of the chassis and the lateral side
portion of the upper adjacent to the lateral sidewall of the
chassis. The method also comprises stitching the medial side
portion of the upper directly to the medial sidewall of the chassis
in a Welt construction, and stitching the lateral side portion of
the upper directly to the lateral sidewall of the chassis in a Welt
construction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is an isometric view showing a medial side of a
footwear assembly configured in accordance with an embodiment of
the disclosure.
[0008] FIG. 2 is a side elevation view of a lateral side the
footwear assembly of FIG. 1.
[0009] FIG. 3 is an enlarged elevation view of a side portion of
the footwear assembly of FIG. 2.
[0010] FIG. 4 is an enlarged side elevation view of a toe portion
of the footwear assembly of FIG. 2.
[0011] FIG. 5 is an enlarged side elevation view of a heel portion
of the footwear assembly of FIG. 2.
[0012] FIG. 6 is a partially cut away elevation view of the side
portion of the footwear assembly of FIG. 2.
[0013] FIG. 7 is a partially exploded schematic view of the
footwear assembly in accordance with an embodiment of the
invention.
[0014] FIG. 8 is a schematic cross-sectional view taken
substantially along line 8-8 of FIG. 2.
DETAILED DESCRIPTION
[0015] Footwear assemblies with a light weight sole assembly
securely attached to an upper using a Welt construction, and
associated methods for using and making such assemblies, are
described in detail herein in accordance with embodiments of the
present disclosure. In one embodiment, for example, a footwear
assembly includes an upper connected to a light weight sole
assembly, wherein the sole assembly has a durable outsole securely
attached to a lightweight midsole, and a light weight cradle style
chassis is attached to the midsole. The chassis has a body portion
and sidewalls forming Welt portions extending upwardly from the
lateral and medial side portions of the body portion to define a
concave structure that securely engages and supports the upper. A
bottom portion of the upper is cemented to the chassis, and lateral
and medial side portions of the upper are stitched to the lateral
and medial sidewalls with a Welt-style construction.
[0016] In one embodiment, the sole assembly includes a toe bumper
attached to a toe portion of the outsole, and the toe bumper wraps
upwardly over the front edge of the chassis and is cemented or
otherwise attached to a toe portion of the upper. A heel guard can
be attached to a heel portion of the outsole, and the heel guard
extends upwardly over the rear edge of the chassis and is cemented
or otherwise attached to a heel portion of the upper. The lateral
and medial sidewalls in one embodiment terminate immediately
adjacent to the toe bumper and the heel guard so that the chassis
body portion extends forwardly and rearwardly beyond the sidewalls
at the toe and heel ends of the chassis, and the sidewalls do not
extend under the toe bumper or the heel guard.
[0017] In one embodiment, the footwear assembly is a waterproof
assembly wherein the upper has an external layer of sufficiently
durable material, and a waterproof layer inwardly adjacent to the
external layer. In one embodiment, the waterproof layer is a
waterproof booty attached to the inside surface of the exterior
layer. The footwear assembly is constructed so that the waterproof
booty is not punctured or otherwise perforated by the stitching
that extends through the sidewalls and the edge portions of the
upper. In one embodiment, the waterproof booty is stitched to the
exterior layer only at the top edge portion of the upper. The
remaining portion of the waterproof booty is cemented or otherwise
attached to the interior surface of the exterior layer.
[0018] In accordance with one embodiment, the sole assembly is made
by cementing, molding, or otherwise securely joining the
lightweight midsole to the outsole and the chassis. This
lightweight sole assembly is configured to receive the waterproof
upper onto the concave chassis between the sidewalls. The upper
includes the exterior layer and the waterproof booty. The
waterproof upper is fixed to the sole assembly by positioning the
lower portion of the upper onto the top surface of the chassis body
portion between the sidewalls. The exterior layer is cemented onto
the chassis with the lateral and medial sidewalls immediately
adjacent to the edge portions of the exterior layer. The waterproof
booty is moved away from the edge portions of the exterior layer
adjacent to the sidewalls. The edge portions of the upper's
exterior layer are then stitched to the lateral and medial
sidewalls of the sole assembly without stitching or otherwise
perforating the waterproof booty. After the exterior layer is
stitched to the chassis, an adhesive is applied to the waterproof
booty and the waterproof booty is moved into its final positioned
in full engagement with the interior surface of the exterior layer.
The upper can be lasted until the adhesive is cured such that the
waterproof booty is securely and permanently bonded to the interior
surface of the exterior layer.
[0019] Certain details are set forth in the following description
and in FIGS. 1-8 to provide a thorough and enabling description of
various embodiments of the disclosure. Other details describing
well-known structures and components often associated with footwear
assemblies and methods of forming such assemblies, however, are not
set forth below to avoid unnecessarily obscuring the description of
various embodiments of the disclosure. Many of the details,
dimensions, angles, relative sizes of components, and/or other
features shown in the Figures are merely illustrative of particular
embodiments of the disclosure. Accordingly, other embodiments can
have other details, dimensions, angles, sizes, and/or features
without departing from the spirit and scope of the present
disclosure. In addition, further embodiments of the disclosure may
be practiced without several of the details described below, while
still other embodiments of the disclosure may be practiced with
additional details and/or features. In the Figures, identical
reference numbers identify identical, or at least generally
similar, elements. Moreover, one of ordinary skill in the art will
appreciate that any relative positional terms such as above, below,
over, under, etc. do not necessarily require a specific orientation
of the footwear assemblies as described herein. Rather, these or
similar terms are intended to describe the relative position of
various features of the disclosure described herein.
[0020] FIG. 1 is an isometric view of a footwear assembly 10
configured in accordance with an embodiment of the disclosure. As
will be appreciated by one of ordinary skill in the art, the
assembly 10 can include any article of footwear (e.g., a boot,
shoe, etc.) and is not limited to the boot shown in FIG. 1. In the
illustrated embodiment, the assembly 10 includes a sole assembly 14
attached to an upper 12. The sole assembly 14 includes a rugged
outsole 16 that covers a lightweight midsole 18, and a cradle-style
chassis 20 is supported atop the midsole 18. The chassis 20 defines
a concave structure that supports and is fixedly attached to the
upper 12. The upper 12 has a bottom portion 28 cemented and
stitched to the chassis with at least a partial Welt construction.
The upper 12 defines an interior area 22 that receives the foot of
a wearer through an opening 26 formed by a top edge portion 24 of
the upper. These features of the footwear assembly 10 are discussed
in greater detail below.
[0021] The sole assembly 14 of the illustrated embodiments shown in
the Figures includes a durable rubber outsole 16 that has a bottom
surface 40 configured to engage the ground, and a top surface 42
opposite the bottom surface 40. The outsole 16 is a one piece,
full-length outsole that extends between heel and toe portions 48
and 50 of the sole assembly 14. In other embodiments, the outsole
16 can be a multi-piece outsole made of rubber or other
sufficiently durable material. The outsole's top surface 42 is
connected to and supports the midsole 18. The midsole 18 of the
illustrated embodiment is a full-length, lightweight, polyurethane
midsole having a bottom surface 46 cemented directly to the top
surface 42 of the outsole 16. In other embodiments, the midsole 18
can be attached to the rubber outsole 16 with other techniques,
such as direct-attach construction. In alternate embodiments, the
lightweight midsole 18 can be a multi-piece midsole. Further,
intermediate layers may be provided between the midsole 18 and the
outsole 16.
[0022] The lightweight polyurethane midsole 18 has a top surface 56
opposite the bottom surface 46. The top surface 56 is attached to a
bottom surface 60 of the chassis 20. In the illustrated embodiment,
the midsole 18 is direct-attached to the chassis 20, although other
attachment techniques can be used. Accordingly, the sole assembly
14 has the lightweight polyurethane midsole 18 sandwiched between
the bottom of the chassis 20 and the top of the rubber outsole 16.
In other embodiments, intermediate layers may be included between
the chassis 20 and the midsole 18. In addition, each of the rubber
outsoles 16, the polyurethane midsole 18, and the chassis 20 can be
made of differing thicknesses as is desired for the intended use or
other requirements of the footwear assembly 10.
[0023] The cradle-style chassis 20 of the illustrated embodiment is
a full-foot structure extending between the heel area 48 and toe
area 50 of the sole assembly 14. The chassis 20 has a full-length
body portion 70 with a bottom surface 72 directly attached to the
top surface 56 of the midsole 18. The body portion 70 has a top
surface 74 opposite the bottom surface 72 that connects to and
supports the upper 12. The chassis 20 includes lateral and medial
sidewalls 76 (FIG. 2) and 78 (FIG. 1) extending upwardly away from
the lateral and medial sides 80 and 82 of the body portion 70 to
define a concave, a cradle structure that receives the upper
therein. These sidewalls 76 and 78 provide Welt portions used to
stitch the cradle 20 to the bottom portion 28 of the upper 12 along
at least lateral and medial sides of the sole assembly 14. As seen
in FIG. 6, stitching 84 extends fully through the sidewalls 76 and
78 and through medial and lateral portions of upper's bottom
portion 28 so as to securely stitch and anchor the upper 12 to the
chassis 20 in a Welt-style construction. The upper's bottom portion
28 can also be cemented to the chassis' body portion 70 and/or
interior surfaces of the sidewalls to securely and permanently
assemble the components.
[0024] In the illustrated embodiment, the body portion 70 is a
full-length, one-piece layer having a selected thickness and being
integrally connected to the sidewalls 76 and 78. In other
embodiments, the sidewalls 76 and 78 can be separate components
permanently fixed to the body portion 70. In other embodiments, the
body portion 70 can be a multi-piece component. The body portion 70
in some embodiments may include peripheral areas connected to the
sidewalls 76 and 78, and an open middle area that allows direct
contact between portions of the midsole and portions of the bottom
of the upper. Such construction can be helpful to provide selected
impact absorption and/or to further reduce the weight of the sole
assembly 14.
[0025] The outsole's construction with a durable outsole, a
lightweight polyurethane midsole, and a cradle-style chassis
stitched to the upper along the medial and lateral sidewalls with a
Welt construction, along with a cement bond therebetween provides a
very durable, lightweight construction that has exceptional lateral
stability along the length of the boot.
[0026] In the illustrated embodiment, the lateral and medial
sidewalls 76 and 78 are stitched with a single line of stitching 84
that extends along the full length of the medial and lateral
sidewalls and that securely engages the lateral and medial sides of
the upper's bottom portion immediately adjacent to the sidewalls.
Other embodiments can include other stitching patterns, including
two, three or more lines of stitching along lateral and/or medial
sidewalls.
[0027] The lateral and medial sidewalls 78 and 76 shown in the
Figures extend fully between the heel and toe areas 48 and 50 on
both the lateral and medial sides, but the sidewalls terminate in
the heel and toe areas 48 and 50 of the sole assembly 14 without
wrapping fully around the heel and toe ends of the chassis 20. In
other embodiments, the lateral and medial sidewalls 76 and 78 can
extend around the toe and/or heel ends of the chassis 20.
[0028] The illustrated sole assembly 14 includes a toe bumper 90
attached to the toe area of the rubber outsole 16. The toe bumper
90 extends upwardly from the outsole, wraps over the front end of
the midsole 18 and the chassis' body portion 70. The toe bumper 90
is cemented to the midsole 18, the chassis' body portion 70 and/or
the toe portion of the upper 12. The illustrated toe bumper 90 is a
rubber bumper integrally connected to the outsole 16, so as to form
a durable and rugged toe portion, which is a high wear area of the
footwear assembly. In other embodiments, the toe bumper 90 can be a
separate component cemented or otherwise securely fixed in
place.
[0029] The front portions of the lateral and medial sidewalls 76
and 78 terminate immediately adjacent to the toe bumper 90, such
that the front most edge of the sidewalls 76 and 78 substantially
abut the edges of the toe bumper. Accordingly, the sidewalls 76 and
78 are not covered by the toe bumper 90. This arrangement with the
sidewalls 76 and 78 and the toe bumper 90 provides sufficient space
at the toe of the upper to accommodate a protective toe structure,
such as a steel toe, aluminum toe, plastic toe, or other protective
toe member. The same construction can, of course, be utilized when
a protective toe structure is not provided in the upper.
[0030] The sole assembly 14 also includes a heel guard 92 connected
to the heel area 102 of the outsole 16. The heel guard 92 extends
upwardly from the outsole's heel area 102 and covers the rear edges
of the midsole 18 and the chassis 20. The illustrated sole assembly
14 includes a heel guard 92 attached to the heel area of the rubber
outsole 16. The heel guard 92 extends upwardly from the outsole 16,
wraps over the rear end of the midsole 18 and the chassis' body
portion 70. The heel guard 92 is cemented to the midsole 18, the
chassis' body portion 70 and/or the heel portion of the upper 12.
The illustrated heel guard 92 is a rubber member integrally
connected to the outsole 16, so as to form a durable and rugged
portion in another one of the high wear areas of the footwear
assembly. In other embodiments, the heel guard 92 can be a separate
component cemented or otherwise securely fixed in place.
[0031] The rear portions of the lateral and medial sidewalls 76 and
78 also terminate immediately adjacent to the heel guard 92, such
that the rear most edge of the sidewalls 76 and 78 substantially
abut the edges of the heel guard 92. Accordingly, the sidewalls 76
and 78 are not covered by the heel guard 92. The heel guard 92 can
be provided with selected contours and/or projections, such as to
provide a kick strip that a wearer may use when removing the boot
from his/her foot.
[0032] The footwear assembly 10 of one embodiment is a waterproof
assembly configured to prevent water from penetrating through the
assembly to the wearer's foot. As seen in FIG. 8, the upper 12 of
the footwear assembly 10 is a multi-layer assembly with a durable
external layer 100 made of leather or other sufficiently durable
material. The external layer 100 has bottom edge portions 101
securely cemented or otherwise fixed to the entire perimeter
portion of an insole board 102, which forms an under-foot portion
of the upper 12 adjacent to the top surface 74 of the chassis' body
portion 20. The waterproof upper 12 also has a waterproof interior
layer defined by a full-foot waterproof booty 104 adjacent to the
inner surface 106 of the exterior layer 100. The waterproof booty
104 can be constructed of a suitable waterproof material, such as
Gortex.TM. or other similar water-impenetrable barrier material,
coupled to an interior liner made of a selected fabric or other
suitable footwear liner material. The booty 104 can be a seamless
full-foot booty, although other embodiments can provide a booty
with seams that are taped or otherwise constructed in a waterproof
manner. In the final assembled footwear, the booty 104 is
immediately adjacent to the exterior's interior surface 106 and the
stitching 84 that secures the bottom portion of the upper's
exterior layer 10 to the sidewalls 76 and 78 in the Welt
construction, as discussed above. The stitching 84, however, does
not extend through or otherwise perforate the waterproof booty 104.
In one embodiment, the stitching on the inside of the exterior area
can be taped or otherwise covered to reduce any inadvertent rubbing
or wear against the waterproof booty 104.
[0033] During construction of the footwear assembly 10, the sole
assembly 14 is constructed as discussed above with the lightweight,
polyurethane midsole 18 cemented, direct attached, molded, or
otherwise securely joined to the outsole 16 and the chassis 20. The
sole assembly 14 is then ready to be attached to the upper 12. The
upper is separately constructed by positioning the waterproof booty
104 within the exterior layer 102, and joining the top portion of
the waterproof booty 104 to the top edge portion 24 (FIG. 2) of the
upper 12 generally adjacent to the opening 26 to the interior area
22 (FIG. 2). In one embodiment, the top portion of the waterproof
booty 104 is initially stitched to the top edge portion 24 of the
exterior layer, but the stitching does extend fully around the top
edge portion 24. A portion of the booty's top portion remains
unstitched so as to form a temporary unstitched access area 110
between the exterior layer 100 and the booty 104. The rest of the
booty 104 is positioned immediately adjacent to the inner surface
106 of the exterior layer 100. At this point, however, the booty
104 is only fixed to the exterior layer 100 by the stitching at the
top edge portion of the upper.
[0034] The exterior layer 100 and the booty 104 are then lasted and
connected to the insole board 102, such that the bottom of the
booty 104 is supported atop the insole board 102. The bottom
peripheral edges 112 of the exterior layer 100 are then stretched
around the edges of the insole board 102 and cemented to the bottom
of the insole board 102. The cement is cured so as to permanently
fix the exterior layer 100 to the insole board 102. The last is
removed from the interior area 22 and the upper 12 is ready for
attachment to the sole assembly 14.
[0035] As indicated above, the upper 12 is attached to the sole
assembly 14 by stitching the upper 12 to the sidewalls 76 and 78,
but the booty 104 is not perforated by the stitching 84. In one
embodiment, before the upper 12 is placed on to the chassis 20, the
booty 104 is partially removed from the interior area by pulling
the booty 104 substantially inside-out through the temporarily
unstitched access area 110. The "inside-out" booty 104 remains
attached to the exterior layer 100, but the booty 104 is no longer
adjacent to the lower portions of the exterior layer 100. In this
configuration, the upper 12 is positioned on the cradle with the
sidewalls 76 and 78 immediately adjacent to the medial and lateral
lower portions of the exterior layer 100. In one embodiment, cement
is applied to either the bottom of the insole board 102 or to the
top of the chassis 20 just before the upper 12 positioned atop the
body 70 between the sidewalls 76 and 78. The sidewalls 76 and 78 of
the chassis 20 are then stitched to the side portions of the
exterior layer 100, such that the stitching 84 perforates the
sidewalls and the exterior layer and securely fixes the two
components together.
[0036] After the exterior layer 100 is stitched to the chassis 20,
the booty 104 can be returned from its inside-out position to its
final position within the interior area 22 immediately adjacent to
the interior surface 106 of the exterior layer 100 and into
engagement with the top of the insole board 102. In one embodiment,
a conventional adhesive is applied to the outside surface of the
booty 104, the booty is moved from the inside-out configuration
into its final position, and the upper 12 is lasted a second time
so as to securely press the waterproof booty 104 into engagement
with the interior surface 106 of the exterior layer 100 and with
the insole board 102 while the adhesive or other bonding agent is
cured or otherwise dried. After the waterproof booty 104 is moved
to its final position, the temporary access area 110 at the top of
the upper 12 is closed by stitching the top portion of the booty
104 to the top portion of the exterior layer 100 so as to close and
finish the top edge of the footwear assembly.
[0037] From the foregoing, it will be appreciated that specific
embodiments of the disclosure have been described herein for
purposes of illustration, but that various modifications may be
made without deviating from the spirit and scope of the disclosure.
While various advantages associated with certain embodiments of the
disclosure have been described above in the context of those
embodiments, other embodiments may also exhibit such advantages,
and not all embodiments need necessarily exhibit such advantages to
fall within the scope of the disclosure.
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