U.S. patent application number 14/397434 was filed with the patent office on 2015-05-28 for flexible footwear.
The applicant listed for this patent is CROCS, INC.. Invention is credited to Dale R. Bathum, Luca Faggin, Stefano Ferniani.
Application Number | 20150143722 14/397434 |
Document ID | / |
Family ID | 49515036 |
Filed Date | 2015-05-28 |
United States Patent
Application |
20150143722 |
Kind Code |
A1 |
Faggin; Luca ; et
al. |
May 28, 2015 |
FLEXIBLE FOOTWEAR
Abstract
A footwear product includes a sole assembly and an upper and has
an at least partially flexible construction. The sole assembly
includes a number of sole sections with one or more connecting
members disposed between adjacent sole sections.
Inventors: |
Faggin; Luca; (Padova,
IT) ; Ferniani; Stefano; (Padova, IT) ;
Bathum; Dale R.; (Boulder, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CROCS, INC. |
Niwot |
CO |
US |
|
|
Family ID: |
49515036 |
Appl. No.: |
14/397434 |
Filed: |
May 2, 2013 |
PCT Filed: |
May 2, 2013 |
PCT NO: |
PCT/US2013/039253 |
371 Date: |
October 27, 2014 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61641766 |
May 2, 2012 |
|
|
|
61755880 |
Jan 23, 2013 |
|
|
|
61763868 |
Feb 12, 2013 |
|
|
|
Current U.S.
Class: |
36/25R ;
156/245 |
Current CPC
Class: |
A43D 25/047 20130101;
A43B 13/04 20130101; A43B 3/128 20130101; A43B 3/248 20130101; A43B
13/141 20130101; A43B 13/16 20130101; A43B 13/14 20130101; A43B
3/108 20130101 |
Class at
Publication: |
36/25.R ;
156/245 |
International
Class: |
A43B 13/14 20060101
A43B013/14; A43B 13/04 20060101 A43B013/04; A43D 25/047 20060101
A43D025/047 |
Claims
1. An outsole comprising: a plurality of independent segments each
formed of an injection moldable material, wherein each of the
plurality of independent segments includes a top surface and a
bottom surface, wherein each of the plurality of independent
segments includes at least one hole formed entirely through the
segment and positioned between the top and bottom surfaces; and at
least one band extending through the at least one hole of each of
the plurality of independent segments, wherein the at least one
band is elastic and permits stretching apart of each of the
plurality of independent segments with respect to each other, and
wherein the at least one band applies a compression force to the
plurality of independent segments causing the plurality of
independent segments to align in an overall shape of a foot absent
external forces, and wherein nothing spans adjacent segments of the
plurality of independent segments except for the at least one
band.
2. The outsole of claim 1, wherein an edge of the top surface of
each of the plurality of independent segments is beveled.
3. The outsole of claim 1, wherein the plurality of independent
segments is four or more independent segments.
4. The outsole of claim 1, wherein the plurality of independent
segments is five or more independent segments.
5. The outsole of claim 1, wherein the plurality of independent
segments is six or more independent segments.
6. The outsole of claim 5, wherein each of the plurality of
independent segments includes a portion of a medial perimeter and a
portion of a lateral perimeter of the outsole.
7. The outsole of claim 6, further comprising a toe bar attached to
a forward-most segment of the six or more independent segments, and
a foot strap connected to the toe bar at one end and to an other
segment of the six or more independent segments at another end,
wherein the other segment of the six or more independent segments
is separated from the forward-most segment by at least three
segments of the six or more independent segments.
8. The outsole of claim 1, wherein the plurality of independent
segments is thirteen or more independent segments.
9. The outsole of claim 1, wherein each of the plurality of
independent segments includes a portion of a medial perimeter and a
portion of a lateral perimeter of the outsole.
10. The outsole of claim 1, further comprising one or more spacers
between each adjacent pair of the plurality of independent
segments.
11. A sole assembly for a footwear product, the sole assembly
comprising: a first outsole section including a first surface and a
second surface; a second outsole section adjacent to the first
outsole section, the second outsole section having a first surface
and a second surface; a connection member having a top surface and
a bottom surface, wherein a first portion of the bottom surface of
the connection member is disposed on at least a first portion of
the first surface of the first outsole section, a second portion of
the bottom surface of the connection member is disposed on at least
a first portion of the first surface of the second outsole section,
and a third portion of the connection member extends between the
first and second outsole sections; and at least one footbed section
disposed on at least a portion of the top surface of the connection
member.
12. The sole assembly of claim 11, further comprising a third
outsole section.
13. The sole assembly of claim 12, further comprising a fourth
outsole section.
14. The sole assembly of claim 11, wherein the first surface of the
first outsole section includes a lip extending along at least a
portion of a periphery of the first surface of the outsole
section.
15. A method of constructing a sole assembly for a footwear
product, the method comprising: injection molding a plurality of
independent outsole sections; injection molding a connecting
member; arranging at least a first and second of the plurality of
independent outsole sections such that the first outsole section is
adjacent to the second outsole section; adhering a first portion of
a bottom surface of the connecting member to at least a portion of
a first surface of the first outsole section; and adhering a second
portion of the bottom surface of the connecting member to at least
a portion of a first surface of the second outsole section, such
that a third portion of the connecting member extends between the
first and second outsole sections; wherein the connecting member
holds together the first and second outsole sections while
permitting the first and second outsole sections to flex about the
connecting member and to flex with respect to each other.
16. The method of claim 15, wherein each of the plurality of
outsole sections is molded from a foam material.
17. The method of claim 16, wherein the foam material comprises
ethylene vinyl acetate (EVA).
18. The method of claim 15, wherein the connecting member is
created using an elastomeric material.
19. The method of claim 15, wherein the first surface of the first
outsole section is a top surface of the first outsole section, and
wherein the first surface of the second outsole section is a top
surface of the second outsole section.
20. The method of claim 19, further comprising: forming a first
hole from a front surface of the first outsole section to a rear
surface of the first outsole section; forming a second hole from a
front surface of the second outsole section to a rear surface of
the second outsole section; inserting an elastically deformable
band through the first and second holes, without otherwise
connecting the elastically deformable band to the first and second
outsole sections.
21. The method of claim 20, further comprising: forming a third
hole from the front surface of the first outsole section to the
rear surface of the first outsole section; and forming a fourth
hole from the front surface of the second outsole section to the
rear surface of the second outsole section.
22. The method of claim 21, wherein the elastically deformable band
is a first elastically deformable band, the method further
comprising inserting a second elastically deformable band through
the third and fourth holes, without otherwise connecting the second
elastically deformable band to the first and second outsole
sections.
23. The method of claim 21, further comprising inserting the
elastically deformable band through the third and fourth holes,
without otherwise connecting the elastically deformable band to the
first and second outsole sections.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 61/641,766, filed on May 2, 2012, and
of U.S. Provisional Patent Application Ser. No. 61/755,880, filed
on Jan. 23, 2013, and of U.S. Provisional Patent Application Ser.
No. 61/763,868, filed on Feb. 12, 2013, all of which are
incorporated by reference herein in their entireties for all
purposes.
TECHNICAL FIELD
[0002] Embodiments of the present invention relate generally to
footwear, and more specifically to segmented flexible footwear.
SUMMARY
[0003] This summary is provided to introduce a selection of
concepts in a simplified form that are further described below in
the Detailed Description. This summary is not intended to identify
key features or essential features of the claimed subject matter,
nor is it intended to be used, in isolation, as an aid in
determining the scope of the claimed subject matter. At a high
level, embodiments of the invention relate to a footwear product
having an at least partially flexible construction.
[0004] An outsole according to embodiments of the present invention
includes a plurality of independent segments each formed of an
injection moldable material, wherein each of the plurality of
independent segments includes a top surface and a bottom surface,
wherein each of the plurality of independent segments includes at
least one hole formed entirely through the segment and positioned
between the top and bottom surfaces; and at least one band
extending through the at least one hole of each of the plurality of
independent segments, wherein the at least one band is elastic and
permits stretching apart of each of the plurality of independent
segments with respect to each other, and wherein the at least one
band applies a compression force to the plurality of independent
segments causing the plurality of independent segments to align in
an overall shape of a foot absent external forces, and wherein
nothing spans adjacent segments of the plurality of independent
segments except for the at least one band.
[0005] The outsole of paragraph [0004], wherein an edge of the top
surface of each of the plurality of independent segments is
beveled.
[0006] The outsole of any of paragraphs [0004] to [0005], wherein
the plurality of independent segments is four or more independent
segments.
[0007] The outsole of any of paragraphs [0004] to [0006], wherein
the plurality of independent segments is five or more independent
segments.
[0008] The outsole of any of paragraphs [0004] to [0007], wherein
the plurality of independent segments is six or more independent
segments.
[0009] The outsole of any of paragraphs [0004] to [0008], wherein
each of the plurality of independent segments includes a portion of
a medial perimeter and a portion of a lateral perimeter of the
outsole.
[0010] The outsole of any of paragraphs [0004] to [0009], further
comprising a toe bar attached to a forward-most segment of the six
or more independent segments, and a foot strap connected to the toe
bar at one end and to an other segment of the six or more
independent segments at another end, wherein the other segment of
the six or more independent segments is separated from the
forward-most segment by at least three segments of the six or more
independent segments.
[0011] The outsole of any of paragraphs [0004] to [0010], wherein
the plurality of independent segments is thirteen or more
independent segments.
[0012] The outsole of any of paragraphs [0004] to [0011], wherein
each of the plurality of independent segments includes a portion of
a medial perimeter and a portion of a lateral perimeter of the
outsole.
[0013] The outsole of any of paragraphs [0004] to [0012], further
comprising one or more spacers between each adjacent pair of the
plurality of independent segments.
[0014] A sole assembly for a footwear product according to
embodiments of the present invention includes a first outsole
section including a first surface and a second surface; a second
outsole section adjacent to the first outsole section, the second
outsole section having a first surface and a second surface; a
connection member having a top surface and a bottom surface,
wherein a first portion of the bottom surface of the connection
member is disposed on at least a first portion of the first surface
of the first outsole section, a second portion of the bottom
surface of the connection member is disposed on at least a first
portion of the first surface of the second outsole section, and a
third portion of the connection member extends between the first
and second outsole sections; and at least one footbed section
disposed on at least a portion of the top surface of the connection
member.
[0015] The sole assembly of paragraph [0014], further comprising a
third outsole section.
[0016] The sole assembly of any of paragraphs [0014] to [0015],
further comprising a fourth outsole section.
[0017] The sole assembly of any of paragraphs [0014] to [0016],
wherein the first surface of the first outsole section includes a
lip extending along at least a portion of a periphery of the first
surface of the outsole section.
[0018] A method of constructing a sole assembly for a footwear
product according to embodiments of the present invention includes:
injection molding a plurality of independent outsole sections;
injection molding a connecting member; arranging at least a first
and second of the plurality of independent outsole sections such
that the first outsole section is adjacent to the second outsole
section; adhering a first portion of a bottom surface of the
connecting member to at least a portion of a first surface of the
first outsole section; and adhering a second portion of the bottom
surface of the connecting member to at least a portion of a first
surface of the second outsole section, such that a third portion of
the connecting member extends between the first and second outsole
sections; wherein the connecting member holds together the first
and second outsole sections while permitting the first and second
outsole sections to flex about the connecting member and to flex
with respect to each other.
[0019] The method of paragraph [0018], wherein each of the
plurality of outsole sections is molded from a foam material.
[0020] The method of any of paragraphs [0018] to [0019], wherein
the foam material comprises ethylene vinyl acetate (EVA).
[0021] The method of any of paragraphs [0018] to [0020], wherein
the connecting member is created using an elastomeric material.
[0022] The method of any of paragraphs [0018] to [0021], wherein
the first surface of the first outsole section is a top surface of
the first outsole section, and wherein the first surface of the
second outsole section is a top surface of the second outsole
section.
[0023] The method of any of paragraphs [0018] to [0022], further
comprising: forming a first hole from a front surface of the first
outsole section to a rear surface of the first outsole section;
forming a second hole from a front surface of the second outsole
section to a rear surface of the second outsole section; inserting
an elastically deformable band through the first and second holes,
without otherwise connecting the elastically deformable band to the
first and second outsole sections.
[0024] The method of any of paragraphs [0018] to [0023], further
comprising: forming a third hole from the front surface of the
first outsole section to the rear surface of the first outsole
section; and forming a fourth hole from the front surface of the
second outsole section to the rear surface of the second outsole
section.
[0025] The method of any of paragraphs [0018] to [0024], wherein
the elastically deformable band is a first elastically deformable
band, the method further comprising inserting a second elastically
deformable band through the third and fourth holes, without
otherwise connecting the second elastically deformable band to the
first and second outsole sections.
[0026] The method of any of paragraphs [0018] to [0025], further
comprising inserting the elastically deformable band through the
third and fourth holes, without otherwise connecting the
elastically deformable band to the first and second outsole
sections.
[0027] While multiple embodiments are disclosed, still other
embodiments of the present invention will become apparent to those
skilled in the art from the following detailed description, which
shows and describes illustrative embodiments of the invention.
Accordingly, the drawings and detailed description are to be
regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The present invention is described in detail below with
reference to the attached drawing figures, wherein:
[0029] FIG. 1A is a perspective view of a sandal in accordance with
embodiments of the invention;
[0030] FIG. 1B is a side view of a sandal in accordance with
embodiments of the invention;
[0031] FIG. 2 is a perspective exploded view of a sandal in
accordance with embodiments of the invention;
[0032] FIG. 3A is a side view of a shoe in accordance with
embodiments of the invention;
[0033] FIG. 3B is a side view of the shoe of FIG. 3A, showing
internal features, in accordance with embodiments of the
invention;
[0034] FIG. 4A is a perspective view of a sandal in accordance with
embodiments of the invention;
[0035] FIG. 4B is a side view of a foot wearing a sandal in
accordance with embodiments of the invention;
[0036] FIG. 5A is a perspective view of a shoe in accordance with
embodiments of the invention;
[0037] FIG. 5B is a side view of a shoe in accordance with
embodiments of the invention;
[0038] FIG. 5C is a bottom view of a shoe in accordance with
embodiments of the invention; and
[0039] FIG. 5D is a side view of a shoe being flexed in accordance
with embodiments of the invention.
[0040] FIG. 6 illustrates a top view of a sandal according to
embodiments of the present invention.
[0041] FIG. 7 illustrates a top view of the sandal of FIG. 6 in a
twisted configuration, according to embodiments of the present
invention.
[0042] FIG. 8 illustrates the sandal of FIGS. 6 and 7 being bent
over itself, according to embodiments of the present invention.
[0043] FIG. 9 illustrates a top view of a shoe outsole, according
to embodiments of the present invention.
[0044] FIG. 10 illustrates the shoe outsole of FIG. 9 in a twisted
configuration, according to embodiments of the present
invention.
[0045] FIG. 11 illustrates a bottom view of a shoe and insole,
according to embodiments of the present invention.
[0046] FIG. 12 illustrates a top view of the shoe and insole of
FIG. 11, according to embodiments of the present invention.
[0047] FIG. 13 illustrates a bottom view of an alternative outsole,
according to embodiments of the present invention.
[0048] FIG. 14 illustrates a cross sectional view of the
alternative outsole of FIG. 13 taken along line A-A of FIG. 13,
according to embodiments of the present invention.
DETAILED DESCRIPTION
[0049] The subject matter of embodiments of the invention is
described with specificity to meet statutory requirements. However,
the description itself is not intended to limit the scope of this
patent. Rather, the inventors have contemplated that the claimed
subject matter might also be embodied in other ways, to include
different steps or features or combinations of steps or features
similar to the ones described in this document, in conjunction with
other technologies. Moreover, although aspects of methods of
constructing products according to embodiments of the invention are
described with reference to "blocks," the term "block" should not
be interpreted as implying any particular order among or between
various aspects unless the order of individual aspects is
explicitly described.
[0050] Embodiments of the invention include a footwear product
having an at least partially flexible construction. The footwear
product can be a shoe, a boot, a sandal, a clog, or any other type
of footwear product having at least a partially-flexible
construction in accordance with embodiments of the invention.
Embodiments of the invention can include different combinations of
the features and components described herein, additional features
or components that are not described herein, and components made
from different materials or combinations of materials than those
described herein. All such implementations are considered to be
within the ambit of the invention.
[0051] FIG. 1A depicts a sandal 1 having a partially-flexible
construction in accordance with embodiments of the invention. As
illustrated in FIG. 1A, the sandal 1 includes a sole assembly 10
and an upper 12 disposed on top of the sole assembly 10. The sole
assembly 10 includes a number of sole sections 14, 16, 18, and 20.
According to embodiments, the sole assembly can include two
sections, three sections, four sections, five sections, or the
like. In embodiments, the upper 12 can be coupled to the sole
assembly 10.
[0052] FIG. 1B shows a sandal 30 that includes a sole assembly 32
and an upper 34, which is coupled to the sole assembly 32. The sole
assembly 32 includes four sole sections: a forefoot section 36, two
mid sections 38 and 40, and a heel section 42. In embodiments, a
sole assembly 32 can include fewer than four sections or more than
four sections. For example, as shown in FIGS. 4A and 4B, a sandal
400, in accordance with embodiments of the invention, may include a
sole assembly 410 having five sole sections 414, 416, 418, 420, and
422. An upper 412 is coupled to the first sole section 414 and the
fourth sole section 420. As shown in FIG. 4B, various constructions
of a footwear product in accordance with embodiments of the
invention facilitate an at least partially flexible construction
that can flex with the movement of the wearer's foot 430.
[0053] In FIG. 1B, each sole section includes an outsole section 44
and a footbed section 46. In embodiments, an outsole section 44 can
include a tread feature 47. A connecting member 48 extends between
adjacent sole sections 40 and 42. As illustrated, the sole assembly
32 can include a connecting member 48, 50, and 52 that extends
between each pair of adjacent sole sections 36 and 38, 38 and 40,
and 40 and 42. In embodiments, the connecting members 48, 50, and
52 can be a single piece, extending between each of the adjacent
sole sections, while, in other embodiments, the connecting members
48, 50, and 52 can be individual pieces.
[0054] As shown in FIG. 1B, a first portion 52 of the upper 34 can
be coupled to a first sole section 36 and a second portion 54 of
the upper 34 can be coupled to a third sole section 40. In other
embodiments, various portions of the upper 34 can be coupled to any
number of different sole sections. For example, as shown in FIG.
3A, a portion of the upper can be coupled to each sole section. In
embodiments, portions of the upper can be coupled to a footbed
portion, an outsole portion, a connecting member, or a combination
of these.
[0055] FIG. 2 shows an exploded view of a footwear product 200 (a
sandal, in the illustrated embodiments) according to embodiments of
the invention. As shown in FIG. 2, the footwear product 200
includes a sole assembly 210 and an upper 212. The sole assembly
210 includes outsole sections 214, 216, 218, and 220; footbed
sections 222, 224, 226, and 228; and a connecting member 230. The
upper 212 can be coupled to any number or combination of outsole
sections, footbed sections, the connecting member 230, or a
combination thereof. Although four outsole sections and four
footbed sections are illustrated in FIG. 2; in embodiments, the
footwear product 200 may include fewer than, or more than, four of
each of these sections. In some embodiments, each outsole section
may correspond to a footbed section, while in other embodiments,
there may be a different number of footbed sections compared to
outsole sections. For example, in embodiments, a sole assembly may
include a number of outsole sections and one footbed section.
[0056] According to embodiments of the invention, as illustrated in
FIG. 2, a first portion 232 of the bottom surface 233 of the
connecting member 230 is disposed on at least a first portion 234
of a first surface 235 of a first outsole section 214; a second
portion 236 of the bottom surface 233 of the connecting member 230
is disposed on at least a first portion 238 of a first surface 239
of a second outsole section 216; a third portion 240 of the
connecting member 230 extends between the first and second outsole
sections 214 and 216. Similar arrangements, as shown, can be
constructed with respect to the other outsole sections.
[0057] As is further illustrated in FIG. 2, a first footbed section
222 is disposed on a first portion 242 of the top surface 243 of
the connecting member 230 such that a bottom surface 245 of the
first footbed section 222 interfaces with the first portion 242 of
the top surface 243 of the connecting member 230; a second footbed
section 224 is disposed on a second portion 244 of the top surface
243 of the connecting member 230 such that a bottom surface 247
interfaces with the second portion 244 of the top surface 243 of
the connecting member 230. In embodiments, a wearer's foot (not
shown) rests on a top surface 249 of each footbed portion.
[0058] In embodiments, as shown in FIG. 2, an outsole portion 218
can include one or more lips 250. For example, outsole section 250
includes a pair of opposed lips 250 that are substantially parallel
to one another. Each lip 250 includes an inner surface 252 oriented
at an angle with respect to a first surface 253; an outer surface
254 that is opposed to the inner surface 252; a top surface 256, a
forward surface 258, and a rear surface 260. In embodiments, any
one or more of the surfaces of a lip 250 can be integral with one
or more other surfaces of the outsole portion 218. Additionally, in
embodiments, a lip 250 may have continuous, rounded surfaces,
angled interfaces between surfaces, beveled edges, or the like. As
shown in FIG. 2, in some embodiments, a forefoot outsole section
214 and a heel outsole section 220 may include a continuous lip 262
extending around a portion of the periphery of the section,
including the front of the section and the rear of the section,
respectively. In embodiments, a connecting member and/or a footbed
portion can be configured to be disposed between lips 250 of an
outsole section. In other embodiments, a footbed portion may not
include lips and a connecting member and/or a footbed portion may
be configured to be disposed on top of the outsole section.
[0059] In embodiments, the outsole-interfacing portions 232, 236,
282, and 285 of the connecting member 230 can be joined with the
connecting-member interfacing portions 234, 238, 283, and 286 of
the outsole portions 214, 216, 218, and 220, in any number of
manners. For example, in embodiments, the interfacing portions can
be adhered to each other using an adhesive (e.g., glue, tape),
integrated with one another, fastened to one another (e.g., using a
hook-and-loop fastening mechanism, stitches), or the like.
Additionally, in embodiments, portions of the connecting member 230
can be coupled (e.g., adhered, fastened) to one or more of the lips
250 disposed on the outsole portions.
[0060] In embodiments of a method of constructing the footwear
product 200, the first footbed section 222 can be disposed on a
first portion 242 of the top surface 243 of the connecting member;
the second footbed section 224 can be disposed on a second portion
244 of the top surface 243 of the connecting member 230; the third
footbed section 226 can be disposed on a third portion 290 of the
top surface 243 of the connecting member 230; and the fourth
footbed portion 228 can be disposed on a fourth portion 292 of the
top surface 243 of the connecting member 230. In embodiments, the
footbed portions can be adhered to the connecting member, fastened
to the connecting member, or the like. According to embodiments,
various portions of the footwear product 200 can be adhered to
other portions using techniques such as, for example, welding,
fusing, taping, clipping, and the like.
[0061] In embodiments of the illustrative method, the upper 212 is
coupled to the sole assembly 210 by passing the toepost 280 through
the set of apertures 270, 272, and 274 such that the anchor 294 of
the toepost 280 engages at least a portion of the bottom surface
278 of the first outsole section 214. Each strap 296 of the upper
212 can be coupled, for example, to the third footbed portion 226,
the third outsole portion 218, the connecting member 230, or a
combination of the above. In embodiments, an end 298 of each strap
296 can be disposed between a lip 250 of the third outsole section
218 and an outside edge 299 of the third footbed portion 226. Any
number of other manners of coupling the upper 212 to the sole
assembly 210 can be implemented.
[0062] In the embodiment illustrated in FIG. 2, the footwear
product 200 can be assembled by performing any number of different
steps, in any number of different orders. One illustrative method
of assembling the footwear product 200 includes creating a number
of outsole sections 214, 216, 218, and 220. The illustrative method
also includes creating a number of footbed sections 222, 224, 226,
and 228. In embodiments, the outsole sections and/or the footbed
sections may be molded from a foam material such as ethylene vinyl
acetate (EVA). For instance, in embodiments, to form sections of a
sole assembly, liquid EVA may be injected into two pieces of a
clamshell-type mold. An example of such a molding process is
described in U.S. Pat. No. 6,439,536 to Piccolo, which is
incorporated herein by reference. In other embodiments, various
sections of the sole assembly may be molded from rubber, while, in
other embodiments, different portions of the sole assembly may be
constructed using different materials.
[0063] A connecting member 230 is also created. In embodiments, the
connecting member 230 can be constructed using an elastomeric or
nonelastomeric textile material, a thermoplastic elastomer (TPE)
material (e.g., thermoplastic polyurethanes (TPUs), styrenic block
copolymers), a rubber material, or the like. The illustrative
method also includes creating an upper 212. In embodiments, the
upper 212 is molded from a foam material such as EVA. In other
embodiments, the upper 212 is constructed using a TPE material,
nylon, or other textile material.
[0064] To assemble the sandal illustrated in FIG. 2, corresponding
apertures 270, 272, and 274 are formed through the first outsole
portion 214, the first footbed portion 222, and the connecting
member 230, respectively. The apertures 270, 272, and 274 are
formed such that, when the sandal 200 is assembled, the apertures
270, 272, and 274 line up to form a continuous passage through from
the top surface 276 of the first footbed section 222 to the bottom
surface 278 of the first outsole section 214 for receiving the
toepost 280 of the upper 212. In embodiments in which the footwear
product is not a sandal such as, for example, where the footwear
product is a shoe, a boot, a clog, or the like, an aperture may not
be necessary as the upper may include a larger foot-covering that
can be coupled to the sole assembly 210 without using a
toepost.
[0065] In embodiments of the illustrative method, the outsole
sections 214, 216, 218, and 220 are arranged such that the first
outsole section 214 is adjacent to the second outsole section 216,
the second outsole section 216 is adjacent to the third outsole
section 218, and the third outsole section 218 is adjacent to the
fourth outsole section 220. The connecting member 230 is positioned
such that a first portion 232 of the bottom surface 233 of the
connecting member 230 is disposed on at least a first portion 234
of a first surface 235 of a first outsole section 214; a second
portion 236 of the bottom surface 233 of the connecting member 230
is disposed on at least a first portion 238 of a first surface 239
of a second outsole section 216; a third portion 240 of the
connecting member 230 extends between the first and second outsole
sections 214 and 216; a fourth portion 282 of the bottom surface
233 of the connecting member 230 is disposed on at least a first
portion 283 of the first surface 253 of the third outsole section
218; a fifth portion 284 of the connecting member 230 extends
between the second outsole section 216 and the third outsole
section 218; a sixth portion 285 of the bottom surface 233 of the
connecting member 230 is disposed on at least a first portion 286
of a first surface 287 of the fourth outsole section 220; and a
seventh portion 288 of the connecting member 230 extends between
the third outsole section 218 and the fourth outsole section
220.
[0066] FIGS. 3A and 3B show a shoe 300 having an at least partially
flexible construction in accordance with embodiments of the
invention. As illustrated, the shoe 300 includes a sole assembly
310 and an upper 312 that is coupled to the sole assembly 310. In
embodiments, the upper 312 can be coupled to the sole assembly 310
using stitching, adhesive, or the like. In embodiments, for
example, the sole assembly 310 may be constructed similar to the
sole assembly 210 described in relation to FIG. 2. The sole
assembly 310 includes sole sections 314, 316, 318, and 320. Each
sole section may include an outsole section 322 and a footbed
section 324. A connecting member 326 extends between each adjacent
sole section. In embodiments, the shoe 300 can include a single
footbed section 324 or a number of footbed sections 324. In
embodiments, an insole (not shown) can be disposed on or over the
footbed sections 324. Additionally, in embodiments, the upper 310
can be constructed using an elastic canvas, leather, or any number
of other different types of material and can be configured to cover
a portion of a wearer's foot (not shown) or the entire foot.
[0067] FIGS. 5A-5D show a shoe 500 having an at least partially
flexible construction in accordance with embodiments of the
invention. The shoe 500 includes a sole assembly 510 and an upper
512, which is coupled to the sole assembly 510. The upper 512
includes an elastic member 514 that can enhance the stretchability
of the upper 512. The elastic member 514 may stretch across the
entire upper 512 or a portion of the upper 512. In embodiments, the
upper 512 may include a number of elastic members 514. In
embodiments, the upper 512 can be connected to the sole assembly
510 using any number of different techniques. In embodiments, for
example, the upper 512 is coupled to a number of outsole sections
516, 518, 520, and 522 using a stitch and turn elastic.
[0068] In embodiments, the shoe 500 can be configured to be
flexible and/or stretchable along any number of different axes, in
any number of different directions, and in any number of different
amounts. For example, in embodiments, an elastomeric connecting
member can be used to connect the sole sections 516, 518, 520, and
522 such that the sole assembly 510 (and thus, in embodiments, the
shoe 500) is stretchable longitudinally along a first axis 520.
Additionally, the shoe 500 can be flexible along the first axis
520, as shown in FIG. 5D. In embodiments, elastic members 514 can
be used to facilitate flexibility and/or stretchability of the shoe
500 along or about a second axis 522. Additionally, in embodiments,
the shoe 500 can be stretchable and/or flexible along any number of
different axes. According to some embodiments of the present
invention, all of the materials of the upper 512 and lining (in
addition to elastic member 514) are flexible and/or stretchable in
order to improve stretchability of the overall shoe.
[0069] FIGS. 6-8 illustrate footwear 60 which includes multiple
outsole segments 61, 62, 63, 64, 65, and 66. The segments 61-66,
which may also be referred to as sections, are completely
independent of each other (e.g. are separate, distinct pieces),
except for one or more bands 67, 68 which run through one or more
holes 670 formed longitudinally through each segment, according to
embodiments of the present invention. The bands 67, 68 provide
enough compression to keep the segments 61-66 together in a manner
resembling a normal outsole during use by a wearer, while also
permitting the segments to bend and flex with respect to each other
during use. For example, FIG. 7 illustrates the footwear 60 being
twisted about its longitudinal axis, whereas FIG. 8 illustrates the
footwear 60 being bent along a transverse axis, according to
embodiments of the present invention.
[0070] The footwear 60 may also include one or more separators 690
between two or more adjacent segments 61, 62. Separators 690 may be
placed over or around bands 67, 68 in order to keep them in place,
and may further enhance the range of motion in flexibility of
adjacent segments by providing a small degree of separation as well
as a natural pivot location, according to embodiments of the
present invention. As shown in FIGS. 6-8, various vamp or footwear
upper features may be attached to one or more of the segments
61-66, in order to permit the outsole formed by the segments 61-66
to serve as the outsole of a piece of footwear. For example, a toe
bar 610 may be attached to segment 61, and one or more straps
attached to segment 65, which permits the footwear 60 to be worn as
a flip flop type sandal, according to embodiments of the present
invention.
[0071] FIGS. 9 and 10 illustrate an alternative outsole 90,
according to embodiments of the present invention. Outsole 90
includes two or more segments 94, which are completely independent
of each other except for one or more cords or bands 91, 92
extending through longitudinal holes formed in the segments 94.
While FIGS. 6-10 illustrate two bands extending through each
segment, with one band on each side of a longitudinal centerline of
the outsoles 60, 90, one of ordinary skill in the art will
appreciate that fewer than two or more than two bands or cords may
be used to connect the segments. For example, a single band may be
used to connect the segments, and may extend at or to either side
of a longitudinal centerline of the outsole, according to
embodiments of the present invention. A single band may also be
inserted through each of the segments in one direction, and then
looped back around and extended through each of the segments along
the other direction. Such a band assembly may be tied with knots or
other connectors at one end to prevent the ends of the bands (e.g.
ends 910, 920 of FIG. 9) from slipping back through the holes in
end segment, and may be looped at the other end of the outsole to
prevent the band from slipping back through the holes in such other
end. According to other embodiments of the present invention, the
band or cord may be a loop, for example a continuous loop like a
rubber band, around which the sole segments have been molded or
otherwise attached.
[0072] The band 67, 68, or 91, 92, may be an elastic band which
permits the outsole segments to flex or move with respect to each
other in three different modes: pulling apart (e.g. FIG. 10),
twisting longitudinally (e.g. FIG. 7), and bending/curling/rolling
(e.g. FIG. 8). When such flexional positions are released, the
elasticity of the connecting band 67, 68 or 91, 92 as well as the
compression force imparted by its elasticity, may cause the
segments to be pulled back together in the configuration of a
traditional outsole, as shown in FIG. 6. According to some
embodiments of the present invention, the bands 67, 68 extend
through holes in each segment 61-66, or 94, but are not otherwise
attached to each segment, such that the entire outsole may be
pulled apart as shown in FIG. 10. According to other embodiments
(not shown), the bands 67, 68 or 91, 92 are connected or attached
to segments at locations other than the end segments (e.g. 61 and
66 in FIG. 6); for example, being knotted between every two or
every three or four or five segments. FIGS. 9 and 10 illustrate
thirteen segments 94, each with a first hole through which band 91
extends and each with a second hole through which band 92 extends,
and the only point of connection of the bands 91, 92 to the outsole
90 is at loop 95 and knots 960, 961. Otherwise, the segments 94 are
each capable of sliding along the bands 91, 92. This arrangement
permits a wide range of flexibility that more closely reflects
natural flexibility of a user's foot. The edges 96 formed by the
transverse gaps between the segments 94 may be beveled or otherwise
shaped with a lower profile in order to increase the range of
flexibility between adjacent segments 94, and/or to minimize
potential pinching of the foot between adjacent segments 94 during
use, according to embodiments of the present invention.
[0073] As shown in FIGS. 6-8, two or more adjacent segments may
have top surfaces that include a footbed pattern which aligns when
the segments (e.g. 61 and 62) are in their resting position (e.g.
FIG. 6). Two or more adjacent segments may also have bottom surface
that include a tread pattern (see FIG. 8) which aligns when the
segments (e.g. 61 and 62) are in their resting position (e.g. FIG.
6). As seen in FIG. 6, the footbed pattern of raised bumps is
visually continuous across multiple segments 61-66 when the
segments 61-66 are brought together via the default compression of
the bands 67, 68, according to embodiments of the present
invention. Also, as shown in FIG. 6 and FIG. 9, in the resting
position (unflexed or "flat" position), the lateral (right side of
FIG. 6) and medial (left side of FIG. 6) outer perimeter of the
overall outsole is substantially continuously curved, such that the
outer perimeter(s) of each segment 61-66 and 94 add up to form the
overall continuous curvature in the shape of a foot, according to
embodiments of the present invention.
[0074] Although some embodiments of the present invention are
described as outsoles, such embodiments may alternatively be used
as insoles, and/or used in combination with corresponding outsoles.
For example, the outsole 90 of FIG. 9 may form the outsole 90 of a
shoe, and one or more layers of fabric or other material may
separate the user's foot from the outsole 90. Above such layer or
layers, an insole similar to outsole 90 may be placed for contact
with or in proximity with a user's foot. The shape and positioning
of each segment of such insole may correspond with the shape and
positioning of each segment of the outsole 90, such that each
segment of both outsole and insole above and below the middle
layers operate in unison to permit flexing of the entire sole at
the breaks between adjacent segments, with such breaks being
substantially vertically aligned. Embodiments of the present
invention may also be used as an insole only, in some
situations.
[0075] Although the break lines between adjacent segments 61-66, 94
are shown in FIGS. 6 and 9 as being substantially lateral, in other
words substantially perpendicular to a longitudinal centerline of
the outsole, one of ordinary skill in the art will appreciate,
based on the present disclosure, that such break lines may be
formed at an angle with respect to the longitudinal centerline.
Break lines between different sets of segments 61-66, 94 may also
be formed at different angles with respect to each other. Also,
instead of being substantially linear, such break lines may be
formed in non-linear or curved shapes or patterns, thus permitting
flexibility of the outsole 60, 90 about varying and differing
directions, according to embodiments of the present invention.
[0076] FIG. 11 illustrates a bottom view of a shoe 70 and insole
80, according to embodiments of the present invention. FIG. 12
illustrates a top view of the shoe 70 and insole 80 of FIG. 11,
according to embodiments of the present invention. Shoe 70 is
similar to shoe 500, according to embodiments of the present
invention. Shoe 70 includes various sole segments 71 which are
independent segments having breaks or gaps 72 between them. The
segments 71 may be adhered or otherwise attached to the upper 74,
but may be otherwise free to flex at the breaks 72 or boundaries
between each segment 71. In addition, a cord, such as an elastic
cord or band as described with respect to FIGS. 6-10, may be placed
longitudinally along or between two or more adjacent segments,
according to embodiments of the present invention. Such a band may
be placed in channels 130 in the top side of each segment 71 or
120, as shown in FIG. 14. The band may provide additional
compression force to resist bending of the outsole 70, and/or to
customize the bending resistance among the segments 71, according
to embodiments of the present invention. The insole 80 may be made
of a similar material as the outsole 70, or may be made of a softer
material for greater footbed comfort, according to embodiments of
the present invention. According to some embodiments of the present
invention, the insole 80 is loose (e.g. not adhered) with respect
to the shoe 70, and may simply be inserted into opening 73 such
that it becomes the footbed of the shoe 70 to receive the user's
foot. The insole 80 may include flexure lines 82 (e.g. grooves or
gaps) that correspond in location to one or more of the breaks 72
when the insole 80 is placed into the shoe 70. For example, one or
more of the breaks 82 in the outsole 80 may each be configured to
be located directly above a corresponding break 72 in the outsole
of shoe 70, according to embodiments of the present invention.
[0077] FIG. 13 illustrates a bottom view of an alternative outsole
77, according to embodiments of the present invention. FIG. 14
illustrates a cross sectional view of the alternative outsole 77
taken along line A-A of FIG. 13, according to embodiments of the
present invention. The outsole 77 includes one or more segments 120
(for example, the two adjacent segments 120 located in a foot arch
or midfoot location) that each have a groove 121 which extends from
the bottom surface upwardly into the outsole 77, for example
halfway or just over halfway between the bottom and top surfaces of
the outsole 77, according to embodiments of the present invention.
According to some embodiments, groove 121 extends substantially
longitudinally along the two segments 120, but not to additional
adjacent segments.
[0078] The present invention has been described in relation to
particular embodiments, which are intended in all respects to be
illustrative rather than restrictive. Alternative embodiments will
become apparent to those of ordinary skill in the art to which the
present invention pertains without departing from its scope. It
will be understood that certain features and subcombinations are of
utility and may be employed without reference to other features and
subcombinations. This is contemplated by and is within the scope of
the claims.
* * * * *