U.S. patent application number 14/095367 was filed with the patent office on 2015-06-04 for article of footwear.
The applicant listed for this patent is NIKE, Inc.. Invention is credited to Nathan Van Hook.
Application Number | 20150150339 14/095367 |
Document ID | / |
Family ID | 52130855 |
Filed Date | 2015-06-04 |
United States Patent
Application |
20150150339 |
Kind Code |
A1 |
Van Hook; Nathan |
June 4, 2015 |
Article of Footwear
Abstract
An article of footwear may include a polymer foam shell. The
shell may include a midsole zone and an upper zone. An interior
region of the shell may be defined by interior surfaces of the
midsole zone and by interior surfaces of the upper zone. The
article may further include a polymer foam inner midsole that is
separate from and contained within the shell.
Inventors: |
Van Hook; Nathan;
(Beaverton, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
|
|
Family ID: |
52130855 |
Appl. No.: |
14/095367 |
Filed: |
December 3, 2013 |
Current U.S.
Class: |
36/84 |
Current CPC
Class: |
A43B 9/00 20130101; A43B
23/06 20130101; A43B 23/028 20130101; A43B 13/187 20130101; A43B
1/0018 20130101; A43B 7/12 20130101 |
International
Class: |
A43B 13/18 20060101
A43B013/18; A43B 23/02 20060101 A43B023/02 |
Claims
1. An article of footwear, comprising: a polymer foam shell having
a midsole zone and an upper zone, the shell having an interior
region defined by interior surfaces of the midsole zone and by
interior surfaces of the upper zone; and a polymer foam inner
midsole separate from and contained within the shell.
2. The article of footwear of claim 1, wherein the midsole zone and
the upper zone are portions of a unitary polymer foam boot
structure.
3. The article of footwear of claim 1, further comprising an
outsole located on at least a bottom of the midsole zone.
4. The article of footwear of claim 1, wherein the upper zone
includes a toe section extending across and in front of a forefoot
region to form, in conjunction with a corresponding portion of the
midsole zone, an enclosed toe box.
5. The article of footwear of claim 4, wherein the upper zone
includes medial and lateral side sections, the medial and lateral
side sections extend rearward from the toe section and merge in a
heel region, the medial side section extends upward from medial
side edges of the midsole zone to medial edges of an instep gap and
of an ankle opening, and the lateral side section extends upward
from lateral side edges of the midsole zone to lateral edges of the
instep gap and of the ankle opening.
6. The article of footwear of claim 5, further comprising a
plurality of billows defined in exterior surfaces of the upper
zone.
7. The article of footwear of claim 6, wherein the billows include
longitudinally oriented segments on the medial and lateral side
sections and transversely oriented segments on the toe section.
8. The article of footwear of claim 7, wherein the billows extend
continuously around the upper zone.
9. The article of footwear of claim 1, wherein a density of the
shell polymer foam is at least 25% greater than a density of the
inner midsole polymer foam.
10. The article of footwear of claim 1, further comprising a bootie
located within the shell, wherein the inner midsole is located
within the bootie.
11. The article of footwear of claim 10, wherein the inner midsole
extends substantially the entire length and width of a bottom of an
interior of the shell, the inner midsole includes heel, midfoot and
forefoot sections, a thickness of the heel section is greater than
a thickness of the forefoot section.
12. The article of footwear of claim 11, wherein a medial side of
the inner midsole midfoot section includes a raised arch region
support.
13. The article of footwear of claim 1, wherein the shell includes
a single main opening, the single main opening having a rear
portion forming an ankle opening and a front portion forming an
instep gap, the article further comprises comprising a tongue
spanning the instep gap and forming at least a portion of a
waterproof barrier in the instep gap, and the shell lacks any
openings in regions below the waterproof barrier.
14. An article of footwear, comprising: a polymer foam shell having
a midsole zone and an upper zone, the shell having an interior
region defined by interior surfaces of the midsole zone and by
interior surfaces of the upper zone, and wherein the shell includes
a single main opening, the single main opening having a rear
portion forming an ankle opening and a front portion forming an
instep gap, the article further comprises comprising a tongue
spanning the instep gap and forming at least a portion of a
waterproof barrier in the instep gap, and the shell lacks any
openings in regions below the waterproof barrier.
15. The article of footwear of claim 14, wherein the upper zone
includes a toe section, a medial side section and lateral side
section, the medial and lateral side sections extend rearward from
the toe section and merge in a heel region, the medial side section
extends upward from medial side edges of the midsole zone to medial
edges of the instep gap and of the ankle opening, the lateral side
section extends upward from lateral side edges of the midsole zone
to lateral edges of the instep gap and of the ankle opening, and
the shell further comprises a plurality of billows defined in
exterior surfaces of the upper zone.
16. The article of footwear of claim 15, wherein the billows
include longitudinally oriented segments on the medial and lateral
side sections and transversely oriented segments on the toe
section.
17. The article of footwear of claim 14, further comprising an
outsole located on at least a bottom of the midsole zone.
18. An article of footwear, comprising: a polymer foam shell having
a midsole zone and an upper zone, the shell having an interior
region defined by interior surfaces of the midsole zone and by
interior surfaces of the upper zone, and wherein the midsole zone
and the upper zone are portions of a unitary polymer foam boot
structure, and the upper zone includes a toe section extending
across and in front of a forefoot region to form, in conjunction
with a corresponding portion of the midsole zone, an enclosed toe
box.
19. The article of footwear of claim 18, wherein the upper zone
includes a medial side section and a lateral side section, the
medial and lateral side sections extend rearward from the toe
section and merge in a heel region, the medial side section extends
upward from medial side edges of the midsole zone to medial edges
of an instep gap and of an ankle opening, the lateral side section
extends upward from lateral side edges of the midsole zone to
lateral edges of the instep gap and of the ankle opening, and the
shell further comprises a plurality of billows defined in exterior
surfaces of the upper zone.
20. The article of footwear of claim 19, wherein the billows
include longitudinally oriented segments on the medial and lateral
side sections and transversely oriented segments on the toe
section.
21. The article of footwear of claim 18, further comprising an
outsole located on at least a bottom of the midsole zone.
22. An article of footwear, comprising: a polymer foam shell having
a midsole zone and an upper zone, the shell having an interior
region defined by interior surfaces of the midsole zone and by
interior surfaces of the upper zone, and wherein the upper zone
includes a toe section, a medial side section and lateral side
section, the medial and lateral side sections extend rearward from
the toe section and merge in a heel region, the medial side section
extends upward from medial side edges of the midsole zone to medial
edges of an instep gap and of an ankle opening, the lateral side
section extends upward from lateral side edges of the midsole zone
to lateral edges of the instep gap and of the ankle opening, and
the shell further comprises a plurality of billows defined in
exterior surfaces of the upper zone.
23. The article of footwear of claim 22, wherein the billows
include longitudinally oriented segments on the medial and lateral
side sections and transversely oriented segments on the toe
section.
24. The article of footwear of claim 22, wherein the midsole zone
and the upper zone are portions of a unitary polymer foam boot
structure, and the toe section forms, in conjunction with a
corresponding portion of the midsole zone, an enclosed toe box.
25. The article of footwear of claim 22, wherein the shell includes
a single main opening, the single main opening having a rear
portion forming the ankle opening and a front portion forming the
instep gap, the article further comprises comprising a tongue
spanning the instep gap and forming at least a portion of a
waterproof barrier in the instep gap, and the shell lacks any
openings in regions below the waterproof barrier.
Description
BACKGROUND
[0001] Conventional articles of footwear typically include two
primary elements, namely, an upper and a sole structure. The upper
may provide a covering for the foot that securely receives and
positions the foot with respect to the sole structure. In addition,
the upper may have a configuration that protects the foot. The sole
structure is secured to a bottom surface of the upper and generally
is positioned between the foot and a contact surface. In addition
to attenuating ground reaction forces and absorbing energy, the
sole structure may provide traction and control potentially harmful
foot motion, such as excessive pronation. The general features and
configurations of the upper and the sole structure are discussed in
greater detail below.
[0002] An upper typically forms a void on the interior of the
footwear for receiving the foot of a wearer. The void has the
general shape of the foot, and access to the void may be provided
at an ankle opening. The upper normally extends over the instep and
toe areas of the foot, along the medial and lateral sides of the
foot, and around the heel area of the foot. A lacing system often
is incorporated into the upper to selectively change the size of
the ankle opening and to permit the wearer to modify certain
dimensions of the upper, particularly girth, to accommodate feet
with varying proportions. In addition, an upper may include a
tongue that extends under the lacing system to enhance the comfort
of the footwear, e.g., to moderate pressure applied to the foot by
the laces.
[0003] A sole structure generally incorporates multiple layers that
are conventionally referred to as an insole, a midsole, and an
outsole. The insole (which also may constitute a sock liner) is a
thin member located within the upper and adjacent the plantar
(lower) surface of the foot to enhance footwear comfort, e.g., to
wick away moisture and provide a soft, comfortable feel. The
midsole, which is traditionally attached to the upper along the
entire length of the upper, forms the middle layer of the sole
structure and serves a variety of purposes that can include
controlling foot motions and attenuating impact forces. The outsole
forms a ground-contacting element of footwear and is usually
fashioned from a durable, wear-resistant material that may include
texturing or other features to improve traction.
[0004] The primary element of a conventional midsole is a
resilient, polymer foam material, such as polyurethane or
ethylvinylacetate ("EVA"), that extends throughout the length of
the footwear. The properties of the polymer foam material in a
midsole are primarily dependent upon factors that include the
dimensional configuration of the midsole and the specific
characteristics of the material selected for the polymer foam,
including the density of the polymer foam material. By varying
these factors throughout the midsole, the relative stiffness,
degree of ground reaction force attenuation, and energy absorption
properties may be altered to meet the specific demands of the
activity for which the footwear is intended to be used.
[0005] An ongoing need remains for improved footwear models and
improved footwear constructions.
SUMMARY
[0006] 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 invention.
[0007] In some embodiments, an article of footwear may include a
polymer foam shell. The shell may include a midsole zone and an
upper zone. An interior region of the shell may be defined by
interior surfaces of the midsole zone and by interior surfaces of
the upper zone. The article may further include a polymer foam
inner midsole that is separate from and contained within the
shell.
[0008] In at least some additional embodiments, an article of
footwear may include a polymer foam shell that includes a midsole
zone and an upper zone, and that further includes an interior
region defined by interior surfaces of the midsole zone and by
interior surfaces of the upper zone. The shell may further include
a single main opening, the single main opening having a rear
portion forming an ankle opening and a front portion forming an
instep gap. A tongue may span the instep gap and form at least a
portion of a waterproof barrier in the instep gap. The shell may
lack any openings in regions below the waterproof barrier in the
instep gap.
[0009] In at least some further embodiments, an article of footwear
may include a polymer foam shell that includes a midsole zone and
an upper zone, and that further includes an interior region defined
by interior surfaces of the midsole zone and by interior surfaces
of the upper zone. The upper zone may include a toe section, a
medial side section and a lateral side section, the medial and
lateral side sections extending rearward from the toe section and
merging in a heel region. The medial side section may extend upward
from medial side edges of the midsole zone to medial edges of an
instep gap and of an ankle opening. The lateral side section may
extend upward from lateral side edges of the midsole zone to
lateral edges of the instep gap and of the ankle opening. The shell
may further comprise a plurality of billows defined in exterior
surfaces of the upper zone.
[0010] Additional embodiments are described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Some embodiments are illustrated by way of example, and not
by way of limitation, in the figures of the accompanying drawings
and in which like reference numerals refer to similar elements.
[0012] FIG. 1A is a medial side view of an article of footwear
according to some embodiments.
[0013] FIG. 1B is a lateral side view of the article of footwear of
FIG. 1A.
[0014] FIG. 1C is a front top perspective view of the article of
footwear of FIG. 1A.
[0015] FIG. 1D is a rear view of the article of footwear of FIG.
1A.
[0016] FIG. 1E is a bottom view of the article of footwear of FIG.
1A.
[0017] FIG. 2 is a partially schematic area cross-sectional view
taken from the location indicated in FIG. 1A.
[0018] FIG. 3A is a medial side view of an internal midsole of the
article of footwear of FIG. 1A.
[0019] FIG. 3B is a lateral side view of an internal midsole of the
article of footwear of FIG. 1A.
DETAILED DESCRIPTION
[0020] In at least some embodiments, an article of footwear may
include a polymer foam shell that serves as an upper and as at
least part of a sole structure. In particular, the shell may have a
midsole zone and an upper zone. The midsole zone may be situated
between the article interior and the ground and may provide
cushioning and support to a wearer foot. The upper zone may extend
upward from midsole zone and, in combination with the midsole zone,
form a foot-receiving interior void of the article. The midsole and
upper zones may be integral parts of a unitary polymer foam boot
structure. More specifically, the shell may be a single piece of
polymer foam material having an interior void with a shape that
approximates a human foot. The midsole zone may constitute a bottom
portion of the shell and the upper zone may constitute a top
portion of the shell. In some embodiments the boot structure may be
an over-ankle or "high top" design configured to extend over a
wearer ankle. In other embodiments the boot structure may be a
below-ankle or "low top" design configured to not extend over a
wearer ankle. The article of footwear may further include an
outsole on a bottom of the midsole zone. That outsole and the
midsole zone may form an external portion of a sole structure for
the article.
[0021] In some embodiments, the article of footwear may further
include a separate internal midsole located within the shell. That
internal midsole and the external sole structure may form the
complete sole structure for the article. The internal midsole may
also be a polymer foam element. In at least some embodiments, the
polymer foam of the internal midsole is less dense than the polymer
foam of the shell. A full or partial foot contacting element, i.e.,
an internal "bootie," may also be located within the shell and may
serve as a full or partial lining. In some embodiments, the
internal midsole may be located within the bootie, while in other
embodiments the internal midsole may be situated between a bottom
of the bootie and a top of the midsole zone.
[0022] In some embodiments, an article of footwear such as is
described above is configured for use as a rain shoe or for wear in
other wet environments. In at least some such embodiments, the
shell may be formed of a polymer foam material through which water
will not penetrate, e.g., the polymer foam may be a closed cell
polymer foam. That shell may have a single main opening in the top
of the upper zone. A portion of that main opening may form an ankle
opening through which a wearer foot is inserted. Another portion of
that main opening may form an instep region gap. A tongue may span
the instep region gap and be attached to the shell with gussets at
or near interior edges of the instep region gap. The shell may lack
any additional openings below edges of a waterproof barrier formed
by (or that includes) the tongue. The tongue and gussets may be
formed from a material that is impenetrable by water. In other
embodiments in which an article of footwear is intended for use in
wet environments, the shell may have one or more ventilation
openings, with those ventilation openings covered by a material
that resists water penetration but that allows air flow. A tongue
may similarly be formed from a breathable material that resists
water penetration.
[0023] These and other embodiments are described in more detail
below. To assist and clarify subsequent description of various
embodiments, various terms are defined herein. Unless context
indicates otherwise, the following definitions apply throughout
this specification (including the claims). "Shoe" and "article of
footwear" are used interchangeably to refer to articles intended
for wear on a human foot. A shoe may or may not enclose the entire
foot of a wearer. For example, a shoe could include a sandal or
other article that exposes large portions of a wearing foot. The
"interior" of a shoe refers to space that is occupied by a wearer's
foot when the shoe is worn. An interior side, surface, face or
other aspect of a shoe element refers to a side, surface, face or
other aspect of that element that is (or will be) oriented toward
the shoe interior in a completed shoe. An exterior side, surface,
face or other aspect of an element refers to a side, surface, face
or other aspect of that element that is (or will be) oriented away
from the shoe interior in the completed shoe. In some cases, the
interior side, surface, face or other aspect of an element may have
other elements between that interior side, surface, face or other
aspect and the interior in the completed shoe. Similarly, an
exterior side, surface, face or other aspect of an element may have
other elements between that exterior side, surface, face or other
aspect and the space external to the completed shoe.
[0024] Unless the context indicates otherwise, "top," "bottom,"
"over," "under," "above," "below," and similar locational terms
assume that a shoe or shoe structure of interest is in the
orientation that would result if the shoe (or shoe incorporating
the shoe structure of interest) is in an undeformed condition with
its outsole (and/or other ground-contacting sole structure
element(s)) resting on a flat horizontal surface. Unless the
context requires otherwise, however, the term "upper" is reserved
for use in describing the portion of a shoe that at least partially
covers the sides and top of a wearer foot and that helps to secure
the wearer foot to a shoe sole structure.
[0025] Elements of a shoe can be described based on regions and/or
anatomical structures of a human foot wearing that shoe, and by
assuming that shoe is properly sized for the wearing foot. As an
example, a forefoot region of a foot includes the metatarsal and
phalangeal bones. A forefoot element of a shoe is an element having
one or more portions located over, under, to the lateral and/or
medial sides of, and/or in front of a wearer's forefoot (or portion
thereof) when the shoe is worn. As another example, a midfoot
region of a foot includes the cuboid, navicular, medial cuneiform,
intermediate cuneiform and lateral cuneiform bones and the heads of
the metatarsal bones. A midfoot element of a shoe is an element
having one or more portions located over, under and/or to the
lateral and/or medial sides of a wearer's midfoot (or portion
thereof) when the shoe is worn. As a further example, a heel region
of a foot includes the talus and calcaneus bones. A heel element of
a shoe is an element having one or more portions located over,
under, to the lateral and/or medial sides of, and/or behind a
wearer's heel (or portion thereof) when the shoe is worn. The
forefoot region may overlap with the midfoot region, as may the
midfoot and heel regions.
[0026] Unless indicated otherwise, a longitudinal axis refers to a
horizontal heel-toe axis along the center of a shoe and that is
roughly parallel to a line that would follow along the second
metatarsal and second phalanges of a wearer foot. A transverse axis
refers to a horizontal axis across a shoe that is generally
perpendicular to a longitudinal axis. A longitudinal direction is
parallel (or roughly parallel) to a longitudinal axis. A transverse
direction is parallel (or roughly parallel) to a transverse
axis.
[0027] FIG. 1A is a medial side view of a shoe 100 according to
some embodiments. As can be appreciated from FIG. 1A, shoe 100 is a
right foot shoe. Shoe 100 is part of a pair that includes a left
foot shoe (not shown) that is a mirror image of shoe 100. FIG. 1B
is a lateral side view of shoe 100. FIG. 1C is a front top
perspective view of shoe 100. FIG. 1D is a rear view of shoe 100.
FIG. 1E is a bottom view of shoe 100.
[0028] Components of shoe 100 visible in FIGS. 1A-1E include a
shell 101, an outsole 102 and a bootie 103. Although not visible in
FIGS. 1A-1E, shoe 100 further includes an internal midsole 201.
Bootie 103 and internal midsole 201 are further described below in
connection with subsequent drawing figures.
[0029] In the embodiment of shoe 100 and in at least some other
embodiments, shell 101 is a unitary polymer foam boot structure.
More specifically, shell 101 is a single piece of polymer foam
material having an interior void with a shape that approximates a
human foot. The bottom of shell 101 is closed and provides a layer
of the shell polymer foam between the bottom of a wearer foot and
the ground or other contact surface. The top of shell 101 wraps
around the sides, rear and top forefoot regions of a wearer foot. A
separate outsole 102, discussed more fully below, is located on the
bottom of shell 101 and in the front of shell 101.
[0030] Shell 101 includes a single main opening 105. A rear portion
of main opening 105 forms an ankle opening 106 (FIGS. 1A and 1B).
Ankle opening 106 provides the opening through which a wearer foot
may be inserted so as to don shoe 100. A front portion of main
opening 105 forms an instep gap 107. Similar to conventional shoes,
instep gap 107 provides a means by which the size of shoe 100 can
be adjusted to accommodate variations in wearer foot width and/or
thickness of a sock worn by a wearer. A tongue 108 spans instep gap
107. In the embodiment of shoe 100, a front exterior part of tongue
108 is attached to the interior of shell 101 forward of a front
edge 120 of instep gap 107. Gussets, not shown, attach medial and
lateral sides of tongue 108 to the interior of shell 101 below
medial and lateral edges of instep gap 107. A lace 110 passes
through lace holes 111 in shell 101 near edges of a front part of
gap 107 and through separately attached eyelets 112 near edges of a
rear part of gap 107. Lace 108 can be cinched so as to secure shoe
100 to a wearer foot.
[0031] Shell 101 acts as both an upper and as a midsole of shoe
100. Similar to a conventional midsole, a bottom portion of shell
101 provides a layer of foam to surround, support and cushion the
plantar (bottom) and edge regions of a wearer foot. Similar to a
conventional upper, a top portion of shell 101 covers and protects
the front, top forefoot, sides and rear of the wearer foot and
helps to secure the wearer foot relative to the bottom portion of
shell 101. For convenience, the bottom and top portions of shell
101 are referred to herein as the "midsole zone" and the "upper
zone" of shell 101.
[0032] A broken line L1 in FIGS. 1A, 1B and 1D indicates an
approximate boundary between upper zone 114 and midsole zone 115.
As indicated above, shell 101 is a single piece of polymer foam
material. Upper zone 114 and midsole zone 115 merge seamlessly with
each other. Accordingly, line L1 is not intended to not represent a
seam or other discontinuity between upper zone 114 and midsole zone
115. Instead, line L1 merely indicates the approximate location of
where the shell 101 polymer foam transitions from being a part of a
shoe 100 sole structure to being a part of the shoe 100 upper. The
location of a boundary between a midsole zone and an upper zone may
vary in different embodiments.
[0033] A reinforcement strip 116 surrounds the exterior edge of
main opening 105. Strip 116 may be cut or otherwise formed from
synthetic leather, thermoplastic polyurethane (TPU), polyurethane
(PU), vinyl or other material and may be stitched and/or or
adhesively bonded and/or otherwise attached to shell 101. Strip 116
reinforces the edges of main opening 105 so as to help prevent
tearing of the shell 101 foam material as a result of tension in
lace 110 or abrasion of an exposed foam edge.
[0034] Upper zone 114 includes a medial side section 117 (FIGS. 1A
and 1D), a lateral side section 118 (FIGS. 1B and 1D) and a toe
section 119 (FIGS. 1A through 1C). For convenience, and as
discussed below, FIGS. 1A through 1D includes broken lines L2, L3
and L4 to indicate approximate boundaries between these sections of
upper zone 114. Similar to line L1, however, none of lines L2, L3
or L4 is intended to represent a seam or other discontinuity. In
the embodiment of shoe 100 and in at least some other embodiments,
toe section 119, medial side section 117 and lateral side section
118 merge seamlessly with one another. Locations of boundaries
between sections of a shell upper zone may vary in different
embodiments.
[0035] Toe section 119 is the portion of upper zone 114 forward of
lines L2 and L3. Toe section 119 extends across and in front of the
frontmost portion of the forefoot region and forms the frontmost
section of upper zone 114. Toe section 119 merges with and extends
upward from the sides and front of a corresponding frontmost
forefoot region of midsole zone 115. In the embodiment of shoe 100,
toe section 119 extends forward from the front edge 120 of gap 107
(FIG. 1C). Toe section 119 approximately corresponds to the region
of a wearer foot forward of the metatarsal-phalangeal joints. When
shoe 100 is worn, a toe box formed by toe section 119 and the
frontmost forefoot region of midsole zone 115 completely surrounds
the top, sides, bottom and front of that corresponding wearer foot
region.
[0036] In the vertical direction, and as seen in FIGS. 1A and 1D,
medial side section 117 extends upward from medial side edge and
medial rear edge portions of midsole zone 115 to medial side edge
and medial rear edge portions of main opening 105. In the
horizontal direction, medial side section 117 extends from toe
section 119 to lateral section 118 at the center of the rear of
shell 101. Line L2 (FIG. 1A) indicates an approximate boundary
between toe section 119 and medial side section 117. Line L4 (FIG.
1D) indicates an approximate boundary between medial side section
117 and lateral side section 118.
[0037] As seen in FIGS. 1B and 1D, lateral side section 118 extends
vertically from the lateral side edge and lateral rear edge
portions of midsole zone 115 to lateral side edge and lateral rear
edge portions of main opening 105. In the horizontal direction,
lateral side section 118 extends from toe section 119 to medial
section 117 at the center of the rear of shell 101. Line L3 (FIG.
1B) indicates an approximate boundary between toe section 119 and
lateral side section 118.
[0038] As seen in FIGS. 1A, 1B and 1D, shell 101 is a "high top"
boot structure in which upper zone 114 is sized to extend over the
ankle of a wearer. When worn, an edge of ankle opening 106 is
positioned above the wearer's medial and lateral malleoli at peaks
121 (FIG. 1A) and 122 (FIG. 1B). Other embodiments include shells
in which a boot structure is a "low top." Stated differently, in
some embodiments a shell boot structure includes an upper zone that
does not extend over a wearer's ankle.
[0039] In at least some embodiments, upper zone 114 of shell 101
may have a billowed structure. Specifically, a plurality of billows
124 are formed in the exterior surfaces of upper zone 114. Billows
124 are peaks of ridges that are separated from one another so as
to define valleys 125. In the embodiment of shoe 100 billows 124
include longitudinally oriented segments on medial side section 117
and lateral side section 118, as well as transversely oriented
segments on toe section 119. Further, most of billows 124 and
valleys 125 extend continuously around upper zone 114. In the
embodiment of shoe 100, and as discussed in further detail below in
connection with FIG. 2, billows are not formed on the interior
surfaces of upper zone 114.
[0040] The billowed structure of upper zone 114 increases
flexibility in the regions of valleys 125. For example, valleys 125
between billows 124 in toe section 119 reduce resistance of upper
zone 114 to dorsiflexion of a wearer foot. Valleys 125 between
billows 124 in ankle region portions of medial side section 117 and
lateral side section 118 reduce resistance of upper zone 114 in
response to medial or lateral tilting of a wearer ankle.
[0041] The billowed structure shown in FIGS. 1A-1D is merely
exemplary. There are innumerable additional embodiments in which an
upper zone may be functionally similar to upper zone 114 of shoe
100, but which may have a different visual appearance. For example,
the number and size of billows could be varied. The precise
arrangement of billows could also be varied. Shapes of billows
could also be varied. Billows need not extend continuously around
an entire upper component.
[0042] FIG. 1E shows additional details of outsole 102. In some
embodiments, and so as to provide increased resistance to abrasion
or other wear in ground contacting zones, at least some portions of
outsole 102 are formed from one or more materials different from
the polymer foam of shell 101. Examples of such other different
materials include, without limitation, synthetic and natural
rubbers, polymer foams having increased density or other
characteristics to enhance wear resistance, non-foamed TPU,
non-foamed PU and other non-foamed polymers. In the embodiment of
shoe 100, outsole 102 includes a perimeter 126 formed of a first
material and an inner region 127 formed by a second material. The
first material may be harder than the second region. The harder
first material provides increased wear resistance on the edges of
outsole 102. The softer second material of inner region 127
provides enhanced slip resistance.
[0043] As indicated above, shoe 100 according to some embodiments
is configured for wear in rain or other wet environments. So as to
increase traction in wet conditions, perimeter 126 of outsole 102
includes a plurality of lugs 128 separated by gaps 129. At least a
portion of lugs 128 also extend further downward than inner region
127. In this manner, gaps 129 provide channels for water to escape
from under outsole 102 when a wearer steps into standing water, and
thereby increase traction. A plurality of grooves 130 may also be
formed in inner region 127 to increase traction. The arrangement of
outsole 102 elements shown in FIG. 1E is also exemplary. There are
innumerable additional embodiments in which a sole structure may
include an outsole that is functionally similar to outsole 102 of
shoe 100, but which may have a different visual appearance. For
example, the number, size and arrangement of lugs and grooves could
be varied. The precise arrangement of a perimeter relative to an
inner region also be varied, as could other aspects of an
outsole.
[0044] As seen in FIGS. 1A through 1C, outsole 102 includes a
medial forefoot wing extension 131, a toe cap extension 132 and a
lateral forefoot wing extension 133. Medial forefoot wing 131
extends upward and around the medial edge of midsole zone 115 in a
location approximately corresponding to an end of a wearer first
metatarsal. Lateral forefoot wing 133 extends upward and around the
lateral edge of midsole zone 115 in a location approximately
corresponding to an end of a wearer fifth metatarsal. Wings 131 and
133 help provide additional support and stability in response to
sideways movements of a wearer. Toe cap 132 extends upward and
around the front of midsole zone 115. Toe cap 132 provides further
protection to the frontmost portion of shell 101 in response to
contact with external objects (e.g., kicked objects).
[0045] Midsole zone 115 and outsole 102 form the external sole
structure of shoe 100. This is further shown in FIG. 2, a partially
schematic area cross-sectional view taken from the location
indicated in FIG. 1A. Elements visible in FIG. 2 include shell 101,
outsole 102, bootie 103 and strip 116. The approximate locations of
upper zone 114 and midsole zone 115 are also indicated. An internal
midsole 201, also shown in FIG. 2, is discussed in further detail
below. For purposes of simplification and to avoid obscuring FIG. 2
with detail not needed to understand the relationship of shoe 100
elements, bootie 103 is represented in FIG. 2 as a solid line. For
similar reasons, FIG. 2 includes small spaces between elements that
may actually be in direct contact. In particular, some or all of
the exterior of bootie 103 may be in contact with interior surfaces
of shell 101. Similarly, some or all exterior surfaces of inner
midsole 201 may be in contact with interior faces of bootie
103.
[0046] Outsole 102 is located on the bottom side of the midsole
zone 115 exterior. As indicated above, and as seen more clearly in
FIG. 2, outsole 102 and shell 101 are separate elements in the
embodiment of shoe 100. If outsole 102 were removed, for example,
the foam material in midsole zone 115 of shell 101 would still
separate the plantar sides of bootie 102 and inner midsole 201 from
the ground. In some embodiments, outsole 102 does not cover the
entire bottom side of midsole zone 115. For example, and as seen in
FIG. 1E, a medial midfoot region 136 of midsole zone 115 is exposed
between front and rear lobes of outsole 102.
[0047] Returning to FIG. 2, midsole zone 115 includes an interior
base surface 202, an interior medial lower side surface 203 and an
interior lateral lower side surface 204. Interior base surface 202
extends the full length and width of the shell 101 interior. Medial
lower side surface 203 and lateral lower side surface 204 extend
the full length of the shell 101 interior to wrap around and meet
in the front and rear of the shell 101 interior. Base surface 202,
interior medial lower side surface 203 and interior lateral lower
side surface 204 define the bottom portion of the shell 101
interior.
[0048] The top portion of the shell 101 interior is defined by an
interior surface (not shown) of toe section 119, a medial side
section interior surface 205 and a lateral side section interior
surface 206. Medial side section interior surface 205 extends
vertically from medial lower side surface 203 to the edge of main
opening 105. Lateral side section interior surface 206 extends
vertically from lateral lower side surface 204 to the edge of main
opening 105. In the horizontal direction, medial side section
interior surface 205 and lateral side section interior surface 206
extend rearward from the interior surface of toe section 119,
around the rear of the shell 101 interior, and meet along an
interior line corresponding to line L4 of FIG. 1D. In the
embodiment of shoe 100, the interior surfaces of shell 101 are
smooth.
[0049] Inner midsole 201 is located inside bootie 103 and fits
snugly in the bottom of the shell 101 interior. Inner midsole 201
may also be a polymer foam element. Inner midsole 201 may be sized
and shaped to have an interior surface 207 that conforms to and
supports the entire plantar surface of a wearer foot. Edge surfaces
208 and 209 may be sized to conform to and support edges of a
wearer foot. In at least some embodiments, and as discussed in more
detail below, the polymer foam of inner midsole 201 may be softer
and/or less dense than the polymer foam of shell 101.
[0050] FIGS. 3A and 3B are respective medial and lateral side views
of inner midsole 201. So as to generally show the position of inner
midsole 201 within shoe 100, shell 101 is approximately indicated
with a broken line silhouette. Edge surfaces 208 and 209 may extend
the length of inner midsole 201 and around the rear of inner
midsole 201. In the rear, edge surfaces 208 and 209 meet and form a
heel cup 210. On the medial side, a midfoot portion of edge surface
208 is enlarged to be an arch support 211. Returning briefly to
FIG. 2, a thickness t of inner midsole 201 is shown. Thickness t in
one or more areas of the heel and/or midfoot regions of inner
midsole 201 may be greater than thickness t in one or more areas of
the inner midsole 201 forefoot region. In some embodiments, and as
partially seen in FIGS. 3A and 3B, base surface 207 and edge
surfaces 208 and 209 may have may have a pattern formed thereon so
as to increase friction relative to the socked foot of a shoe 100
wearer. The pattern shown is only exemplary, however, and other
patterns could be used.
[0051] In some embodiments, bootie 103 may be removable, while in
other embodiments bootie 103 may be glued (in whole or in part) to
interior surfaces of shell 101. Numerous materials or combinations
of materials can be used for bootie 103. As but one example, side
and top portions of bootie 103 could be a knitted spacer mesh
material and the bottom of bootie 103 could be a woven Strobel or
other lasting element. The lasting element edges could be stitched
or otherwise joined to lower edges of the knitted spacer mesh
element(s). In some embodiments, bootie 103 may line substantially
all of the interior of shell 101 but may include an instep region
gap so as not to overlap with tongue 108.
[0052] In at least some embodiments, the polymer foam of shell 101
is selected from the group that includes ethylvinylacetate (EVA)
foam, polyurethane foam and phylon foam. In at least some of these
and other embodiments, the shell 101 polymer foam may have a
density higher than the density of the foam material of inner
midsole 201. As more specific examples, shell 101 may be an
ethylvinylacetate foam material, a polyurethane foam material,
and/or a phylon foam material having a density greater than 0.2
g/cm.sup.3, and in some examples, a density of greater than 0.25
g/cm.sup.3, and in some further examples, having a density within a
range of 0.25 g/cm.sup.3 to 1 g/cm.sup.3 or even within the range
of 0.25 g/cm.sup.3 to 0.75 g/cm.sup.3. The polymer foam of shell
101 could be a material like the shell material described in U.S.
Pat. No. 7,941,938 (which patent is incorporated by reference
herein). The polymer foam of shell 101 at one location may differ
from the polymer foam at another location (e.g., with regard to
density, hardness, abrasion resistance, color, thickness, etc.) to
provide desired properties at desired locations.
[0053] Examples of polymer foams for inner midsole 201 include,
without limitation, EVA foam, polyurethane foam, phylon foam, and
phylite foam. As further examples, inner midsole 201 may be at
least partially made from a foam material having a density of less
than 0.25 g/cm.sup.3 (and in some examples, a density of less than
0.2 g/cm.sup.3, within the range of 0.075 to 0.2 g/cm.sup.3, and
even within the range of 0.1 to 0.18 g/cm.sup.3). If desired, the
inner midsole 201 foam material may include one or more openings
defined therein and/or another impact-force attenuating component,
such as a fluid-filled bladder, included therein. In certain
embodiments, inner midsole 201 will constitute lightweight foam
material (e.g., with a density feature as described above) and will
extend to support the complete foot of the wearer (e.g., the
complete plantar surface). Alternatively, inner midsole 201 may
comprise multiple inner midsole components. One or more of those
components may have one or more properties (e.g., density) that
differ from properties of another of those components.
[0054] As a further example, inner midsole 201 may be made from a
foam material as described, for example, in U.S. Pat. No.
7,941,938. In at least some embodiments, all, substantially all, or
at least some portion of inner midsole 201 may include a foam
material comprising a reaction product of about 10 to about 100
parts per hundred hydrogenated or non-hydrogenated acrylonitrile
butadiene copolymer, 0 to about 40 parts per hundred modified
hydrogenated acrylonitrile butadiene copolymer, and 0 to about 90
parts per hundred alpha olefin copolymer, and at least one additive
in an amount suitable to form the foam material. This foam material
may have a lightweight, spongy feel. The density of the foam
material may be generally less than 0.25 g/cm.sup.3, less than 0.20
g/cm.sup.3, less than 18 g/cm.sup.3, less than 0.15 g/cm.sup.3,
less than 0.12 g/cm.sup.3, and in one aspect, about 0.10
g/cm.sup.3. As example ranges, the foam density may fall within the
range, for example, of 0.05 to 0.25 g/cm.sup.3 or within the
various ranges noted above.
[0055] Also, in accordance with at least some embodiments, the
resiliency of the foam material for inner midsole 201 may be
greater than 40%, greater than 45%, at least 50%, and in one aspect
from 50-70%. Compression set may be 60% or less, 50% or less, 45%
or less, and in some instances, within the range of 20 to 60%. The
hardness (Durometer Asker C) of the foam material for this example
inner midsole 201 may be, for example, 25 to 50, 25 to 45, 25 to
35, or 35 to 45, e.g., depending on the type of footwear. The
tensile strength of the foam material for inner midsole 201 may be
at least 15 kg/cm.sup.2, and typically 15 to 40 kg/cm.sup.2. The
elongation % may be 150 to 500, typically above 250. The tear
strength may be 6-15 kg/cm, typically above 7. In at least some
embodiments, the foam material of at least some portion of inner
midsole 201 may have lower energy loss and may be more lightweight
than traditional EVA foams. The energy loss may be less than 30%,
and optionally within the range of about 20% to about 30%. As
additional examples, if desired, at least some portion of inner
midsole 201 may be made from foam materials used in the LUNAR
family of footwear products available from NIKE, Inc. of Beaverton,
Oreg.
[0056] In at least some embodiments, some or all of the shell 101
polymer foam may have a density at least 10% greater than the
density of the inner midsole 201 polymer foam. In some embodiments
some or all of the shell 101 polymer foam may have a density at
least 25% greater, at least 50% greater, at least 100% greater, or
even at least 200% greater than the density of the inner midsole
201 polymer foam.
[0057] In some embodiments, midsole 201 polymer foam may be an EVA
foam having properties in ranges such as are listed in Table 1.
TABLE-US-00001 TABLE 1 Property Unit Min. Max. expansion ratio
(mold % 189 191 cavity size to finished component size) hardness
(Asker C) n/a 36 40 specific gravity gr/cc 0.1 0.12 split tear
strength kg/cm 1.2 compression set % 60 tensile strength
kg/cm.sup.3 14 elongation % 250 tear strength kg/cm 7 shrinkage % 2
resiliency % 45
[0058] In at least some embodiments, shell 101 is molded as a
single piece. Outsole 102, which may be separately molded or
otherwise formed as a single piece or as multiple pieces, is then
attached to shell 101 with adhesive, by thermal bonding, by
mechanical fasteners and/or using other attachment mechanisms. In
some embodiments, an outsole may be integrally formed with a shell
through dual density molding or other technique.
[0059] Shoe 100 according to some embodiments is intended for wear
during rain or in other wet conditions, and thus is configured to
prevent water from reaching the shoe 100 interior from the outside.
In at least some such embodiments, shell 101 may have a single main
opening (i.e., main opening 105) in the top of upper zone 114. With
the exception of lace holes 111 and holes filled by fasteners for
eyes 112, shell 101 may lack any other openings below the edge of
main opening 105. Shell 101 may be formed from a polymer foam
through which water will not penetrate, e.g., a closed cell polymer
foam such as one of the types of foam described above. Tongue 108
also resists water penetration and spans the instep gap 107 portion
of main opening 105 below lace holes 111 and attachment holes of
eyelets 112, thereby forming at least a portion of a waterproof
barrier in instep gap 107. Medial and lateral sides of tongue 108
could be attached to medial and lateral side edges of instep gap
107 with waterproof gussets, which gussets could be part of tongue
107 or could be separate elements. The waterproof barrier in instep
gap 107, combined with the lack of shell 101 openings below that
barrier, prevents water incursion into shell 101.
[0060] In some embodiments, shell 101 may include apertures, vents
or other openings in lower portions of upper zone 114. Such other
openings could be left open. Alternatively, pieces of breathable
waterproof or water-resistant material could be glued over one or
more of those other openings so as to permit perspiration moisture
to escape from the shoe interior but prevent water reaching the
interior from the outside. Tongue 108 could also comprise a
breathable waterproof or water-resistant material.
[0061] Additional embodiments include numerous variations on one or
more of the features described thus far. In some embodiments, for
example, an inner midsole may not be located within a bootie as
shown in FIG. 2. In some such embodiments, an inner midsole may be
located directly on the bottom of the shell interior and the bootie
bottom may rest on top of the inner midsole, i.e., the internal
midsole may be situated between a bottom of the bootie and a top of
a midsole zone of the shell. In other embodiments, a first inner
midsole may be located between the shell and the bootie and a
second inner midsole may be located within the bootie.
[0062] An inner midsole need not extend under the entire plantar
surface of a wearer foot. For example, an inner midsole could be
limited to heel and/or midfoot regions of a shell interior. An
inner midsole could be nondestructively removable from a shoe.
Alternatively, an inner midsole could be glued or otherwise secured
within a shoe.
[0063] A shell and/or an inner midsole could include additional
components. For example, non-foam stiffening elements could be
embedded in a shell during the molding process so as to provide
additional support and/or protection in certain regions. Examples
of elements that might be embedded include, without limitation,
protective covers in a toe region, a counter in a heel region, a
protective plate in an ankle region and a support plate in an arch
region. As further examples, reinforcing rods could be embedded in
a midsole zone of a shell and/or in an inner midsole. A cavity
could be created in a shell and/or in an inner midsole during the
molding process, which cavity could then hold a fluid filled
cushioning bladder.
[0064] Other types of outsole elements and/or other patterns of
elements could be included in addition to or instead of the
elements and patterns shown for outsole 102. Additional types of
outsole elements that might be included in other embodiments
include lugs having cone, truncated cone, pyramid, truncated
pyramid or other type of shape, cleats or other type of traction
elements, etc.
[0065] In at least some embodiments, shell 101 is a unitary and
substantially homogeneous polymer foam boot structure. In addition
to lacking seams or discontinuities, the polymer foam may be of
consistent properties throughout substantially the entire structure
(e.g., throughout the entire structure except for a thin skin on
the interior and exterior surfaces). In other embodiments, shell
101 may be a non-unitary polymer foam boot structure and may be
non-homogeneous. For example, a portion of a boot structure may be
formed from a first type of polymer foam. Gaps may be formed in the
first polymer foam during molding and/or by cutting after molding.
One or more of those gaps may then be filled with a second type of
polymer foam. The second polymer foam may be lighter and the gaps
filled by the second polymer foam may be in regions of the boot
subject to lesser stress during shoe wear. In some embodiments,
upper and midsole zones of a shell may be formed separately and
then bonded or otherwise joined.
[0066] The foregoing description of embodiments has been presented
for purposes of illustration and description. The foregoing
description is not intended to be exhaustive or to limit
embodiments of the present invention to the precise form disclosed,
and modifications and variations are possible in light of the above
teachings or may be acquired from practice of various embodiments.
The embodiments discussed herein were chosen and described in order
to explain the principles and the nature of various embodiments and
their practical application to enable one skilled in the art to
utilize the present invention in various embodiments and with
various modifications as are suited to the particular use
contemplated. Any and all combinations, subcombinations and
permutations of features from above-described embodiments are the
within the scope of the invention. With regard to claims directed
to an apparatus, an article of manufacture or some other physical
component or combination of components, a reference in the claim to
a potential or intended wearer or a user of a component does not
require actual wearing or using of the component or the presence of
the wearer or user as part of the claimed component or component
combination.
* * * * *