U.S. patent application number 15/367395 was filed with the patent office on 2018-06-07 for shoe sole and method of manufacturing same.
This patent application is currently assigned to G-III Apparel Group, Ltd.. The applicant listed for this patent is G-III Apparel Group, Ltd.. Invention is credited to Cory HABERMAN, Shane Henry WARD.
Application Number | 20180153253 15/367395 |
Document ID | / |
Family ID | 62240588 |
Filed Date | 2018-06-07 |
United States Patent
Application |
20180153253 |
Kind Code |
A1 |
WARD; Shane Henry ; et
al. |
June 7, 2018 |
SHOE SOLE AND METHOD OF MANUFACTURING SAME
Abstract
A shoe including a shoe sole and a method of manufacturing a
shoe sole are disclosed. The sole includes a sole body possessing a
rear section, a midsection, and a front section. The sole further
includes a rear cavity at the rear section, an arched portion at
the midsection, and a front cavity at the front section. A first
cushion is located at or inside the rear cavity and possesses a
first hardness. A rigid member is located at the arched portion of
the midsection. A second cushion is located at or inside the front
cavity and possesses a second hardness greater than the first
hardness. The sole optionally includes flex grooves along a bottom
portion of the front section.
Inventors: |
WARD; Shane Henry; (New
York, NY) ; HABERMAN; Cory; (Ridgewood, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
G-III Apparel Group, Ltd. |
New York |
NY |
US |
|
|
Assignee: |
G-III Apparel Group, Ltd.
New York
NY
|
Family ID: |
62240588 |
Appl. No.: |
15/367395 |
Filed: |
December 2, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 7/144 20130101;
A43B 13/188 20130101; A43B 13/141 20130101; A43B 13/20 20130101;
A43B 7/148 20130101; A43B 7/1445 20130101; A43B 13/04 20130101;
A43B 13/186 20130101 |
International
Class: |
A43B 13/18 20060101
A43B013/18; A43B 13/14 20060101 A43B013/14; A43B 13/20 20060101
A43B013/20; A43B 13/04 20060101 A43B013/04; A43B 7/14 20060101
A43B007/14 |
Claims
1. A shoe comprising a shoe sole comprising: a sole body possessing
a rear section, a midsection, and a front section; a rear cavity at
the rear section; an arched portion at the midsection. a front
cavity at the front section; a first cushion located at or inside
the rear cavity and possessing a first hardness; a rigid member
located at the arched portion of the midsection; and a second
cushion located at or inside the front cavity and possessing a
second hardness, the second hardness being greater than the first
hardness.
2. The sole of claim 1, wherein the rear cavity and the front
cavity are open to a top surface of the sole body.
3. The sole of claim 1, wherein the rigid member comprises an
elongated portion possessing a longer extent along a rear
section-to-front section direction of the sole body.
4. The sole of claim 3, wherein the elongated portion is located
against a bottom surface of the sole body at the midsection.
5. The sole of claim 3, wherein the sole includes a middle cavity
located at the midsection and closed to a bottom surface of the
sole body, and the rigid member is located at or inside the middle
cavity.
6. The sole of claim 1, wherein the rear section includes a
suspended middle portion between two lateral portions, the lateral
portions extending further than the suspended middle portion in a
top-to-bottom direction of the sole body.
7. The sole of claim 6, further comprising an air pocket located
above or inside the suspended middle portion of the rear
section.
8. The sole of claim 1, wherein the rigid member includes
nylon.
9. The sole of claim 1, wherein the first cushion includes
compression molded ethylene vinyl acetate.
10. The sole of claim 1, wherein the first cushion includes 55-60
degree ethylene vinyl acetate.
11. The sole of claim 1, wherein the second cushion includes
elastic ethylene vinyl acetate foam.
12. The sole of claim 1, wherein the second cushion includes 45
degree ethylene vinyl acetate.
13. The sole of claim 1, wherein the front section further includes
flex grooves along a bottom portion of the sole body.
14. The sole of claim 1, wherein the sole body includes ethylene
vinyl acetate.
15. The sole of claim 1, wherein the sole body includes
polyurethane.
16. The sole of claim 1, wherein the sole body includes ethylene
propylene.
17. The sole of claim 1, wherein the sole body includes rubber.
18. A shoe comprising: an upper configured to receive a foot of a
user; and the sole of claim 1 coupled to the upper such that, when
the foot of the user is received in the upper, a heel portion of
the foot is supported by the rear section of the sole body and a
forefoot portion of the foot is supported by the front section of
the sole body.
19. A method of manufacturing a shoe and shoe sole comprising:
forming a sole body possessing a rear section, a midsection, and a
front section, the sole body including a rear cavity at the rear
section, an arched portion at the midsection shaped, and a front
cavity at the front section; placing a first cushion at or inside
the rear cavity, the first cushion possessing a first hardness;
placing a rigid member at the arched portion of the midsection; and
placing a second cushion at or inside the front cavity, the second
cushion possessing a second hardness greater than the first
hardness.
Description
TECHNICAL FIELD
[0001] The present disclosure relates to a shoe including a shoe
sole, and more particularly, to a shoe sole configured to maximize
comfort, stability and energy return during the stages of foot
movement during walking, trail hiking, running, and the like, and
further to a method of manufacturing the shoe and sole.
BACKGROUND INFORMATION
[0002] A typical walking movement includes a landing phase, a
neutral/transitional phase, and a lift-off phase. The user's heel
impacts the ground during the landing phase. The user's weight is
then shifted forward at the neutral/transitional phase as the user
prepares for the lift-off phase, during which the user's weight is
concentrated at the midfoot/arch region. Finally, the forefoot area
is activated during the lift-off state. Shoes typically contain
foam materials and the like to absorb the impact of the user's foot
on the ground. Conventional shoe designs however do not adequately
account for the role played by the three core stages of the user's
foot during the natural walking gate. The present disclosure is
directed in part to assisting in the perambulatory processes by
providing for cushioning, stabilizing, and energy return
(propelling) during the various stages of walking, trail hiking,
running, and the like.
SUMMARY
[0003] A shoe and shoe sole are disclosed. The sole comprises a
sole body possessing a rear section, a midsection, and a front
section. The sole possesses a top portion and a bottom portion. In
certain embodiments, the sole further includes a rear cavity at the
rear section, an optionally arched portion at the midsection formed
such that a bottom surface of the sole body is substantially
concave at the midsection, and a front cavity at the front section.
A first cushion is located inside the rear cavity and possesses a
first hardness. A rigid member is located at the midsection. A
second cushion is located inside the front cavity and possesses a
second hardness that may in preferred embodiments be greater than
the first hardness. The shoe comprises the aforementioned sole and
an upper attached directly or indirectly thereto. As used herein,
the term shoe may generically refer to any article of footwear that
has a sole.
[0004] A method of manufacturing a shoe and sole is disclosed. The
method comprises forming a sole body possessing a rear section, a
midsection, and a front section. The sole body includes a rear
cavity at the rear section, an arched portion at the midsection
shaped such that a bottom surface of the sole body is substantially
concave at the midsection, and a front cavity at the front section.
The method further comprises placing a first cushion inside the
rear cavity, the first cushion possessing a first hardness, placing
a rigid member at the arched portion of the midsection, and placing
a second cushion inside the front cavity. The second cushion
possesses a second hardness that in preferred embodiments may be
greater than the first hardness.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Other features and advantages disclosed herein will become
more apparent from the following detailed description of exemplary
embodiments when read in conjunction with the attached drawings,
wherein:
[0006] FIG. 1 is a schematic illustration of an exemplary
embodiment of a sole;
[0007] FIG. 2 is a schematic cross section of the heel area of an
exemplary embodiment of a sole coupled to a shoe upper;
[0008] FIG. 3 is a schematic illustration of another exemplary
embodiment of a sole;
[0009] FIG. 4 is a schematic illustration of another exemplary
embodiment of a sole;
[0010] FIG. 5 is a schematic illustration of an exemplary
embodiment of a shoe including a sole; and
[0011] FIG. 6 is a schematic illustration of another exemplary
embodiment of a shoe including a sole.
DETAILED DESCRIPTION
[0012] FIGS. 1, 3 and 4 show an exemplary embodiments of a sole
100, which includes a sole body 110 possessing a rear section 112,
a midsection 114, and a front section 116. The sole 100 further
includes a rear cavity 122 at the rear section 112, an arched
portion at the midsection formed such that the top surface of the
sole body 110 is convex and/or the bottom surface S of the sole
body 110 is substantially concave at the midsection 114, and a
front cavity 126 at the front section 116. The sole further
includes a top portion 1101 and a bottom portion 1102. A first
cushion 132 is located at or inside the rear cavity 122 and
possesses a first hardness. A rigid member 134 is located at the
arched portion of the midsection 114. A second cushion 136 is
located at or inside the front cavity 126 and possesses a second
hardness. In exemplary embodiments, the second hardness is greater
than the first hardness. In exemplary embodiments, the second
cushion 136 is bouncier than the first cushion 132. In exemplary
embodiments, the rigid member 134 is substantially harder than the
first and second cushions 132, 136. In exemplary embodiments, the
rigid member 134 is substantially rigid or semi-rigid and in
preferred embodiments may have a hardness greater than that of the
first cushion 132 and the second cushion 136, individually or
combined. In exemplary embodiments, the rigid member 134 is located
within or upon a middle cavity 124, which may be located on the top
portion 1101 (see FIG. 3) or the bottom portion 1102 (FIGS. 1 and
4) of the midsection 114. In exemplary embodiments, plural rigid
members are placed at the midsection 114 in or on the top or bottom
portions.
[0013] In exemplary embodiments, the rear section 112 supports the
heel area of the foot of the user, and is configured to absorb the
impact made during walking, hiking, running, or the like, when the
heel strikes the ground. The first cushion 132 located at the rear
section 112 allows for a softer heel landing, thereby potentially
reducing stress on the joints, knees and back of the user.
[0014] In exemplary embodiments, as the foot of the user
transitions from heel impact to a more neutral state, the rigid
member 134 provides arch support, promotes stability, and prepares
and supports the foot of the user for the next phase in the
walking, hiking, or running motion. The midsection with its rigid
member 134 allows for stable and smooth transition between the
immediate heel strike and the forefoot lift-off phase of the
walking, hiking, or running motion. The rigid member 134 is
proportioned and configured so as to reduce rolling and prevent
collapsing of the foot, thus reducing pain and the amount of work
needed to move forward. In exemplary embodiments, the rigid member
134 is manufactured in a very dense compound for desirable arch
support, for example nylon or thermoplastic polyurethane. In FIGS.
1 and 4, the rigid member 134 is inserted from the bottom, and in
FIG. 3, the rigid member 134 is inserted from the top. The rigid
member 134 supports the foot and prevents the arch from collapsing,
therefore stabilizing the foot as it transitions forward to the
final portion of the walking gate.
[0015] In exemplary embodiments, the front section 116 supports the
forefoot area, and is configured to propel the foot forward. The
hardness and positioning of the second cushion 136 promotes energy
return, thus potentially producing a bounce or propel sensation,
which may or may not be perceptible to the user, during the thrust
phase of the walking, hiking, or running motion.
[0016] In exemplary embodiments (see FIGS. 1 and 3), the rear
cavity 122 and the front cavity 126 are open to a top surface of
the sole body 110. In certain embodiments, an insole may cover the
top surface of the sole, and be considered as part of the sole
disclosed herein. The insole may be configured with section to
further aid in the absorption, stabilizing and energy return
(propel) advantages of the sole 100.
[0017] In various exemplary embodiments (see FIGS. 1, 3 and 4), the
rear cavity 122 and/or the front cavity 126 can be open or closed
to various sides of the sole body 110, including the upper, bottom,
front, rear, and lateral surfaces of the sole body 110. The first
cushion 132, second cushion 136 and/or rigid member 134 may
optionally be accessible or removable through any of the upper,
bottom, front, rear, and lateral surfaces of the sole body 110,
such feature being informed by whether a corresponding cavity is
open or closed to any one of those surfaces. In FIGS. 1 and 3, both
the rear cavity 122 and the front cavity 126 are open to the top
surface of the sole body 110, and are closed to all other sides of
the sole body 110. In FIG. 4, the rear cavity 122 is open to the
top surface of the sole body 110 and is closed to all other sides
of the sole body 110, and the front cavity 126 is open to the
bottom surface of the sole body 110 and is closed to all other
sides of the sole body 110. In such these embodiments, an insole
may optionally be placed substantially abutting (directly or
indirectly) the top portion of the sole body 110.
[0018] In exemplary embodiments, the rigid member 134 includes an
elongated portion possessing a longer extent along a rear
section-to-front section direction (i.e., the major axis) of the
sole body 110. The rigid member 134 may further comprise a shorter
extent along a transverse direction perpendicular to the rear
section-to-front section direction of the sole body 110.
[0019] In exemplary embodiments, the elongated portion is located
against the bottom surface S of the sole body 110 at the midsection
114.
[0020] In exemplary embodiments, the sole includes a middle cavity
124 located at the midsection 114 and optionally closed to the
upper surface and/or to the bottom surface S of the sole body 110,
to promote stabilization of the arch of the foot, and to reduce the
risk of collapsing of the arch of the foot. The middle cavity 124
may optionally be located along the top portion of the midsection
114. The rigid member 134 is located at or inside the middle cavity
124, as illustrated by the dotted line in FIG. 5. In an exemplary
embodiment, the rigid member 134 includes injected nylon,
thermoplastic polyurethane, and/or steel. In FIGS. 1 and 4, the
middle cavity 124 is open to the bottom, and in FIG. 3, the middle
cavity 124 is open to the top.
[0021] In exemplary embodiments, the rear section 112 includes a
suspended middle portion 1121 (shown in FIG. 2) between two lateral
portions 1122. The lateral portions 1122 extend further than the
suspended middle portion 1121 in a top-to-bottom direction of the
sole body 110.
[0022] In exemplary embodiments, the suspended middle portion 1121
further allows for a softer heel landing, thereby further reducing
stress on the joints, knees and back of the user. This structure
may also provide a softer sensation at the user's heel area. In an
exemplary embodiment, the two lateral portions 1122 touch the
ground during the process of walking. Alternatively, the two
lateral portions 1122 may be separated from the ground by outsole
portions 1123, as shown in FIG. 2.
[0023] In exemplary embodiments, an air pocket 1124 is located
above or inside the suspended middle portion 1121 of the rear
section 112. In exemplary embodiments, the air pocket 1124 further
allows for a softer heel landing, thereby further reducing stress
on the joints, knees and back of the user. For example, the air
pocket 1124, along with the suspended middle portion 1121 of the
rear section 112, creates a comfortable landing area wherein the
air pocket 1124 allows for freedom of movement down for the heel,
and cantilevered heel portions on either sides of the suspended
middle portion 1121 can splay/flares out, as illustrated for
example by the white arrows in the sectional X-X view in FIG. 3.
This allows for a softer heel landing, thereby further reducing
stress on the joints, knees and back of the user, for example
during the initial heel strike of the walking gate. For example,
the first cushion 132 located at the rear section 112, the air
pocket 1124 and the cantilevered heel portion design, can together
allow for a softer heel landing, thereby potentially reducing
stress on the joints, knees and back of the user.
[0024] In exemplary embodiments, the suspended middle portion 1121
is substantially oval in shape when viewed from the bottom. In
other embodiments, the suspended middle portion 1121 may be
circular or substantially rectangular in shape without deviating
from the disclosure.
[0025] In exemplary embodiments, the front section 116 may have
flex grooves 1161 along the bottom portion of the sole body 110. In
preferred embodiments these flex grooves 1161 are disposed along
the bottom portion of the front section 116 in a substantially
lateral direction, perpendicular to the major axis of the shoe
sole. The flex grooves 1161 may additionally or alternatively be
present on the bottom portion of the front section 116 in a
direction parallel to the major axis of the shoe sole, and/or may
be further disposed in such directions as may facilitate or enhance
the deformation of the shoe sole in directions that would
complement contemplated foot movements encountered during exercise,
hiking, cross training, running, climbing, etc. Flex grooves 1161
can be formed on the sole body 110 and/or on the second cushion
136. The combination of the flex grooves 1161 and the second
cushion 136 creates desirable propulsion effects during walking and
other exercise activities.
[0026] In exemplary embodiments, the bottom surface of the shoe
sole may include striations 1125 that are positioned so as to
complement the functions (absorb, stabilize, propel) of the various
portions of the shoe sole. In certain embodiments, such striations
1125 in the front section 116 may be substantially perpendicular to
the major axis of the shoe; in the midsection 114 may be
substantially radially disposed in relation to the midpoint(s) of
the lateral edges of the midsection 114; and/or in the read section
112 may be disposed substantially radially to the midpoint of the
rear section 112 or center of curvature of the suspended middle
portion 1121.
[0027] In exemplary embodiments, the rigid member 134 includes
nylon. In an exemplary embodiment, a nylon rigid member 134 at the
midsection 114 further promotes stability.
[0028] In exemplary embodiments, the first cushion 132 includes
compression molded ethylene vinyl acetate (EVA). In exemplary
embodiments, the compression molded EVA cushion at the rear section
112 further allows for a softer heel landing, thereby further
reducing stress on the joints, knees and back of the user.
[0029] In exemplary embodiments, the first cushion 132 includes
55-60 degree EVA. In an exemplary embodiment, the 55-60 degree EVA
cushion at the rear section 112 further allows for a softer heel
landing, thereby further reducing stress on the joints, knees and
back of the user. In exemplary embodiments, the first cushion 132
is formed of the same material as the sole body 110. In exemplary
embodiments in which the sole body 110 is injection molded, the
first cushion 132 is integrally formed with the sole body 110 and
does not exist as a separate component (see FIG. 6). In exemplary
embodiments, one purpose of the first cushion 132 is to close, and
thereby form, the air pocket 1124 at the rear section 112.
[0030] In exemplary embodiments, the sole body 110 is made of EVA,
ethylene propylene (EPR), polyurethane, and/or rubber, or any
suitable materials known in the art.
[0031] In exemplary embodiments, the second cushion 136 includes
elastic EVA foam. In an exemplary embodiment, the elastic EVA foam
cushion at the front section 116 of the sole body 110 includes
55-60 degree EVA. In an exemplary embodiment, the elastic EVA foam
cushion at the front section 116 of the sole body 110 includes EPR.
In an exemplary embodiment, the elastic EVA or EPR foam cushion at
the front section 116 of the sole body 110 further promotes energy
return during the thrust phase of the walking motion. In exemplary
embodiments, the second cushion 136 is arranged and configured to
align with the user's metatarsal bones.
[0032] In exemplary embodiments, the first cushion 132 and second
cushion 136 maybe be substantially rectangular or trapezoidal when
viewed from the top or bottom, with the sides and/or edges of the
rectangular shapes being optionally rounded. In exemplary
embodiments, the top and bottom surfaces of the first cushion 132
and second cushion 136 may be substantially flat, or may be curved
so as to allow for their top surfaces to receive the curvature of
the foot and/or insole. In certain embodiments, the bottom surface
of the second cushion 136 may optionally include lateral
projections disposed in a direction perpendicular to the major axis
of the sole, as shown in FIG. 1. The first cushion 132 and second
cushion 136 may be shaped and/or proportioned so as to maximize
energy return with design constraints and materials cost
considerations.
[0033] In exemplary embodiments, the second cushion 136 includes 45
degree EVA. In an exemplary embodiment, the 45 degree EVA cushion
at the front section 116 of the sole body 110 further promotes
energy return during the thrust phase of the walking motion.
[0034] FIG. 5 shows an exemplary embodiment of a shoe 300 including
a sole 100 and an upper 200. The upper 200 is configured to receive
the foot of a user. The sole 100 is coupled directly or indirectly
to the upper 200 such that a heel portion of the foot is supported
by the rear section 112 of the sole body 110 and a forefoot portion
of the foot is supported by the front section 116 of the sole body
110.
[0035] In exemplary embodiments, the shoe 300 includes an outsole
250 coupled to the sole 100 such that the sole 100 is located
between the outsole 250 and the upper 200. The shoe 300 may
optionally further comprise an insole. It will be appreciated that
the sole 100 disclosed herein may be a midsole between an outsole
and an insole, or may include one or more of an outsole or insole,
integrally or via attachment, without deviating from the present
disclosure. An exemplary embodiment of an insole includes a 360
degree EVA insock. The combination of the sole and the insock
creates desirable propulsion effects during walking and other
exercise activities.
[0036] An exemplary method of manufacturing a shoe and sole
comprises forming a sole body 110 possessing a rear section 112, a
midsection 114, and a front section 116. The sole body 110 includes
a rear cavity 122 at the rear section 112, an arched portion at the
midsection 114 shaped such that a bottom surface S of the sole body
110 is substantially concave at the midsection 114 and/or a top
surface of the sole body 110 is substantially convex at the
midsection 114, and a front cavity 126 at the front section 116.
The method further comprises placing a first cushion 132 at or
inside the rear cavity 122, the first cushion 122 possessing a
first hardness, placing a rigid member 134 at the arched portion of
the midsection 114, and placing a second cushion 136 at or inside
the front cavity 126. In exemplary embodiments, the second cushion
136 possesses a second hardness greater than the first hardness. In
exemplary embodiments, the second cushion 136 is bouncier than the
first cushion 132.
[0037] It will be appreciated by those skilled in the art that the
disclosure herein can be embodied in other specific forms without
departing from the spirit or essential characteristics thereof. The
presently disclosed embodiments are therefore considered in all
respects to be illustrative and not restricted. The scope of the
invention is indicated by the appended claims rather than the
foregoing description and all changes that come within the meaning
and range and equivalence thereof are intended to be embraced
therein.
* * * * *