U.S. patent application number 16/083110 was filed with the patent office on 2020-09-24 for layers with cells in footwear.
This patent application is currently assigned to HEWLETT-PACKARD DEVELOPMENT COMPANY, L.P.. The applicant listed for this patent is HEWLETT-PACKARD DEVELOPMENT COMPANY, L.P.. Invention is credited to Roya Susan AKHAVAIN, Matthew G. LOPEZ, Edward PONOMAREV.
Application Number | 20200297068 16/083110 |
Document ID | / |
Family ID | 1000004903713 |
Filed Date | 2020-09-24 |
United States Patent
Application |
20200297068 |
Kind Code |
A1 |
LOPEZ; Matthew G. ; et
al. |
September 24, 2020 |
LAYERS WITH CELLS IN FOOTWEAR
Abstract
In some examples, a sole layer for a footwear includes a housing
structure, a cell in the housing structure, a solid support inside
the cell to maintain a shape of the cell, and an inlet to the cell
to receive an injected material to dissolve the solid support.
Inventors: |
LOPEZ; Matthew G.; (San
Diego, CA) ; AKHAVAIN; Roya Susan; (San Diego,
CA) ; PONOMAREV; Edward; (San Diego, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HEWLETT-PACKARD DEVELOPMENT COMPANY, L.P. |
Houston |
TX |
US |
|
|
Assignee: |
HEWLETT-PACKARD DEVELOPMENT
COMPANY, L.P.
Houston
TX
|
Family ID: |
1000004903713 |
Appl. No.: |
16/083110 |
Filed: |
April 10, 2017 |
PCT Filed: |
April 10, 2017 |
PCT NO: |
PCT/US2017/026779 |
371 Date: |
September 7, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 7/28 20130101; A43B
7/144 20130101; A43B 13/188 20130101; A43B 7/142 20130101; B32B
2250/03 20130101; B32B 2437/02 20130101; A43B 7/1465 20130101; A43B
13/20 20130101 |
International
Class: |
A43B 7/28 20060101
A43B007/28; A43B 7/14 20060101 A43B007/14 |
Claims
1. A sole layer for a footwear, comprising: a housing structure; a
cell in the housing structure; a solid support inside the cell to
maintain a shape of the cell; and an inlet to the cell to receive
an injected material to dissolve the solid support.
2. The sole layer of claim 1, wherein the solid support has a
lattice shape.
3. The sole layer of claim 1, wherein the cell is a first cell, the
solid support is a first solid support, and the inlet is a first
inlet, the sole layer further comprising: a second cell in the
housing structure; a second solid support inside the second cell to
maintain a shape of the second cell; and a second inlet to the
second cell to receive an injected material to dissolve the second
solid support.
4. The sole layer of claim 3, wherein the first and second cells
are to receive respective materials through the first and second
inlets after dissolution of the first and second solid
supports.
5. The sole layer of claim 1, wherein the sole layer is to be
attached as part of a plurality of layers in a sole of the footwear
during manufacture of the footwear.
6. An assembly comprising: a footwear comprising a sole including a
plurality of layers, a first layer of the plurality of layers
comprising: a plurality of cells; solid supports inside respective
cells of the plurality of cells; and inlets to the respective cells
to receive injected materials to dissolve the solid supports.
7. The assembly of claim 6, wherein upon dissolution of the solid
supports, the inlets are to receive additional materials to fill
the respective cells.
8. The assembly of claim 7, wherein the further materials are
selected from among a fluid, a foam, a plastic, and wax.
9. The assembly of claim 7, wherein the further materials in at
least two of the respective cells are of different types.
10. The assembly of claim 6, wherein the inlets comprise
self-sealing membranes.
11. The assembly of claim 6, wherein the injected materials to
dissolve the solid supports comprise liquid.
12. The assembly of claim 6, further comprising an injection kit
comprising an injection element to inject a first material into a
first cell of the plurality of cells after the solid support in the
first cell has been dissolved.
13. The assembly of claim 12, wherein the injection kit further
comprises a second injection element to inject a second material
into a second cell of the plurality of cells after the solid
support in the second cell has been dissolved, wherein the first
material is different from the second material.
14. A method of forming a sole for a footwear, comprising:
providing a sole layer of the sole, the sole layer comprising a
cell including an inner cavity to receive a material injected
through an inlet, to customize support for a foot of a user; and
arranging a solid support in the inner cavity of the cell, the
solid support to break up inside the inner cavity of the cell in
response to an applied force.
15. The method of claim 14, wherein the solid support before
breaking up is to provide support to prevent collapse of the cell.
Description
BACKGROUND
[0001] Various footwear can be worn on the feet of users. Footwear
can be used for various purposes, including walking, jogging,
playing sports, and so forth. Users desire that footwear be
comfortable and provide adequate support when the users are engaged
in various activities.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] Some implementations of the present disclosure are described
with respect to the following figures.
[0003] FIG. 1 is a perspective view of a portion of a footwear
according to some examples.
[0004] FIG. 2 is a schematic view of a solid support having a
lattice shape, according to further examples.
[0005] FIG. 3 is a bottom view of a sole layer of a footwear,
according to some examples.
[0006] FIG. 4 is a perspective bottom view of a sole layer of a
footwear, according to some examples.
[0007] FIG. 5 is a perspective exploded view of various layers of a
sole of a footwear, according to some examples.
[0008] FIG. 6 is a perspective assembled view of various layers of
a sole of a footwear, according to some examples.
[0009] FIG. 7 is a bottom perspective view of an assembly including
various layers of a sole, along with an injection element to inject
a material into a cell of a sole layer, according to some
examples.
[0010] FIG. 8 is a flow diagram of a footwear customizing process
according to some examples.
[0011] FIG. 9 is a flow diagram of forming a sole of a footwear,
according to further examples.
[0012] Throughout the drawings, identical reference numbers
designate similar, but not necessarily identical, elements. The
figures are not necessarily to scale, and the size of some parts
may be exaggerated to more clearly illustrate the example shown.
Moreover, the drawings provide examples and/or implementations
consistent with the description; however, the description is not
limited to the examples and/or implementations provided in the
drawings.
DETAILED DESCRIPTION
[0013] In the present disclosure, use of the term "a," "an", or
"the" is intended to include the plural forms as well, unless the
context clearly indicates otherwise. Also, the term "includes,"
"including," "comprises," "comprising," "have," or "having" when
used in this disclosure specifies the presence of the stated
elements, but do not preclude the presence or addition of other
elements.
[0014] Examples of footwear include shoes, sandals, boots, socks,
or any other article that is to be worn on a foot (or feet) of a
user. The sole of a footwear is designed to support a foot of a
user. The sole can refer generally to a footwear's underlying
structure on which the user's foot is placed and which provides
support for the user's foot. Feet of different users can have
different shapes and other characteristics. Thus, footwear that may
satisfactorily support the feet of one user may not adequately
support the feet of another user. Moreover, footwear can be used in
different activities, including walking, jogging, playing sports,
standing, and so forth, which can be associated with different
support and user comfort issues. Inadequate support for a user's
feet can result in discomfort or pain to the user, and in some
cases can lead to damage to the user's feet.
[0015] After a user purchases a footwear and finds that it does not
provide adequate support or comfort (either because the footwear
does not conform properly to the shape of the user's feet or the
footwear does not provide adequate support for the user's intended
activity), the user may either return the footwear to the retailer
(which results in added cost to the retailer), or the user may
purchase additional inserts to place in the footwear to add support
or improve comfort (which results in added cost to the user).
[0016] In accordance with some implementations of the present
disclosure, solutions are provided to allow footwear to be
individually customized for respective users. In some examples, a
footwear can include cells that can be customized on demand. As
used here, a "cell" can refer to a containing structure, such as a
pouch, pocket, or any other receptacle in which is provided an
inner cavity. The cells are provided as part of a layer of a sole
of a footwear.
[0017] The sole can be formed of multiple layers (referred to as
"sole layers"), where one sole layer of the multiple sole layers
can include cells according to some implementations of the present
disclosure. In other examples, more than one sole layer can include
cells according to some implementations.
[0018] Cells in a sole layer can be injected with respective
materials to customize a footwear for a user. Different cells in a
sole layer can be injected with a same type of material, or with
different types of materials. Different types of materials can be
injected into the cells of the sole layer to achieve different
dynamic behaviors of the sole layer, such as different dynamic
performance of the elastomer material (or other material) that is
used to form the sole (or a portion of the sole). The selection of
a material to inject into each cell of a sole layer can depend on
any one or some combination of the following factors: the shape of
a user's foot, the size of the user's foot, the characteristic of
an arch of the user's foot (e.g., high arch or low arch), the
target use of the footwear (e.g., walking, jogging, running,
basketball, soccer, football, standing, etc.), or other
factors.
[0019] By selecting different types of materials or different
amounts of materials to inject into cells, footwear can be
individually customized for a user. In some examples, the
customizing can be performed in a retail setting (such as in a
footwear store) or in the home or other facility of a user who has
purchased the footwear. In other examples, the customizing can be
performed by a manufacturer at the manufacturer's factory. In
further examples, the customizing can be performed in another
setting or by another entity.
[0020] Although reference is made to a sole layer having multiple
cells in some examples, it is noted that in other examples, a sole
layer can include just a single cell into which a material can be
injected for customization.
[0021] FIG. 1 is perspective view of a portion of a sole layer 102
that is part of a footwear, according to some examples. The sole
layer has a housing structure 103 which is the main outer structure
of the sole layer 102.
[0022] The sole layer 102 includes a cell 104, which has an inner
cavity 106. An inlet 108 is provided to allow for injection of a
material into the inner cavity 106 of the cell 104.
[0023] The inlet 108 includes a membrane 110 through which an
injection element can pass and extend into an inner channel 112 of
the inlet 108. For example, the injection element can include the
needle of a syringe, which can penetrate through the membrane 110
to allow for a material in the syringe to be injected into the
inner cavity 106 of the cell 104. When the syringe needle is
removed from the inlet 108, the membrane 110 is self-sealing such
that any material that is in the inner cavity 106 of the cell 104
remains in the cell 104 after the syringe needle has been
removed.
[0024] In other examples, instead of using the self-sealing
membrane 110, a different capping layer can be provided to cap an
opening of the inlet 108 after a material has been injected into
the cell 104. For example, the capping layer can include a lid that
is removable from the inlet 108 to allow a material to be delivered
through the inlet 108 into the inner cavity 106. After delivering
the material into the cell 104, the lid can be re-attached to the
inlet. In other examples, other types of capping layers can be
used.
[0025] In accordance with some implementations of the present
disclosure, to ensure that the cells in a footwear maintain their
shape during shipment and/or other handling of the footwear, a
solid support can be provided in each cell. FIG. 1 shows a solid
support 114 that is initially provided in the inner cavity 106 of
the cell 104. The solid support 114 is to provide initial support
of the cell 104 after manufacture of the footwear (or the sole
layer 102), such that the cell 104 can maintain its expanded shape
as shown in FIG. 1. Without the solid support 114, the cell 104 may
be collapsed when force is applied onto the cell 104, such as
during handling, shipment, or storage, which can make injecting a
material into the cell 104 more difficult.
[0026] As shown in FIG. 1, the solid support 114 has a height that
is approximately the height (to within .+-.5%, or .+-.10%, or
.+-.20% of the height of the inner cavity 106 of the cell 104.
[0027] In some examples, the solid support 114 is formed of a
dissolvable material, which can be dissolved when a fluid is
injected into the inner cavity 106 of the cell 104 through the
inlet 108. Dissolving a solid can refer to a conversion process in
which the solid is converted into solutes (dissolved components),
to form a solution of the fluid and the solutes. In some examples,
the solid support 114 can be formed of a material that includes
polyvinyl alcohol (PVA), which is a water-soluble synthetic
polymer. The PVA solid support 114 remains as a solid in the
absence of a solvent. However, once the solvent is introduced into
the inner cavity 106 of the cell 104, the PVA solid support 114
dissolves. In some examples, the solvent can include water. In
other examples, the solvent can include a warm, high-alkaline water
based liquid plus a thickening agent, such as polyethylene
glycol.
[0028] The amount of solvent that is injected into the inner cavity
106 of the cell 104 to dissolve the PVA solid support 114 can be a
relatively small amount that does not fill the entirety of the
inner cavity 106 of the cell 104. Thus, once the solid support 114
dissolves in the presence of the solvent, the inner cavity 106 of
the cell 104 is just partially filled, to allow more material to be
injected into the inner cavity 106 of the cell 104 if desired.
[0029] Other example materials of a solid support 114 can include
non-hydrated silica gel crystals, sodium chloride or any other
solid material that can be dissolved in the presence of a solvent,
such as water or other fluid, or any other type of solvent.
[0030] More generally, a chemical characteristic of the solid
support 114 can be used to determine what solvent would be
effective in dissolving the solid support 114. For example, the
chemical characteristic can be the pH of the solid support 114,
where the pH determines what solvent would be effective to dissolve
the solid support 114.
[0031] After dissolution of the solid support 114, a selected
material can be injected into the inner cavity 106 of the cell 104.
The injected material can include a fluid, such as a liquid or a
gas. In other examples, the material injected into the cell 104 can
include a foam, a solid (e.g., a wax, a plastic, etc.), or another
material.
[0032] In some examples, different types of materials can include a
Newtonian fluid and a non-Newtonian fluid. The viscosity of a
Newtonian fluid is independent of the rate of shear of the fluid.
Examples Newtonian fluids include water or air. In contrast, the
viscosity of a non-Newtonian fluid is dependent on the rate of
shear. Most fluids are non-Newtonian fluids. One type of
non-Newtonian fluid is a dilatant fluid (or shear thickening
fluid), which has a viscosity that increases with the shear strain.
Another type of non-Newtonian fluid is a pseudoplatic fluid (or
shear thinning fluid), which has a viscosity that decreases with
shear strain.
[0033] In other implementations, instead of dissolving the solid
support 114 using a solvent, a mechanical force can be applied to
the solid support 114 to break up the solid support 114 into
smaller pieces. For example, after a selected material is injected
into the inner cavity 106 of the cell 104 to customize support for
a user's foot, a mechanical force is applied to break up the solid
support 114. The mechanical force can be applied by bending the
sole of the footwear that includes the sole layer 102.
[0034] FIG. 2 is an upper view of the solid support 114 according
to some examples. In FIG. 2, the solid support 114 has a lattice
shape, which includes strips of materials arranged in rows and
columns. In other examples, the solid support 114 can have a
different shape or arrangement, so long as the solid support 114 is
able to provide structural support to maintain the general shape of
the cell 104.
[0035] FIG. 3 is a bottom view of a sole layer 302 that has
multiple cells 304. FIG. 4 is a perspective bottom view of the sole
layer 302. In the example of FIGS. 3 and 4, five cells are shown as
part of the sole layer 302. In different examples, a different
number of cells can be part of the sole layer 302. Each cell 304
has a respective inlet 306 that allows for a material to be
injected into the respective cell 304. Each cell 304 and inlet 306
can have an arrangement similar to the cell 104 and inlet 108,
respectively, shown in FIG. 1.
[0036] In some examples, the housing structure of the sole layer
302 can be formed of two polyethylene films, which can be sealed
together to form the cells 304. In some examples, the films can be
sealed using an ultrasonic sealing process. Ultrasonic sealing
involves applying ultrasonic vibration to the polyethylene films to
seal the films together. In other examples, other types of films or
layers can be employed to form the sole layer 302.
[0037] In some examples, the cells 304 are formed using a vacuum
process during the ultrasonic sealing. The vacuum process can be
used to evacuate chambers inside the sole layer 302.
[0038] The multiple cells 304 shown in FIGS. 3 and 4 can correspond
to different parts of a user's foot, including the heel, arch,
outer arch, metatarsal, and toe box, as examples.
[0039] When customizing a footwear including the sole layer 302 for
an individual user, selected materials can be injected into the
cells 304. In some examples, the same type of material can be
injected into each of the cells 304. In other examples, a first
type of material can be injected into a first of the cells 304,
while a different second type of material can be injected into a
second of the cells 304.
[0040] In further examples, materials do not have to be injected
into all of the cells 304. A subset of the cells 304 can be left
un-injected with any material, leaving the solid support 114 in
each such cell 304.
[0041] The customization of a footwear including the sole layer 302
for an individual user can occur in any of various different
settings. In a retail store setting, a pressure mat or other type
of measuring mechanism can be used to measure the profile of each
region of the user's feet. The pressure mat can measure the
pressures applied by different portions of each foot. Based on
measured pressures, a determination can be made regarding the
support that is to be provided by different portions of the
footwear, which can lead to the decision of what material to inject
into each cell 304 (or whether to not inject any material into a
particular cell 304).
[0042] In other examples, an imaging system can be used to capture
a three-dimensional (3D) image of the user's feet, and based on the
3D image, a decision can be made regarding materials to inject (or
not) into respective cells 304.
[0043] The decision regarding which cells should be injected with
materials, and which materials to use for each cell, can be made by
a human, or by a computer, based on empirical data collected from
tests conducted on users with feet of varying shapes and who use
footwear for different purposes.
[0044] In other examples, the customization of a footwear using the
cells of the sole layer 302 (or the cell 104 of the sole layer 102)
can occur at the factory of a manufacturer of the footwear, or in
the home of a user who purchased the footwear. In examples where
the user is to perform the customization, materials for injection
into the cells of the sole layer 302 can be shipped to the user
with the footwear, along with instructions on how to inject the
materials. For example, an injection kit can be provided with the
footwear, where the injection kit can include a syringe, or
multiple syringes (or other types of injection elements), which can
be used to inject the materials into respective cells 304 of the
sole layer 302.
[0045] If a user expresses dissatisfaction with the support
provided by a particular cell (or cells) that has (have) been
injected with materials, a retailer or manufacturer can send
replacement materials (possibly with another injection kit) to the
user, to replace the material(s) previously injected into the
cell(s).
[0046] Replacing a material in a cell 304 can involve withdrawing
the material from the cell 304, and replacing the material with a
different material. For example, a syringe can be used to withdraw
a material from a cell, and a different syringe can be used to
inject a new material into the cell.
[0047] In accordance with some examples, the sole layer 302 can be
manufactured to be part of other layers of the sole of a footwear.
In such examples, the sole layer 302 is attached to other layers of
a sole of the footwear. For example, FIG. 5 shows an exploded view
of the layers of a sole 500 of a footwear, such as a shoe or other
type of footwear. The layers of the sole 500 include an outer sole
layer 502, a midsole layer 504, and the sole layer 302 with cells
304.
[0048] The sole layer 302 with cells 304 can be received in a
receptacle 506 of the midsole layer 504. The sole layer 302 can
thus reside within the side wall 510 of the midsole layer 504. In
some examples, the sole layer 302 with cells 304 can reside
entirely within the receptacle 506 defined by the side wall 510 of
the midsole layer 504.
[0049] The sole layer 302 with cells 304 can be affixed to a
surface 508 (e.g., the upper surface) of the midsole layer 504. The
affixing of the sole layer 302 to the surface 508 of the midsole
layer 504 can be performed by using an adhesive or other type of
fastener. The midsole layer 504 is in turn affixed to the outer
sole layer 502, either by an adhesive or a different fastener.
Although just a few sole layers are shown as being part of the sole
500 of FIG. 5, it is noted that in other examples, a different
number of sole layers can be provided as part of the sole 500.
[0050] The outer sole layer 502 has openings 512 that align with
the inlets 306 (FIG. 3) of the sole layer 302. As further shown in
FIG. 5, corresponding openings 514 are formed in the midsole layer
504, which are aligned with the openings 512 in the outer sole
layer 502 as well as with the openings 512 in the outer sole layer
502. The aligned openings 512 and 514 allow injection elements to
pass through the respective openings 512, 514, to inject respective
materials through the inlets 306 of respective cells 304 of the
sole layer 302.
[0051] In some examples, the sole layer 302 is placed on the
midsole layer 504 prior to installation of the upper of the
footwear, where the upper refers to the upper structure of the
footwear that covers the upper part of the foot of the user. The
upper can be formed of a fabric, leather, or any other type of
material.
[0052] FIG. 6 is an assembled view that shows the sole 500 with the
outer sole layer 502, midsole layer 504, and sole layer 302 with
cells all attached together in an assembly.
[0053] FIG. 7 is a bottom perspective view of the sole 500 of FIG.
6, which shows openings 702 formed in the bottom surface 704 of the
outer sole layer 502. In the example of FIG. 7, an injection
element 706 is used to inject a material into a cell of the sole
layer 302 through a respective opening 512. In the example of FIG.
7, the injection element 706 is a syringe that has a needle 708
that can penetrate through the membrane of a respective inlet (such
as 306 shown in FIG. 3).
[0054] Although FIG. 7 shows just one injection element 706, it is
noted that in other examples, multiple injection elements can be
used to deliver respective materials to corresponding cells 304 of
the sole layer 302.
[0055] FIG. 8 is a flow diagram of a process that includes
customizing (at 802) a sole layer of a footwear for a user.
Customizing includes injecting (at 804) a material through an inlet
into an inner cavity of a cell in the sole layer, to customize
support for a foot of a user, where a solid support is positioned
in the inner cavity of the cell. The customizing further includes
applying (at 806) a force on the solid support to break up the
solid support inside the inner cavity of the cell.
[0056] FIG. 9 is a flow diagram of a process of forming a sole for
a footwear. The process of FIG. 9 includes providing (at 902) a
sole layer of the sole, the sole layer including a cell having an
inner cavity to receive a material injected through an inlet, to
customize support for a foot of a user. The process of FIG. 9
further includes arranging (at 904) a solid support in the inner
cavity of the cell, the solid support to break up inside the inner
cavity of the cell in response to an applied force.
[0057] In the foregoing description, numerous details are set forth
to provide an understanding of the subject disclosed herein.
However, implementations may be practiced without some of these
details. Other implementations may include modifications and
variations from the details discussed above. It is intended that
the appended claims cover such modifications and variations.
* * * * *