Abstract:
A shoe construction utilizing a gas containing chamber as a cushion. The shoe includes a stabilizer positioned in the shoe and having a heel portion in overlying relation to the cushion and a forward portion in overlying relation to at least a midfoot portion of the shoe bottom. The forward portion extends across a substantial portion of the inside width of the shoe where it is located to resist deformation of the shoe bottom under load from a user both in lateral bending and longitudinal torsion.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is related to U.S application Ser. No. 12/565,383 entitled “Shoe With Support System”, filed Sep. 23, 2009, the contents of which are incorporated herein in their entirety; and is also related to U.S. application Ser. No. 12/703,994 entitled “Shoe Construction Having a Rocker Shaped Bottom and Integral Stabilizer”, filed Feb. 11, 2020, the contents of which are also incorporated herein by reference. 
     
    
     FIELD OF INVENTION 
       [0002]    A shoe construction with a torsion support system. The shoe has an air heel cushion with an overlying support secured in the shoe in at least the heel portion and midfoot portion of the shoe to resist torsional twisting and longitudinal flexure of the shoe. 
       BACKGROUND OF THE INVENTION 
       [0003]    Shoes with improved comfort are sought after by consumers, and thus comfort is a goal of shoe suppliers. Comfort is provided in three basic ways, materials of manufacture, shoe shape and cushioning. In addition to comfort, shoes worn at work sites are constructed to provide an extra margin of safety. Some safety features include hard safety toes and slip resistance. Slip resistance is an important feature in shoes worn at certain work sites such as restaurants where liquids such as oil and water are frequently on the floors in areas where workers walk and stand. In addition to these functional features, style can also be important, particularly in areas where the public visits. Shoe choice by an individual takes both comfort and function into consideration as well as style. One popular style is the so-called clog which has a large toe box and is of a slip on style. In contrast to athletic shoes, the clog type shoe is devoid of laces, straps, zippers or the like which secure the shoe more tightly to the user&#39;s foot. Clog shoes are also devoid of ankle support. Both the laces and the ankle support provide stability to the shoe with the sacrifice of comfort. Athletic shoes are often worn for short periods of time and are generally impractical for use in a job setting where they would need to be worn for as long as twelve hours at a time. Clogs, in contrast, are not cinched to the user&#39;s feet and thus provide more comfort to persons wearing the shoes for long periods. However, as stated earlier, clogs do not provide the stability provided by athletic shoes. Another shortcoming to a clog type shoe relates to the heel. Heels cause the heel of the shoe and thus the heel of the foot to strike the ground prior to the forefoot. Heel strikes often result in a potentially injurious impact force at the beginning of a stride cycle that is not seen when the forefoot strikes the ground first. This means that heel cushioning must be of particular concern when designing a shoe for heel strikes. 
         [0004]    Cushioning can be provided by the insole, midsole and outsole with suitable materials of construction. Although soft soles provide comfort, they tend to be very flexible. Many of these components are made of a cellular or foam material. In addition, air cushions have been used in the heel area of the shoe particularly to reduce impact forces. The cushioning is used to reduce impact on the shoe user during use of the shoe, particularly during fast walking and running where the heel of the user first impacts the underlying surface. One problem with air cushions is that movement of entrapped air inside the cushion in one area causes other areas of the cushion to accommodate that movement, e.g., if one area is compressed, another area expands in a flexible fluid filled cushion. This cushion deformation is commonly referred to as transfer of motion. This movement of fluid is particularly present in large single chamber cushions. One means of reducing this reactive cushion deformation is to provide columns extending between and connected to the upper and lower surfaces of the cushion to restrict movement of the top surface of the air cushion with respect to the bottom surface. Transfer of motion can result in a feeling of instability if the deformation of the cushion is along the side edges of the cushion. 
         [0005]    Another solution to the cushion deformation is the use of a plurality of cushions in the heel area that will limit fluid movement and hence transmission of deformation, keeping deformation more localized. This however is reputed to limit the cushion effect and increases the cost and complexity of a shoe. There is thus a tradeoff between cushion stability and the cushioning effect. 
         [0006]    Another problem with shoes of comfort is their flexibility both laterally and longitudinally. Longitudinal flexure (bending in an area transverse to the longitudinal axis of the shoe) can be somewhat controlled by use of a shank in the heel area and midfoot area of the shoe. Flexure can also be limited by the use of thick, heavy and rigid soles instead of soft flexible soles, but at the cost of comfort to the wearer. 
         [0007]    There is thus a need for an improved shoe construction to overcome the problems attendant with the use of fluid cushioned shoes using lightweight flexible materials of construction. The shoe construction should provide stability to clog type shoes having particularly thick heel areas with air cushions therein. 
       SUMMARY 
       [0008]    The present invention involves the provision of a clog type shoe having an upper with a forefoot portion, midfoot portion and an elevated heel portion. The shoe also includes a bottom member also having a forefoot portion, midfoot portion and heel portion positionally corresponding to the mentioned upper shoe portions. The bottom member can include an outsole portion and a midsole portion. A midsole is provided in overlying relation to at least a portion of the outsole heel portion. The midsole can be used to provide elevation of a user&#39;s heel in the shoe as would a separate heel. An air cushion member is located in the heel portion of the midsole portion that extends over at least about one-half of the interior width of the heel portion of the upper. A relatively rigid support member is provided and has a heel portion and a forward portion. The support member heel portion is secured in overlying relation to at least a portion of the air cushion member and covers a substantial portion of the width of the cushion member. The support member forward portion has a maximum width greater than the maximum width of the support member heel portion and extends forwardly therefrom along a substantial portion of the midfoot portion of the shoe bottom member to provide a rigid foot support platform for the shoe. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a fragmentary perspective view of a shoe of the invention showing internal structure of the shoe. 
           [0010]      FIG. 2  is an exploded perspective view of the insole, cushion and associated support member. 
           [0011]      FIG. 3  is an enlarged plan view of a support member in overlying relation to the cushion and outsole. 
           [0012]      FIG. 4  is a side sectional view of a form of the invention with the support member shown embedded in the shoe bottom. 
       
    
    
       [0013]    Like numbers used throughout this application represent like or similar parts and/or construction. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0014]    While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described presently preferred embodiments with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated. 
         [0015]    Referring to  FIGS. 1-4 , the reference numeral  1  indicates generally a shoe construction which, for convenience, is shown as a clog type shoe; although the invention is usable with any suitable shoe style. The shoe  1  is shown as a slip on clog type shoe that uses no auxiliary cinching device, such as a shoe string, or ankle support to assist in securing the shoe to a foot. Generally, the shoe includes an upper  3 , a bottom member  5  with outsole portion  6  and a midsole portion  7  with a gas cushion member  9  therein. A bed liner layer  13  is secured to the support member and bonded to the midsole  7 . The shoe can also include an insole  11 . A support member  12  is associated with the cushion  9  and the bottom  5  as hereinafter described. 
         [0016]    The upper  3  can be made of any suitable material or combination of materials such as leather, fabric, polymers or the like as is known in the art. The shoe  1  and the upper  3  have a forefoot portion  15 , a midfoot portion  17  and a heel or hindfoot portion  19 . These parts of the shoe and upper correspond and generally contain the similarly named parts of the foot. The forefoot of the foot is composed of the five toes (called phalanges) and their connecting long bones (metatarsals). The midfoot is composed of the irregularly shaped tarsal bones, forms the foot&#39;s arch, and serves as a shock absorber. The hindfoot is composed of three joints and links the midfoot to the ankle (talus). In a preferred embodiment, the upper  3  is of a slip on type, such as a clog. Such a construction typically provides a loose fit of the shoe to a foot and provides for ease of foot entry and exit. A loose fit may also improve ventilation of the shoe during use. However, as described earlier, the loose fit reduces stability between the user&#39;s foot and the shoe. The upper  3  has a foot receiving opening  21 ; and as shown, the upper  3  has an enclosed toe box  16  in the forefoot portion  15  and midfoot portion  17 . The upper  3  may be lined or unlined as desired. A suitable lining can be fabric, fabric plus foam or leather as are known in the art. 
         [0017]    In a preferred embodiment, the shoe  1  is provided with an insole  11  that can extend the full length or a portion of the length and preferably the full width of the interior of the shoe. The insole  11  can be made of any suitable material or combination of materials such as leather, fabric, polymeric or elastomeric foam and can be permanently secured in place as by cementing or can be removable as is known in the art. 
         [0018]    The shoe  1  includes a bottom  5 , which can be of any suitable form. The bottom  5  may be of single or multiple piece construction and is suitably secured to the upper  3  as by stitching and/or cementing. The bottom  5  can be molded construction and could be molded onto the upper  3  forming a molded integral structure. The bottom  5 , like the upper  3 , has a forefoot portion  15 , a midfoot portion  17  and a hindfoot portion  19 . The hindfoot portion  19  contains the midsole portion  7  and the gas cushion  9 . The gas cushion  9  is preferably positioned in hindfoot portion  19  having a thickness that is greater than the forefoot  15  or midfoot  17  portions. The bottom  5  can be made of leather, elastomer, polymer or combinations thereof depending on the method used to assemble a shoe. The bottom  5  can be of a cellular material if desired for softness and lightness, and particularly preferred for work shoes is an outsole portion  6  that is oil resistant and slip resistant. An example of such an outsole is disclosed in U.S. Design Pat. No. 433,792 assigned to the assignee of the instant invention. 
         [0019]    The bottom  5  is provided with a midsole portion  7  particularly in the areas of the hindfoot portion  19 . The midsole portion  7  is shown as integral with the outsole portion  6  and is positioned between the outsole portion  6  and the bed liner layer  13 . If an insole  11  is provided it is placed above the containment layer  13 . The midsole portion  7  overlies the hindfoot portion  19  of the outsole portion  6  and underlies the hindfoot portion  19  of the bed liner layer  13 . The bed liner layer  13  is positioned and secured in the shoe  1  in overlying relation to the support member  12  and the interior portion of the bottom  5 . In a most preferred embodiment, the bed liner layer  13  is riveted to the support member  12  via rivets  14 , and the bed liner is adhered, via over-molding, adhesive or the like to the midsole  7  to create a sandwich construction that secures the support member to the midsole. The midsole  7  also functions as a heel portion  18  to elevate the hindfoot portion  19  of the insole  11 . The heel portion  18  of the present invention provides a mounting area for the gas cushion member  9  as described below. The heel portion  18  of the midsole portion  7  includes a pocket  31 , therein for housing the gas cushion member  9 . The outsole portion  6  can form a bottom wall  32  for the pocket  31  and the midsole portion  7  can form the sidewalls  33  of the pocket  31 . A port  34  can be provided in heel area of the sidewall  33  so the gas cushion member  9  is exposed for viewing. The midsole portion  7  can be made of any suitable material or combination of materials that preferably provide resilient cushioning such as an elastomeric or polymeric foam. The midsole portion  7  can be secured in place as by stitching, cementing or encapsulation in other shoe components if it is made separate from the outsole portion  6 . 
         [0020]    The gas cushion member  9  is positioned in the pocket  31  and is positioned to underlie a portion of the heel portion  18  of the upper  3  and overlie a heel portion of the outsole  6  to provide cushioning support for the heel area of a shoe wearer. The gas cushion  9  can be molded in place in the bottom  5  if desired. The gas cushion member  9  extends laterally across the heel portion  18  of the upper  3  and preferably at least about one-half the interior width of the heel portions  18  for a substantial portion of the length of the heel portion  19 . In one particularly preferred embodiment, the shoe  1  is provided with a heel height  80  of one and one quarter inches, and the gas cushion height  82  is about three quarters of an inch. The gas cushion member  9  is resiliently deformable and is soft to provide cushioning for a user&#39;s foot in the shoe  1 . In a preferred embodiment, the gas cushion member  9  contains a fluid, preferably one or more gases such as air. The gas cushion member  9  has at least one sealed chamber  39  formed by a bottom wall  41 , sidewall  42  and top wall  43  to contain the gaseous fluid therein. Preferably, the walls  41 - 43  of the gas cushion member  9  are made of a polymeric material such as polyethylene, polypropylene or polyurethane that will contain the fluid for an extended period of time of use. The cushion member  9  can have more than one chamber  39 , and at least one chamber preferably extends across a substantial portion of the cushion and the heel portion  18 . More preferably, a chamber  39  extends laterally across at least one-half of the width of the heel portion  18  where the chamber  39  is located at least at the widest part of the chamber  39 . The gas cushion member  9  also extends lengthwise of the heel portion  19  a substantial portion of the length thereof and preferably at least about one-half the length of the heel portion  19 . In a particularly preferred embodiment, there is a single gas cushion member  9  with a single main chamber  39  in a shoe  1 . The cushion  9  can be provided with a plurality of upright columns  44  extending between and secured to the bottom and top walls  41 ,  43 . The columns  44  can be formed hollow and when the cushion  9  is molded in place in the bottom  5 , can receive bottom material therein. The cushion  9  is suitably mounted in a pocket  31  and occupies a substantial portion of the volume thereof and preferably, substantially all of the volume of the pocket  31 . The chamber  39  may be pressurized or at about ambient pressure when not loaded by a shoe user. If the cushion  9  is sealed, it would thereby be pressurized when a user places load on it during use. 
         [0021]    A support member  12  ( FIGS. 1-3 ) is provided in the shoe  1 . One function of the support member  12  is to provide a relatively rigid foot support platform on the top of at least a portion of the cushion  9  and in at least the midfoot portion  17 , and preferably at least about half of the forefoot portion  15  to overlie the outsole  6  in these areas. The support member  12  is configured from a tempered steel to resist torsional twisting of the bottom  5  along its length, and to resist bending or flexing of the bottom laterally across the bottom. The support member  12  has a heel portion  51  and a forward portion  52 . The support member heel portion  51  is positioned and secured in overlying relation to at least a portion of the cushion member  9 . The support member  12  can be molded onto the upper surface of the bottom  5  for securement. Preferably, the support member is slightly embedded into the upper surface of the bottom  5  and the bed liner  13  and is adhered to the support member and the bottom. (see  FIG. 4 ). This can be accomplished by molding the support member  12  and the bed liner in place. Alternatively, adhesives, RF welding and/or rivets  14  may be utilized to provide additional securement to the support member. The overlay of the bed liner  13  creates a sandwich construction that prevents the support member from separating from the bottom. The support member  12  preferably covers a substantial portion of the width and length of the gas cushion member  9 . As shown, the outer perimeter defined by an outer edge  53 , is within the outer perimeter of the gas cushion  9  as defined by the outer edge  56  of the gas cushion. The heel portion  51  of the support member extends along a substantial portion of the length of the heel portion  18  of the upper  3 . The heel portion  51  has a transverse width in the range of between about ⅜ inch to about 1 inch and may vary along its length. The gas cushion  9  can have a width at its widest point on the order of 2-3 inches depending on the shoe size and style. The support member  12  forward portion  52  is shown as having two arms  57  to help fix the position of the support member within the bottom  5 . The arms  57  allow for air flow through the support member  12  in the toe box  16 . The forward portion  52  extends at least over the midfoot portion  17  and, in addition, preferably over a portion of the forefoot portion  15 . In a preferred embodiment, the forward portion  52  has an outer edge of the two arms  57  spaced inwardly of at least the interior edges of the side portions of the midfoot portion  17  and also in the forefoot portion  15  in the range of between about ½ inch and about 1 inch. The interior perimeter edges of the shoe  1  correspond generally to the outer perimeter edge of a full size insole  11  and the bed liner  13 . The support member  12  also includes the forward portion  52  that extends forwardly of the heel portion  51  in the shoe  1  into the midfoot portion  17  and forefoot portion  15  of the upper  3  in overlying relation to the outsole  6 . The forward portion  52  has an upper surface  72  that is concavely curved and a lower surface  73  that can be convexly curved. The support member  12  is relatively stiff and can be made of a resiliently deformable metal alloy such as steel or can be a molded rigid polymer. In a most preferred embodiment, the support member is constructed from a spring tempered steel. If made of steel, the thickness of the support member  12  can be on the order of about 1/64 inch to about 3/32 inch. The width of the component parts of the support member  12  is on the order of about ½ inch to about 1 inch. As shown, the support member  12  is made of a metal alloy and has formed grooves  71  ( FIG. 3 ) extending inwardly from surface  72 . The grooves  71  can be formed with a corresponding rib projecting from the surface  73  as by stamping or rolling. The ribs extend downwardly into the bottom  5  when the support member  12  is embedded in the bottom  5  as seen in  FIG. 4 . The heel portion  51  has a generally oval shaped outer perimeter, and the outer perimeter of the forward portion  52  is generally oval with a flat side facing the front of the heel. 
         [0022]    The support member  12  provides resistance to the cushion deformation from side to side during loading of the cushion  9  centrally during use allowing the use of a cushion with a low number of chambers  39 , e.g., one or two. The forward portion  52  provides a relatively rigid platform for engagement with the forefoot portion of a foot to resist bending of the sole across the shoe  1  and is curved to provide for a substantially normal walking gait. The forward portion  52  and the heel portion  51  also limit torsional twisting or deformation of the bottom  5  about a longitudinal axis of the bottom  5 . This resistance to deformation is further increased by bonding the support member  12  to the bottom  5 . It is also preferred that the bottom surface  78  of the outsole  6  in the forward portion of the midfoot region  17  and at least the rear portion of the forefoot region  15  be relatively straight extending laterally across the outsole  6 , but as noted above, can be convexly curved front to rear. 
         [0023]    It is to be understood that while certain forms of the invention are illustrated, it is not to be limited to the specific forms or arrangements herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein. 
         [0024]    One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.