Abstract:
A comfort system for Cowboy and work boots, including an insole chassis, an insole chassis backing board, and cushioning pads for absorbing and attenuating shocks encountered by a wearer of the boots. Cushioning pads are secured to a surface of the insole chassis backing board, and apertures in the insole chassis allow the cushions to pass through. Additional cushioning pads are retained in recesses in the midsole. Pads on insole chassis backing board and midsole are vertically aligned. A steel toe inset is utilized in conjunction with the comfort system for work boots. A rim may depend below the midsole to receive a foamed plastic pad.

Description:
FIELD OF THE INVENTION 
       [0001]    The invention pertains to a comfort system for boots joined together by a Goodyear Welt, such system enhancing the comfort of the boots, without negative impact upon durability of the boots. 
       BACKGROUND OF THE INVENTION 
       [0002]    The invention relates generally to boots, such as cowboy boots and work boots, which employ a comfort system, relying upon vertically aligned foamed plastic pads, at strategic areas, of high impact, such as the ball and heel areas of the boot. The comfort system is compact and fits easily into the interior of the boot. One pair of pads is secured to an insole liner backing board, while another pair of pads is secured to the upper surface of the midsole. 
         [0003]    The Goodyear welt system is widely used in the manufacture of boots and shoes. The Goodyear welt stitch is applied to the shoe or boot with a great amount of pressure, and a rigid inner sole board must be strong enough to withstand such pressure. However, the rigid inner sole board presents a source of discomfort to the wearer, and resilient cushioning pads have been employed in some boots, in an effort to minimize such discomfort. 
         [0004]    To illustrate, U.S. Pat. No. 5,911,491, granted to Marvin O Huff, discloses a comfort system for a shoe or boot, including a rigid inner sole board ( 10 ). Full-length cushioning pad ( 15 ) is placed on top of the innersole board, and precut detachable pieces ( 11   a,    11   b ) are defined on the innersole board. Removing the detachable pieces allows rectangular cushioning pads ( 20   a,    20   b ) to contact the cushioning pad to provide additional cushioning effect. The rectangular pads are located at the heel of the boot, and under the ball of the foot of the wearer, the points of maximum impact for the wearer of the boot. 
         [0005]    While the comfort system disclosed in Huff represented a step forward, such comfort system exhibited shortcomings. The amount of cushioning achieved by such system was limited by the compression of pad ( 15 ) and cushioning pads ( 20   a,    20   b ). While the full length pad is of uniform thickness, the polyurethane cushioning pad located at the heel of the boot may be considerably thicker than the polyurethane cushioning pad attached at the forepart of the innersole board, as noted in column 3 lines 25-35 of Huff. 
       SUMMARY OF THE INVENTION 
       [0006]    It is an object of the present invention to provide a comfort system that employs two pairs of foamed polyurethane pads. One pair of pads is secured to the insole liner backing board, and the second pair of pads is retained in recesses on the upper surface of the midsole. The pads in the vicinity of the ball of the foot are vertically aligned, and the pads in the vicinity of the heel of the wearer are also vertically aligned. 
         [0007]    It is another object of the invention to provide an insole chassis, with two apertures, to allow one pair of foamed plastic pads secured to an insole chassis backing board, to pass freely therethrough. 
         [0008]    It is another object of the invention to provide a safety boot with a steel toe or hard plastic insert that protects the toes of the wearer. 
         [0009]    It is another object of the invention to provide a midsole with a depending rim that fits over, and around, a foamed polyurethane filler pad that enhances the performance of the comfort system by absorbing shocks. 
         [0010]    Other objects, and advantages, of applicants&#39; comfort system, will become apparent when the specification is construed in harmony with the appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a side elevational view of a cowboy boot employing a first embodiment of applicant&#39;s comfort system; 
           [0012]      FIG. 2  is a bottom plan view of the outer sole of the boot; 
           [0013]      FIG. 3A  is an exploded perspective of the comfort system of  FIG. 1 , taken from a first vantage point; 
           [0014]      FIG. 3B  is an exploded perspective of a portion of the comfort system of  FIG. 1 , taken from a second vantage point. 
           [0015]      FIG. 4  is a side elevational view of a work boot, with a steel toe insert, employing a second embodiment of applicant&#39;s comfort system; 
           [0016]      FIG. 5  is a perspective view and steel toe insert of the comfort system of  FIG. 4 , taken from a first vantage point, and showing the steel toe insert; 
           [0017]      FIG. 6  is another perspective view of the comfort system of  FIG. 4 , taken from a second vantage point; and showing the steel toe insert; 
           [0018]      FIG. 6A  shows the insole chassis backing board, midsole with depending rim, and foamed pad of  FIG. 6  in assembled condition; 
           [0019]      FIG. 7  is an exploded perspective of a third embodiment of applicant&#39;s comfort system, taken from a first vantage point; and 
           [0020]      FIG. 8  is another exploded perspective of the third embodiment of applicant&#39;s comfort system, taken from a second vantage point. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]      FIG. 1  is a side elevational view of a cowboy boot  10  shown in dotted outline, and identified, generally, by reference numeral  10 . The boot includes an upper  12  and a shaft  14  that fits about the calf area of the wearer of the boot. Outer sole  16  is located at the base of the boot, and heel  18  is formed at the rear of the outer sole. The comfort system, indicated generally by reference numeral  20 , is located in the interior of the boot, and extends from the heel to the toe of upper  12 . Upper  12  is secured to the insole of the boot along welt  19  as part of by the Goodyear welting process. The midsole is cemented, and then stitched to the welt. The midsole is cemented, and then stitched to welt  19 . 
         [0022]      FIG. 2  show, the underside of outer sole  16  that contacts the ground. Outer sole  16  comprises a front section  16 A, a midsection  16 B, and a rear section, or heel  18 . 
         [0023]    Smaller bracket  20 , shown in  FIGS. 3A and 3B , encompasses the components of the comfort system located in the interior of boot  10 . Larger bracket  66 , shown only in  FIG. 3A , shows all of the components that comprise the comfort system, plus midsole  50 , insert  51 , shank  54 , and outer sole  16 , which are located below the midsole and complete the boot  10 . 
         [0024]      FIGS. 3A and 3B  are exploded perspective views of applicant&#39;s comfort system, and are taken from different vantage points to clearly show the upper and lower surfaces of each component. A removable orthotic  21  receives the foot of the wearer of the boot. Insole cover layer  22 , of foamed polyurethane, extends from the heel of the boot toward the ball of the foot of the wearer and performs a shock absorbing function. Foam pads  24 ,  26  are located beneath layer  22 , and pass through into apertures  28 ,  30  in insole chassis  32 . Pad  24  is located under the heel of the wearer of the boot, while pad  26  is located under the forepart or ball of the foot of the wearer. 
         [0025]    Pad  24  approximates an ellipse. Pad  24 , has a transverse leading edge  25 ; pad  26  is widest at its leading edge  27  and tapers rearwardly. Insole chassis backing board  34  is located below insole chassis  32 , and pads  24 ,  26  are secured to the upper surface of insole chassis backing board  34 . Score lines  36  are formed in board  34  below the heel of the wearer, and in vertical alignment with pad  24  and aperture  28 . Score lines  38  are also formed in the insole chassis backing board  34  below the ball of the foot of the wearer, and in vertical alignment with pad  26  and aperture  30 . The score lines impart flexibility to the insole chassis backing board  34 , in selected areas, in the vertical direction. 
         [0026]    Insole chassis backing board  34  is the last of the components of the comfort system retained within the interior of the boot. Bracket  20 , shown in  FIGS. 3A and 3B  encloses the components of the comfort system. 
         [0027]    Insole filler layer  40 , formed of foamed plastic material, is located beneath insole chassis backing board  34 . Foamed plastic pads  42  and  44  fit into recesses  46 ,  48  on the upper face of midsole  50 . Foamed plastic pads  42 ,  44  are similar in shape to foamed plastic pads  24 ,  26 , are formed of similar plastic materials, and are in vertical alignment therewith. Insole filler layer  40  overlies midsole  50 . Foamed plastic pads  42 ,  44  are retained in recesses  46 ,  48  on the upper surface of midsole  50 . 
         [0028]    Support layer, indicated generally by reference numeral  51 , is fabricated with a soft polyurethane core  52 , which is more flexible than outer sole  16 . Nylon shank  54  embedded in the core to provide additional strength and rigidity, and layer complete layer  51 . 
         [0029]    An upwardly opening cavity  58  is defined in the upper surface of outer sole  16  and heel  18 . Tab  56 , formed at the leading front end of layer  51  is inserted into notch  60  on outer sole, to locate layer  18  within cavity  58  in outer sole  16 . 
         [0030]    Lead line  62  shows the vertical alignment of pad  26 , aperture  30  in insole chassis backing board  34 , and pad  44  retained in recess  46  on the upper surface of midsole  50 . Insole cover layer  22  and filler layer  40  are also properly aligned. 
         [0031]    Lead line  64  shows the vertical alignment of pad  24 , aperture  28  in insole chassis  32 , score lines  36  in insole chassis backing board  34 , and pad  42  retained in recess  48  on the upper surface of midsole  50 . Insole cover layer  22  and filler layer  40  are also properly aligned. 
         [0032]    Pad  26  includes a leading edge  27  and a parallel trailing edge. The sidewall is perpendicular to the leading and trailing edges. The other sidewall tapers inwardly from leading edge  27  toward the trailing edge, to approximate the shape of the ball of the foot. Pad  44  is shaped in a similar manner. 
         [0033]    Pad  24  has a leading edge  25  that extends perpendicularly part-way across the heel area of insole chassis board  32 . Pads  24  and  26  are glued, or cemented, to the upper surface of insole chassis backing board  34 . Pads  26  and  44  are similar in shape, and elliptical pads  24  and  42  are similar in shape. The thickness of the pads does not exceed the thickness of insole chassis  32 , so that comfort system  20  is compact, and consumes a minimum amount of space within the interior of boot  10 . 
         [0034]      FIG. 4  is a side elevational view of a work boot, shown in dotted outline, and identified generally by reference numeral  100 . The boot includes an upper  102 , a steel toe insert  103 , and an outer sole  104  with a heel  106 . Comfort system  108  is situated in the interior of the upper, when the upper is secured to the inner sole, as part of a known welting process, such as the Goodyear welting process. 
         [0035]    Metal toe insert  103  includes body  124 , which is generally C-shaped in cross-section, with spaced opposing lips  126 ,  128 . The lips engage the forward end of midsole  117 , so that the insert  103  protects the toes of the wearer of the boot. The forward edge of midsole  117  presses against barrier  132  at the closed end of insert  103  for proper alignment. 
         [0036]      FIGS. 5 and 6  show an alternative configuration of the comfort system  108 . System  108  includes foam insole ever  109 , liner board  111 , and insole chassis  112 . Apparatus  113 ,  114  are defined in the forepart and heel areas of insole chassis  112 , and pads  120  and  122  pass through the apparatus. 
         [0037]    Midsole  117  is located beneath insole chassis  112 , and a rim  116  depends from the midsole. Rim  116  is located along the periphery of the midsole, and foamed filler pad  118  fits within the contour of rim  116 . Pads  120 ,  122  are secured to the upper surface of midsole  117 , and pass through apparatus  113 ,  114  in insole chassis  112 . Score lines  117   a,    117   b  impair flexibility to midsole  117 . 
         [0038]    Comfort system  108  includes foam insole cover  109 , liner board  111 , insole chassis  112 , midsole  116 , insole chassis backing board  117  and foamed plastic filler pad  118 . Insole chassis backing board is secured to the upper surface of insole backing board  117 . 
         [0039]    A rigid rim  116  depends below insole chassis backing board  117 . The rib is formed of rib tape. Foamed plastic pad fits within the contours of rim  116 , to attenuate and/or absorb shock loading. Pads  120  and  122  are glued to the upper surface of insole chassis backing board  117 . 
         [0040]    Metal toe insert  103  comprises body  124 , which is generally C-shaped in cross-section, with spaced opposing lips  126 ,  128 . The lips engage the forward end of insole chassis  112 , and the lateral sider of insole chassis  112  may be notched to facilitate alignment. Alternatively, inset may be formed of a high-string in plastic. 
         [0041]      FIGS. 7 and 8  depict another embodiment of applicant&#39;s comfort system, which is identified, generally, by reference numeral  200 .  FIG. 7  shows the components of system  200 , in an exploded perspective view, with orthotic insert  202  on top, and outsole  203 , on the bottom.  FIG. 8  is taken from a different perspective, and shows the components with outsole  203  on top, and orthotic  202  on the bottom. 
         [0042]    Orthotic  202  is a soft foam member shaped to receive the foot of the wearer. Orthotic  202  is removable from the boot, and can be and cleaned, and re-inserted into the boot (not shown). 
         [0043]    Shock absorbing foam insole cover  204  is located beneath, and adjacent to orthotic  202 . The cover, which extends from the heel toward the ball of the foot of the wearer, conforms to the foot of the wearer. Insole chassis  206  is located beneath, and adjacent to, insole cover  204 . A large aperture  208  is located in the forepart of insole chassis  206 , and a smaller, elliptical aperture  210  is located in the area of the heel of the wearer. 
         [0044]    Foam pads  212 ,  214  are secured to the upper surface of insole chassis backing board  216  in the vicinity of the ball and heel of the foot of the wearer. Several score lines  218  and  220  are cut into insole chassis backing layer  216  to increase its flexibility. 
         [0045]    Insole filler pad  222  is located beneath insole chassis backing board  216  for shock attenuation. Pad  222  is formed of a foamed plastic, and contacts, and presses against the forepart of insole chassis backing layer  216 . Midsole retainer  224  is horse-shoe shaped, and cushion or pad  226  is retained within the horse-shoe shape. Midsole retainer  224  rests upon outsole  203 , which serves as a platform to support comfort system  200 . Comfort system  200  provides vertical alignment of pads  212 ,  222  and  226  in the forepart of the boot, i.e. under the ball of the foot of the wearer. Pad  214  is retained in alignment with the heel of the wearer of the boot. The pads remain in alignment due to the compressive forces applied to the insole cover  204  and midsole pad  226 , by the wearer of the boot. Alignment of the resilient pads are maintained by apertures  208 ,  210  in insole board layer  206 . (Apertures not shown in  208 ) 
         [0046]    Revision and modifications to the three disclosed embodiments of applicant&#39;s invention may occur to the skilled artisan, after contemplating the specification, without departing from the spirit of applicant&#39;s invention. For example, the foamed plastic pads on the insole chassis backing board and on the midsole, may be made of different foamed plastics with different functional characteristics. The pads under the ball of the foot may exhibit a rebound characteristic, while the pads under the heel may exhibit a shock absorbing characteristic. A layer of reinforcing material may be applied to the forward end of the midsole, in the vicinity of the steel toe, in the embodiment of  FIGS. 4-6 , to further strengthen the work boot. Consequently, the claim should be broadly construed in a manner consistent with the spirit and scope of applicants&#39; invention, and should not be limited to their literal terms. 
       PARTS LIST 1 for FIGS.  1 - 3   
       [0047]      10 —boot 
         [0048]      12 —upper 
         [0049]      14 —shank 
         [0050]      16 —outer sole 
         [0051]      18 —heel 
         [0052]      19 —welt 
         [0053]      20 —comfort system within bracket  16 A,  16 B,  16 C—parts of outer sole  16   
         [0054]      16 A,  16 B,  16 C—sections of outer sole  16  (see  FIG. 2 ) 
         [0055]      66 —(shown only in  FIG. 3A ) 
         [0056]      50 —midsole 
         [0057]      51 —insole 
         [0058]      21 —removable orthotic 
         [0059]      22 —insole cover layer 
         [0060]      24 ,  26 —foam pads 
         [0061]      28 ,  30 —apertures in insole chassis 
         [0062]      32 —insole chassis 
         [0063]      25 —leading edge on pad  24   
         [0064]      27 —leading edge on pad  26   
         [0065]      34 —insole chassis backing board 
         [0066]      36 ,  38 —score lines on backing board  34   
         [0067]      40 —insole filler layer 
         [0068]      42 ,  44 —foam pads 
         [0069]      51 —support layer 
         [0070]      52 —core of layer  51   
         [0071]      54 —nylon shank 
         [0072]      58 —cavity in outer sole  16   
         [0073]      56 —tab on layer  51   
         [0074]      60 —notch (to receive tab) 
         [0075]      62 ,  64 —lead lines showing vertical alignment 
       PARTS LIST FOR FIGS.  4 - 6 A DISCUSSED BELOW 
       [0076]      100 —work boot (in general) 
         [0077]      102 —upper 
         [0078]      103 —steel toe insert 
         [0079]      104 —outer sole 
         [0080]      106 —heel 
         [0081]      108 —comfort system 
         [0082]      109 —foam insole cover 
         [0083]      111 —liner board 
         [0084]      112 —insole chassis 
         [0085]      117 —midsole with depending rim  16 ;  117   a,    117   b —score lines on midsole 
         [0086]      118 —foam filler pad 
         [0087]      113 ,  114 —apertures in insole chassis  112   
         [0088]      124 —body (of insert  103 ) 
         [0089]      126 ,  128 —lips of insert 
         [0090]      132 —barrier (at closed end of insert  103 ) 
       PARTS LIST FOR FIGS.  7 - 8  DISCUSSED BELOW 
       [0091]      200 —comfort system 
         [0092]      202 —orthotic insert 
         [0093]      203 —midsole 
         [0094]      204 —insole cover 
         [0095]      206 —insole chassis with apertures  208 ,  210   
         [0096]      212 ,  214 —foam pads 
         [0097]      216 —insole chassis backing layer 
         [0098]      222 —midsole pad 
         [0099]      224 —midsole retainer 
         [0100]      226 —midsole pad