Abstract:
A footbed system is disclosed which includes at least one sole pad and at least two heel cups. Each heel cup including a base and a side wall extending from the base on the medial and lateral sides thereof. The volume of the side walls of each heel cup is varied to accommodate different width heels of users. The volume is modified by changing the height and/or thickness of the heel cup side walls. A cushion is coupled to the lower surface of the sole pad in a forefoot region and a damper is coupled to the lower surface of the sole pad in a heel region. The sole pad is detachably connectable to the heel cup that best accommodates the user&#39;s heel width.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Division of U.S. patent application Ser. No. 09/573,341 filed May 18, 2000, which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     The present invention relates to shoes, and more particularly, relates to a removable footbed system with variable sized heel cups for use with golf shoes. 
     BACKGROUND OF THE INVENTION 
     A golfer&#39;s performance depends substantially on the ability of the golfer&#39;s shoes to provide a solid base of support. To that end, golf shoes generally include a shoe upper joined to an outsole to define a chamber for receiving the golfer&#39;s foot. Furthermore, the bottom surface of the outsole includes numerous cleats for providing traction. 
     The traction provided by the cleats upon interaction between the outsole and the ground enables the golfer to perform the body movements necessary to culminate in an ideal contact between the club head and the ball (i.e., a golf swing), if the shoes fit properly. If the shoes are too loose in the heel area, a golfer&#39;s foot can move relative to the ground which is undesirable. Since the majority of golfers cannot afford custom made shoes, they must wear shoes of a pre-made size that best fit their feet. In order to improve fit, insertable shoe insoles are commonly used. These insoles also provide cushioning and arch support for a user&#39;s foot. 
     One example of such an insole is disclosed in U.S. Pat. No. 5,068,983 to Marc. The shoe insole in this patent includes a resilient base piece that is disposed primarily at the heel area and has a cupped peripheral wall. A heel piece is disposed within the base piece and provides shock absorption at the heel. A top cushioning layer overlies the base and heel pieces and is affixed to them with an adhesive. The top cushioning layer extends from the heel area forwardly to underlie the ball and toe areas. 
     There remains, however, a need in the art for other insoles, which are easy to manufacture and improve the fit of user&#39;s feet within their shoes. 
     SUMMARY OF THE INVENTION 
     The invention relates to a footbed system at least two heel cups. Each heel cup includes a base and a side wall that extends upwardly from the base. The first heel cup has a first volume of the side wall and the second heel cup has a second volume of the side wall, with the second volume is different from the first volume. One, selected heel cup is used. The narrower the heel width the greater the volume of the side walls of the heel cup are to assure good fit. 
     In another embodiment, the footbed system further includes a sole pad detachably connectable to the selected heel cup. In yet another embodiment, the footbed system includes a third heel cup with a third volume of the side wall is different from the first and second volumes. 
     Preferably, the first and second volumes are different adjacent a user&#39;s heel, and modified by changing the heights and/or thicknesses of the heel cups. 
     A cushion may be coupled to the lower surface of the sole pad in a forefoot region, and a viscoelastic damper may be coupled to the lower surface of the sole pad in a heel region. Fasteners may be included for to detachably connect the sole pad to each heel cup. The height of the side walls of the heel cups rearward of a shank area may additionally be varied. 
     The present invention further concerns a shoe that includes an upper, a midsole, an outsole, at least one sole pad, and a heel cup selected from at least two heel cups. Each heel cup includes a base and a side wall that extends from the base, with the first heel cup has a first volume of the side wall and the second heel cup has a second volume of the side wall. The second volume is different from the first volume. The selected heel cup is detachably connected to the sole pad to form a footbed system. The upper, midsole, and outsole are joined together to define an opening for receiving the footbed system. 
     The present invention is also related to a method of providing variable fit for a pair of shoes, the method including: providing a first sole pad, providing a first set of first heel cups of variable sizes, each first heel cup has side walls of different volumes from one another, selecting the first heel cup that provides preferred fit for a first foot, detachably connecting the first sole pad to the first selected heel cup to form a first footbed system, with the first selected heel cup underlying the first sole pad; and inserting the first footbed system in one shoe. The method may further include: providing a second sole pad; providing a second set of second heel cups of variable sizes, each second heel cup has side walls of different volumes from one another; selecting the second heel cup that provides preferred fit for a second foot, detachably connecting the second sole pad to the second selected heel cup to form a second footbed system, with the second selected heel cup underlying the second sole pad; and inserting the second footbed system in the remaining shoe. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     To facilitate the understanding of the characteristics of the invention, the following drawings have been provided wherein: 
     FIG. 1 is an exploded, perspective view of a footbed system of the present invention for placement in a shoe, 
     FIG. 2 is a top view of a sole pad of the present invention, 
     FIG. 3 is a top view of a heel cup of the present invention, 
     FIG. 4 is a front, perspective view of the heel cup of FIG. 3; 
     FIG. 5 is a bottom view of the footbed system of the present invention, 
     FIG. 6 is a side view of a medial side of the footbed system of FIG. 5; 
     FIG. 7 is a side view of a lateral side of the footbed system of FIG. 5; 
     FIG. 8 is a side, perspective view of a “low” heel cup for accommodating a wide heel; 
     FIG. 9 is a side, perspective view of a “medium” heel cup for accommodating a medium-width heel 
     FIG. 10 is a side, perspective view of a “high” heel cup for accommodating a narrow-width heel; 
     FIGS. 11 a-c  are side views of the medial side of the three different heel cups of FIGS. 8-10, respectively; 
     FIGS. 12 a-c  are side views of the lateral side of the three different heel cups of FIGS. 8-10, respectively; 
     FIG. 13 is a cross-sectional view of the footbed system shown in FIG. 5 along the line  13 — 13  of FIG. 5 without a cushion; 
     FIG. 14 is a cross-sectional view of the footbed system shown in FIG. 5 along the line  14 — 14  of FIG. 5 without the cushion; 
     FIG. 15 is a cross-sectional view of the footbed system shown in FIG. 5 along the line  15 - 15  of FIG. 5; 
     FIG. 16 is a cross-sectional view of the footbed system shown in FIG. 5 along the line  16 - 16  of FIG.  5 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to the drawings, wherein like reference numbers are used to designate like parts, and as shown in FIG. 1, there is illustrated an embodiment of a footbed system  10  for placement in a golf shoe  12  according to the present development. Golf shoe  12  includes an upper  14 , a midsole  16 , and an outsole  18 . The upper  14  is conventional and formed from a suitable material, such as leather, a synthetic material or the like. The upper  14  is joined to the midsole  16  using cement or the like and conventional techniques. Once joined thereto the upper  14  defines an opening  20  for receiving the footbed system  10  and a wearer&#39;s foot (not shown). 
     The midsole  16  provides cushioning to the wearer, and is formed of a material such as ethylene vinyl acetate copolymer (EVA). The midsole  16  is formed on the outsole  18 . Once the midsole and outsole are joined, the outsole forms the bottom of shoe  12 . 
     Referring to FIGS. 1-5, footbed system  10  includes a sole pad  22  and a heel cup  24 , both of which are preferably formed of EVA. Perforations (not shown) may be provided through sole pad  22  for enhanced breathability. Sole pad  22  has a fabric-covered top side  25   a  and a bottom side  25   b , and underlies substantially the entire length of the user&#39;s foot. The heel cup  24  also has a fabric-covered top side  26   a  and a bottom side  26   b . The EVA is lightweight, and the polymer/fabric composite effectively handles the moisture that develops at the base of the foot. The sole pad and base are formed as separate, single molded pieces with the recesses and other portions as discussed below formed therein during molding. The holes are subsequently die cut. 
     The sole pad  22  further includes cushion  27  provided in the forefoot area and a damper  28  in the heel area. Preferably, the cushion  27  fits within a recess  30  (as best seen in FIG. 14) on the bottom side  25   b  of sole pad  22 , and includes a recess peripheral portion  31  that extends to a peripheral edge  31   a.    
     The cushion  27  may be, for example, a soft polymer pad, an air bladder, or a bladder filled with a cushioning material like a gel or liquid. Most preferably, the cushion is formed by filling a plastic bladder with air and small discrete pieces of cushioning material such as pellets  33 . The pellets  33  are formed of thermoplastic rubber (TPR) with a Shore A hardness of between about  5  to about  15 , and more preferably about  10 . The pellets  33  have a generally cylindrical shape. However, pellets of other shapes can also be used. Such pellets have rubbery properties which permit deformation and thus serve as an effective cushioning material. The bladder is glued, bonded, or otherwise connected to the bottom side of sole pad  22 , thereby encasing pellets  33  within recess  30 . The contents of the cushion  27 , such as pellets, and air. It is recommended that the pellets  33  are at least 4 grams per piece. 
     Referring to FIGS. 2 and 3, damper  28  (shown in phantom) preferably has a generally oval shape, and has a protrusion  34  that fits in a locating hole  36  in sole pad  22 . The remaining portion of the damper  28 , less the protrusion  34 , fits in a recess  37  in sole pad  22 . The damper is permanently attached to sole pad  22  by adhesive, thermal, or other bonding techniques. Damper  28  is accommodated in a matching hole  38  that extends through heel cup  24 . The damper  28  and hole  38  are configured and dimensioned so that damper  28  fits snugly in hole  38  and has about the same thickness as heel cup  24 . Alternate shapes may also be used for damper  28 , such as a circle or two partially-overlapping ovals. The damper may be formed of materials including viscoelastic materials, such as a polyurethane gel. 
     In another embodiment, cushion  27  and damper  28  can be removably attached to sole pad  22 . Additionally, damper  28  may instead be accommodated in a matching recess in the top side  26   a  of heel cup  24  instead of the hole  38  therethrough. 
     Referring again to FIGS. 2 and 3, sole pad  22  is detachably connected to heel cup  24 , such as by hook and loop fasteners  42 . Preferably, separate, matching, circular-shaped fasteners are adhered in recessed areas on both sole pad  22  and heel cup  24 , with the fastener hook portion adhered to one and the fastener loop portion adhered to the other. To adequately secure sole pad  22  to heel cup  24 , fasteners  42  are located near a front edge  44  and a rear area  46  of heel cup  24 , and fasteners are secured at the rear and middle of the sole pad  22 . Although hook and loop fasteners have been used to attach a sole pad to a heel cup, the type of fasteners can vary. 
     Referring to FIGS. 3 and 4, the heel cup  24  further includes side walls  50   a  and  50   b , and back wall  52 , surrounding a raised platform area  54 . Side walls  50   a,b  and back wall  52  extend upwardly from platform area  54 , which extends above base  56 . The medial side wall  50   a  is configured at arch portion  49  to support the arch area of a user&#39;s foot. Notably, the inward slope of the lateral side wall  50   b  is significantly more steep that the inward slope on the medial side wall  50   a  (as best seen in FIG.  15 ). When sole pad  22  is placed on top of heel cup  24  on base  56 , top side  25   a  of sole pad  22  (as shown in FIG. 1) is slightly below the inside edge  57  of raised platform area  54 . Criss-crossing indentations  32  (as best seen in FIG. 5) also may be provided along the bottom side of heel cup  24 . 
     Referring again to FIGS. 2 and 3, different configurations of sole pads  22  and heel cups  24  must be provided for the left foot and the right foot. In particular, because the arch is located on the medial side of the foot, the heel cup arch portion  49  must be provided on the medial side of heel cup  24 . In order to facilitate the proper matching of sole pad  22  configured for a left foot and shoe with heel cup  24  configured for a left foot, a notch  58  is provided on the cup  24 . Preferably, notch  58  is triangular. A matching triangular tongue  59  is provided on the bottom side  25   b  of sole pad  22  for interlocking engagement with notch  58 . Thus, a user can match sole pad  22  configured and dimensioned for use with a left foot with heel cup  24  that is also configured and dimensioned for use with a left foot. Similarly, sole pad  22  and heel cup  24  may be matched for a right foot and shoe. Additional indicia or side indicators may be provided to assist the user in matching sole pads and heel cups, for example lettering on each sole pad and heel cup designating the components for a left or right foot and shoe can be used. 
     As seen in FIGS. 6 and 7, the medial side  50   a  and the lateral side  50   b  of heel cup  24  have different contours at the free edge. For example, medial side wall  50   a  extends to a greater height H M  than the height H L  of lateral side wall  50   b.    
     Referring to FIGS. 8-10, the present footbed system preferably includes a set of three heel cups  60 ,  62 ,  64  having varying sizes for use with one sole pad  22  (as shown in FIG.  1 ). These heel cups  60 ,  62 ,  64  are designated “low”, “medium”, and high”, respectively. Heel cups  60 ,  62 ,  64  are sized to accommodate heel widths of wide (low height walls), medium (medium height walls), and narrow (high walls), respectively. The heel cups are optionally color-coded to facilitate use, such as by using fabric coverings of blue, black, and green for heel cups  60 ,  62 ,  64 . Thus, three different ranges of widths of heel sizes are accommodated with such a footbed system, and as a result, the wearer can customize the footbed by selecting the heel cup that best matches the wearer&#39;s heel width. 
     As shown in FIGS. 8-12, the dimensions for heel cups  60 ,  62 ,  64  are shown. Preferably, the front height of the medial side wall  50   a  remains constant for the different heel cups  60 ,  62 ,  64  or widths, such that H MW1 =H MM1 =H MN1 . The rear height of the medial side wall  50   a  decreases as heel width increases, with H MN2  greater than H MN2,  and H MM2  greater than H HW2 . Similarly, the front height of the lateral side wall  50   b  remains constant for the different heel cup sizes, such that H LW1 =H LM1 =H LN1 , while the rear height of the lateral side wall  50   b  decreases as heel width increases, with H LN2  greater than H LM2 , and H LM2  greater than H LW2 . As used herein, subscripts when read from left to right refer to the side with M for medial or L for lateral, the heel width accommodated with N for narrow, M for medium, or W for wide, and the location of measurement with  1  for the front location and  2  for the rear location. 
     The height of each back wall  52  remains constant for the different heel cup sizes, such that H BW =H BM =H BN , where the subscripts when read from left to right refer to B for back wall, and the heel width accommodated with N for narrow, M for medium, or W for wide. Most preferably, the front and rear heights of the medial and lateral side walls, as well as the height of the back walls, are the values listed in Table I. 
     The thickness of the side walls also changes between cups so that the volume of the side walls for the low cup is less than the volume of the side walls for the high cup. 
     EXAMPLE 
     These and other aspects of the present invention may be more fully understood with reference to the following non-limiting example, which is merely illustrative of one embodiment of the present invention footbed system. Commonly, the dimensions will vary depending on the footbed dimensions built into the last, which is the form around which the shoe is made. Thus, this embodiment is not to be construed as limiting the invention, the scope of which is defined by the appended claims. 
     Table I sets forth dimensions for high, medium, and low heel cups of the present invention. 
     
       
         
               
             
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE I 
               
               
                   
               
               
                 Dimensions for Three Sizes of Heel Cups. 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 HEEL CUP SIZE 
                 HIGH 
                 MEDIUM 
                 LOW 
               
               
                 HEEL WIDTH 
                 narrow 
                 medium 
                 wide 
               
               
                 REFERENCE NUMBER OF HEEL CUP 
                 64 
                 62 
                 60 
               
               
                 COLOR 
                 green 
                 black 
                 blue 
               
             
          
           
               
                 MEDIAL FRONT HEIGHT 
                 22 mm 
                 (H MN1 ) 
                 22 mm 
                 (H MM1 ) 
                 22 mm 
                 (H MW1 ) 
               
               
                 MEDIAL REAR HEIGHT 
                 27 mm 
                 (H MN2 ) 
                 22 mm 
                 (H MM2 ) 
                 16.5 mm 
                 (H MW2 ) 
               
               
                 LATERAL FRONT HEIGHT 
                 16.5 mm 
                 (H LN1 ) 
                 16.5 mm 
                 (H LN1 ) 
                 16.5 mm 
                 (H LN1 ) 
               
               
                 LATERAL REAR HEIGHT 
                 27 mm 
                 (H LN2 ) 
                 22 mm 
                 (H LM2 ) 
                 16.5 mm 
                 (H LW2 ) 
               
               
                 BACK WALL HEIGHT 
                 16.5 mm 
                 (H BN ) 
                 16.5 mm 
                 (H BM ) 
                 16.5 mm 
                 (H BW ) 
               
               
                 THICKNESS AT FRONT LOCATION 
                 6 mm 
                   
                 4 mm 
                   
                 4 mm 
               
               
                 THICKNESS AT REAR LOCATION 
                 8 mm 
                   
                 4 mm 
                   
                 2 mm 
               
               
                 THICKNESS OF BACK WALL 
                 6 mm 
                   
                 4 mm 
                   
                 4 mm 
               
               
                   
               
             
          
         
       
     
     As seen from the dimensions above, the front heights of the medial and lateral side walls each remains constant for high, medium, and low heel cup sizes. Furthermore, the rear heights of the medial and lateral side walls decrease as heel width increases. The back wall heights remain constant for high, medium, and low heel cup sizes. 
     All of the thickness measurements above are taken at the same vertical position on each heel cup side wall. The thickness at the front location is the thickness of both the medial and lateral walls at the position  1  in FIGS. 11 a-c  and  12   a-c . The front location thickness of the high cup  64  for narrow heels is greater than the front thickness of the medium and low cups at the front position. The thickness at the rear position is the thickness of both the medial and lateral walls at the position  2  in FIGS. 11 a-c  and  12   a-c . The thickness of the high cup  64  for narrow heels is greater than the thickness of the medium cup  62  for medium width heels. The thickness of the medium cup  62  is greater than the thickness of the low cup  60  for wide heels. The thickness of the back wall is the thickness of the wall  52  in FIGS. 11 a-c  and  12   a-c . The back wall thickness of the high cup  64  is greater than the back wall thicknesses of the remaining cups. 
     As a result of the height and thickness variations of the side walls between cups, the volume of the side walls of the high cup  64  is greater than the same volume of the medium cup  62 , and the side wall volume of the medium cup  62  is greater than the side wall volume of the low cup  60 . Thus, the high cup for use with narrow heels has a larger side wall volume to fill gaps between the foot and the shoe when compared to the other cups for use with wider heels. 
     Referring to FIG. 13, when the sole pad  22  and heel cup  24  are mated, preferably there is a slight taper such that the thickness T F  of sole pad  22  at front end  66  is less than the combined thickness T B  of sole pad  22  and heel cup  24  near back end  68 . Most preferably, the combined thickness of the sole pad  22  and heel cup  24 , T M , near the front edge  44  of heel cup  24  is equivalent to the combined thickness T B  near the rear end  68 . 
     In a preferred embodiment, sole pad  22  has a thickness T F  at front end  66  of about 5.0 mm, a thickness T M  near the front edge  44  of heel cup  24  of about 6.0 mm, and a thickness T B  at back end  68  of about 6.0 mm. There is a slight taper from the front end  66  of the sole pad  22  to front edge  44  of heel cup  24 , such that the intermediate thickness, T I , of the sole pad is about 5.5 mm. Preferably, the heel cup  24  has a primary cup thickness, T C , of about 3.0 mm, and the portion of sole pad  22  overlaying heel cup  24  also has a thickness T O  of about 3.0 mm. Each indentation  32  on heel cup  24  has a depth of about 1.5 mm, and the portion of sole pad  22  surrounding protrusion  34  in locating hole  36  preferably has a thickness, T H , of about 1.0 mm. Furthermore, a lower rear edge  70  of heel cup  24  is rounded. 
     FIGS. 14-16 show cross-sections of the footbed system  10  (as shown in FIG. 5) at various longitudinal positions. In a preferred embodiment, recess peripheral portion  31  has a depth D I  of 1.5 mm to accommodate the peripheral edge of the cover  27   a  (as shown in FIG. 1) on cushion  27  that extends to peripheral edge  31   a . Preferably, the recess  30  has a total depth D 2  of about 3.0 mm, including the depth of recess peripheral portion  31  used for sealing the cover to sole pad  22 . 
     A kit for custom fitting a user&#39;s foot in a shoe can also be provided. For example, a sole pad  22  (as shown in FIG. 1) and a set of three heel cups  60 ,  62 ,  64  (as shown in FIGS. 8-10) having varying sizes, as discussed above, can be provided for each shoe, packaged together so that the wearer of the shoe can customize the fit in the heel area of the shoe to improve performance. The heel cups and pad can be provided with shoes at the time of sale, or the footbed system may be offered separately for use with existing shoes. The degree of support for each foot can thus be individually selected, and different sized heel cups can even be chosen for use simultaneously, one in each of the left and right shoes of a user. 
     The present invention also involves a method of providing variable fit for a shoe. At least one sole pad is initially provided with a number of heel cups of variable sizes to accommodate different heel widths. The user selects the heel cup that provides a preferred fit for a particular foot based on heel width. The sole pad is detachably connected to the selected heel cup to form a footbed. The sole pad and heel cup are inserted into the shoe. This is repeated for the user&#39;s second foot. 
     While it is apparent that the invention herein disclosed is well calculated to fulfill the objects above stated, it will be appreciated that modifications and other embodiments may be devised by those skilled in the art. For example, the height of the front side walls of the cups can be varied between cups, as can the height of the back wall. In addition, the sole pad can be provided with side walls adjacent the forefoot of the wearer. Sole pads of different sizes and/or different configurations can be provided with each system. Alternatively, sole pads can be provided in an oversized configuration that can include a trimming grid for selective shaping by the user. Likewise, heel cups can include oversize portions with a trimming grid. Furthermore, sets of two or more heel cups are contemplated for each footbed system. Thus, although the aforementioned footbed system contained three heel cups and one sole pad for each shoe, other systems may include a different number of heel cups and sole pads. The present invention is not limited to the heel cup lengths disclosed above. Alternatively, the heel cups can extend the length of the foot and form part of a set with various volumes of sidewalls in the rearward portion. The embodiments above can be modified so that some features of one embodiment are used with the features of another embodiment. It is intended that the appended claims cover all such modifications and embodiments as fall within the true spirit and scope of the present invention.