Footwear with insole system

A shoe including a footwear upper, an outer sole and an insole system, the insole system including a base insole component and an upper insole component. The base insole includes a chassis and first and a second shock absorbing inserts. The upper insole includes a spacer panel, first and a second gel insert members, and a fabric sheet layer. The insole system may be permanently secured in the shoe or be replaceable or interchangeable for installation and removal to and from the article of footwear by a user.

TECHNICAL FIELD

The present invention relates generally to the field of footwear, and more particularly to footwear having an insole system.

BACKGROUND

To a person or wearer of footwear such as a shoe, boot, sneaker or other footwear article, it is commonly preferred that the footwear be comfortable and appealing. Typically, this is not a problem to a wearer of flat bottom shoes—most people can find an article of footwear that is at least comfortable and appealing to the person wearing the footwear. Unfortunately, as the footwear becomes more appealing or dressier—for example, the heel of the footwear increasing in elevation as in womens' high heel footwear, the comfort often declines drastically. Time and time again, high heel shoes fail to provide comfort to the wearer; additionally failing to provide other important factors such as even distribution of pressure of the wearer's foot and supporting the same while ensuring the foot stays odorless, fresh and dry.

Accordingly, needs exist for footwear having improved insole systems, and in particular for womens' high heeled shoes that provide comfort and stability for the wearer. It is to the provision of a high heel shoe or other article of footwear meeting these and other needs that the present invention is primarily directed.

SUMMARY

In example embodiments, the present invention provides an article of footwear such as a shoe comprising an insole system for improved comfort and stability. In one aspect, the article of footwear includes a footwear upper, an outer sole or outsole member and an insole system. The upper generally includes an opening that is configured to receive a wearer's foot. The outer member is generally mounted to the upper. The insole system generally includes a base insole and an upper insole. The base insole includes a chassis or base layer and first and second shock absorbing inserts. The chassis generally has an upper surface and a lower surface, a lateral side and a medial side, a heel end and a forefoot end, and a heel portion, a midfoot portion, and a forefoot portion. The upper insole is generally mounted to the upper surface of the chassis and includes a spacer panel, first and a second gel insert members, and a fabric sheet layer.

In another aspect, the invention relates to an article of footwear such as a shoe including an upper, an outer member and an insole system. The upper includes an opening that is configured to receive a wearer's foot and the outer member is mounted to the upper. The insole system includes a base insole and an upper insole. The base insole includes a chassis and first and a second shock absorbing inserts. The chassis has an upper surface and a lower surface, a lateral side and a medial side, a heel end and a forefoot end, and a heel portion, a midfoot portion, and a forefoot portion. The chassis defines a central well formed at the heel portion having a peripheral wall defined along the well at the heel portion and extending along the lateral and medial sides of the chassis until gradually tapering at the midfoot portion. In one example form, the peripheral wall defines an outer collar that is generally transverse the wall and between the wall and an outer contour of the chassis. First and second shock absorbing inserts are mounted to the chassis wherein the first shock absorbing layer is mounted to at least a portion of the forefoot portion and the second shock absorbing layer is mounted to at least a portion of the central well at the heel portion. The upper insole includes a spacer panel having at least one opening formed therein, at least a first and a second gel insert, and a fabric sheet. The spacer panel includes a midfoot portion and a forefoot portion for extending along the midfoot and forefoot portions of the base insole, with the first gel insert being fitted within the opening of the spacer panel to be adjacent the first shock absorbing layer and the second gel insert abutting a portion of the spacer panel proximal the midfoot portion and being adjacent the second shock absorbing layer, and the fabric sheet mounted atop the spacer panel and at least the first and second gel inserts.

In still another aspect, the invention relates to a method of assembling an article of footwear such as a shoe. The shoe assembly method generally includes providing an upper having an opening configured for receiving a wearer's foot, mounting an outer member to a bottom surface of the upper, affixing a base insole to an interior portion of the upper, and affixing an upper insole to the base insole.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Generally described, the present invention relates to shoes, boots or other articles of footwear comprising an insole system for providing support, comfort and protection to a wearer's foot, and to help keep the wearer's feet odorless, fresh and dry. In an example embodiment, the article of footwear is a dress shoe, for example, a high heel womens shoe. Alternately, the present invention can be adapted to other types of dress footwear (for men or women), casual footwear, athletic footwear, work shoes, etc.

With reference now to the drawing figures, wherein like reference numbers represent corresponding parts throughout the several views,FIG. 1shows a shoe or footwear article10comprising a footwear upper12, an outer sole member or outsole14and an insole system20. In the depicted embodiment, the shoe10is a high heel shoe, which includes a heel16extending a distance downward from the heel or rear end of the outsole14. As depicted, the heel is generally unitary with the outer sole member14. The heel16can be sized and shaped as desired and comprise any length, thickness and/or style as desired by the manufacturer or wearer of the article of footwear10. Generally, the upper12and the outer14are assembled together to form the outer structure of the shoe10. An opening18is provided on the upper12and is preferably configured to receive the wearer's foot. The outer member14and optional heel16are generally configured to contact the ground during use of the article of footwear10. A plurality of thermoplastic polyurethane (TPU) injected slip-resistant treads19may be provided on a bottom side of the outer member. Preferably, the treads19are generally flush or at the same level with the external surface of the outer sole14. Alternatively, the treads19can extend slightly beyond, for example about about 1-3 millimeters beyond, the external surface of the outer sole14. As depicted, the treads19are generally shaped to resemble a teardrop in overall peripheral profile with a portion of the slip-resistant tread19extending from the front end of the teardrop to a keystone shaped or otherwise configured toe end, and can be co-molded or injection molded into the outer sole member14, or otherwise formed. Optionally, other shapes or patterns can be provided. In one example form, the shoe of the present invention is fabricated with the insole system20permanently secured in the shoe. Alternatively, the shoe of the present invention can include an insole system20that is replaceable or interchangeable, such that the insole can be installed or removed from the shoe. In example embodiments, portions of the insole system20can be generally built into the article of footwear10or permanently or semi-permanently attached when constructing the upper12. Thus, as will be described below, at least a portion of the insole system20may be secured to the upper12regardless of whether the balance of the insole system20is permanently secured or replaceable therefrom.

FIG. 3shows an exploded or assembly view of the shoe10, including the upper12, the outer member14and the insole system20. Generally, the upper12and outer member14are constructed of one or more materials such as leather, synthetic leather, wood, plastic, polymer, composites, natural materials, synthetic materials, other materials and/or combinations thereof. In example forms, the upper12optionally comprises a midsole to which the insole system20is affixed or mounted. Generally, the midsole, as is typical with footwear construction, is typically unitary with or affixed to the upper12when constructing the upper12, which generally forms the bottom portion thereof. As such, to construct the shoe10, the outer member14is affixed to the bottom portion of the upper12or external/exposed portion of the midsole (e.g., generally opposite the opening18) and the insole system20is affixed or mounted to the midsole or interior portion of the upper12that is exposed therein (e.g., by inserting the insole system20within the opening18). Thus, in example forms, the midsole is generally sandwiched between the outer member14and the insole system20. Optionally, the upper12is constructed without the use of a midsole such that the outer member14is affixed to the bottom portion of the upper12and the insole system20is affixed within the upper12to a portion of the outer sole member14or an internal portion of the upper12.

As will be described in greater detail below, example forms of the insole system20of the shoe generally comprise a base insole22and an upper insole62, which are generally affixed together to form the insole system20. The base insole22generally comprises a base layer or chassis24and a first and a second (or fore and aft) shock absorbing insert56,60. The upper insole62generally comprises a central spacer panel or gel insert member receiver64, first and a second (or fore and aft) gel insert members70,72and a fabric cover sheet layer74. In alternative embodiments, the first and second shock absorbing inserts56,60and/or the first and second gel insert members70,72of the shoe may comprise unitary or continuous elements optionally incorporating intermediate connector webs or panels of reduced thickness interconnecting first and second primary sections of the inserts and/or members; and/or only a single shock absorbing insert and/or a single gel insert member may be included at either the fore or aft locations.

FIG. 4shows the base insole22of the shoe in greater detail. Generally, as briefly described above, the base insole22comprises the chassis or base layer24and first and second shock absorbing inserts56,60. Typically, the chassis24comprises an upper surface26, a lower surface30, a lateral side32, a medial side34, a heel or rear end36, a forefoot or front end40, a heel or rearward end portion42, a midfoot portion44and a forefoot portion46. As such, the chassis24is generally shaped to comprise an outer contour that is shaped to generally match the shape of a wearer's foot, and thus shaped similarly to the upper12that is it intended to be affixed or removably mounted to. As shown, the base insole22is generally arched as is typical for high heel shoes, with the heel of a wearer's foot elevated above the forefoot by 1″, 2″, 3″ or more. Alternatively, the base insole22may be substantially flat or otherwise configured to accommodate for use in connection with various other types and styles of shoes.

In example forms, the heel portion42of the chassis24comprises a central recess, cup or well50that is generally spaced inwardly from the outer periphery of the heel portion42. A peripheral wall52extends at least partially around the central well50along the rearward end42and the lateral and medial sides32,34from the heel end of the chassis24and gradually tapering away (e.g., reducing in thickness or wall height) around the midfoot portion44or the forefoot portion46. Preferably, the peripheral wall52defines an outer rim or collar53that is generally transverse the wall52and between the wall52and the outer contour of the chassis24such that an inner or central portion of the wearer's heel is positioned over the central well50and an outer or peripheral portion of the wearer's heel is positioned over the collar53, providing improved weight distribution and comfort when worn. In some example forms, the collar or lip53may comprise a ramped or inclined surface generally sloping or tapering downwardly and inwardly towards the central well50. As will be described below, the wall52defines an area for seating portions of the upper insole62therein, and the lip53provides a surface for affixing portions of the upper insole62thereto. Optionally, a surface defined within the central well50comprises a plurality of recessed apertures or indentions54countersunk therein to provide for the alignment and placement of one or more fasteners that can be used for attachment of the heel portion42to the upper12. Alternatively or additionally, an adhesive or other attachment means can be used to affix the heel portion42to the upper12.

The first and second shock absorbing inserts56,60are typically affixed to the upper surface26of the chassis24, for example, the first shock absorbing insert56being affixed between the forefoot portion46and the midfoot portion44and the second shock absorbing insert60being affixed within the central well50. Generally, the outer contour of the central well50is substantially similar to the outer contour of the second shock absorbing insert60so that the insert is closely received within the well. In one form, the central well50is recessed below the upper surface26such that the upper surface of the second shock absorbing insert60is generally flush with the upper surface26when mounted thereto. Similarly, the upper surface of the first shock absorbing insert56is preferably flush with the upper surface26when affixed thereto (between the forefoot portion46and the midfoot portion44). In one example form, a recessed channel or inset is provided within the base layer24such that the first shock absorbing insert56can be affixed within the recessed portion and remain flush with the upper surface26. Optionally, the first shock absorbing insert56and the chassis24(generally near the forefoot portion46) comprise a substantially similar thickness, and the first shock absorbing insert56is affixed between the forefoot portion46and the midfoot portion44, for example, wherein it is the first shock absorbing insert56that couples the midfoot portion44to the forefoot portion46. Optionally, the ends of the first shock absorbing layer56and the ends of the midfoot and forefoot portions44,46(e.g., generally adjacent and abutting each other) can be mitered, dovetailed or overlayed to provide a smoother or improved transition and/or connection between the upper surface of the chassis24and the first shock absorbing layer56.

In example forms, at least portions of the base insole22are permanently or semi-permanently secured to the upper12during the construction or assembly thereof. For example, in one example form, the chassis24and the first shock absorbing insert56are permanently secured to the upper12during the construction or assembly of the upper12, and the second shock absorbing insert60and the upper insole62are separately installed (permanently secured or replaceable/interchangeable) in the upper12. In alternate example forms, the base insole22and the upper insole62are installed after the construction of the upper12, for example to then be permanently secured or replaceable/interchangeable with the upper12. Optionally, the base insole22(or the chassis24and first shock absorbing insert56) is/are permanently secured to the upper12and the upper insole62is replaceable/interchangeable with the upper12.

Optionally, a generally rigid member or shank may be incorporated within the heel and/or forefoot portions42,44of the shoe to provide for enhancing or supporting the arched shape of the base insole22for improved comfort. Example shanks can be constructed from metal, plastic, composite, wood, natural materials, synthetic materials, other materials and/or combinations thereof. Alternatively, the outsole, base layer and/or other components of the footwear and/or the insole provide sufficient structural support and rigidity to eliminate the need for a shank.

In example embodiments, the base layer or chassis24of the shoe's insole system is formed from high density polyethylene (HDPE) and the shock absorbing inserts56,60are formed from polyurethane (PU). Optionally, the HDPE of the chassis24may include a microfiber overlayer or other fiberboard layer, which may comprise antimicrobial characteristics. In one example form, the shock absorbing inserts56,60are formed from a specific polyurethane material, for example, Poron® XRD™ (available at www.poronxrd.com) that may vary in density from about 9 lb/ft3to about 25 lb/ft3and have a range of specific gravity from about 0.14 to about 0.40. Example qualities that may provide superior benefit to the shock absorbing inserts56,60include but are not limited to performance advantage (consistent repeated impact absorption for dependable protection throughout the life of the product), wearable protection advantage (offers thin and flexible alternative to traditional padding, Microban® antimicrobial protection to help prevent growth of bacteria that causes stains, odors and product deterioration, breathable technology for ensuring ease of motion and air flow, contouring, and soft and flexible to the touch, offering the wearer a comfortable and customizable fit), design advantage (lightweight and low profile material technology, available in a variety of density/thickness combinations) and technologically advanced (soft to the touch, firm on impact, conforms to body's move, yet upon impact, forms a comfortable shell that protects the body, open-cell, breathable, excellent compression-set resistance, antifungal and does not contain latex, PVCs, VOCs or heavy metals). In example forms, to construct the base insole12, the chassis24is preferably injection molded as a single piece and the shock absorbing inserts56,60are affixed thereto with an adhesive or other attachment means, press-fit, co-molded, or otherwise constructed. Example forms of adhesives can include but are not limited to glue, resin, cement, or other various types of bonding materials. Optionally, the base insole22(chassis24and shock absorbing inserts56,60) may be constructed using various other manufacturing and assembly methods including cutting (e.g., die cutting, stamping, etc.), casting, molding, stitching, heat bonding, couplings, hook and loop material, tape, etc.

FIGS. 5 and 6show the upper insole62of the shoe's insole system in greater detail. Generally, as briefly described above, the upper insole62comprises the spacer or insert member panel64, the first and second gel insert members70,72, and the fabric cover sheet layer74. As depicted, the spacer panel64is generally formed from a material having a uniform thickness and comprises a forefoot portion65and a midfoot portion66. Preferably, an opening68is provided within the spacer panel64between the forefoot portion65and the midfoot portion66for receiving the first gel insert member70and an end surface67is provided near the midfoot portion66of the spacer panel64for attachment or abutment of a forward edge of the second gel insert member72thereto (seeFIG. 6). Preferably, the outer contour of the opening68is substantially similar in shape to the outer contour of the first gel insert member70to provide a generally close or snug fit of the gel insert member into the opening. In example forms, the first and second gel insert members70,72comprise a plurality of honeycomb or hexagon-shaped indentions or recessed cells73formed on one or both sides thereof, bounded by substantially upright flexible cell walls, which provide for additional comfort, adequate flexibility of the wearer's foot and distribution of a force applied thereon. The fabric sheet layer74is provided for substantially covering a side of the spacer panel64and the gel insert members70,72, and maintaining attachment of the insole components assembled therewith. Preferably, as shown inFIG. 6, portions of the fabric sheet layer74extend beyond the outer contour of the midfoot portion66and the affixed second gel insert72to provide an attachment surface for adhering to the outer rim-like surface or collar53of the base insole22. In example embodiments, breathable holes or openings76are provided through the fabric sheet layer74, to allow air movement, moisture and breathability for increased comfort (seeFIGS. 7-8).

Preferably, the spacer panel64of the shoe's insole system is formed from polyurethane (PU), the first and second gel inserts70,72are formed from a thermoplastic elastomer (TPE) gel having nanoclay incorporated therein, and the fabric sheet layer74is formed from an antimicrobial microfiber fabric material. Optionally, the first and second gel inserts70,72can comprise additional materials incorporated therein, for example, an antimicrobial material or others as desired. Typically, as described above, the antimicrobial characteristics incorporated within one or more components of the base or upper insole22,62provide for preventing growth of bacteria that causes stains, odors and product deterioration.

In one example form, the spacer panel64is formed from a specific polyurethane material, for example, Poron® Performance Cushioning (available at www.poronsuchioning.com) that may vary in density from about 15 lb/ft3to about 25 lb/ft3and have a range of specific gravity from about 0.24 to about 0.40. Example qualities that provide superior benefit to the spacer panel64include but are not limited to superior shock absorption (lower peak deceleration, greater shock reduction), performance ability (long-term comfort, compression-set resistance, open-cell, breathable, Microban® antimicrobial protection) and versatility (available in a variety of densities, thicknesses (1.0 mm to 12.7 mm)). In example forms, the spacer panel64is generally formed from a large roll of the polyurethane sheet material, for example, wherein a die cutting machine is used to form the preferred shape of the spacer panel64. Optionally, the spacer panel64may be formed in a plurality of other ways, which may include casting, stamping, molding, CNC, etc. Similarly, the fabric sheet layer is typically formed by die cutting the preferred shape from a roll of the antimicrobial microfiber fabric material. And, the first and second gel inserts70,72are typically formed by injection molding. Optionally, various other manufacturing and assembly techniques may be employed to obtain the components and/or the assembled upper insole62including cutting, casting, molding, stamping, CNC, stitching, printing, heat bonding, couplings, hook and loop material, etc.

In example embodiments, the upper insole62is generally formed by molding the inserts onto the fabric sheet layer74and then aligning the spacer panel64with the fabric sheet layer74so that the inserts70,72fit within portions thereof (e.g., insert70fitting within opening68and insert72fitting adjacent to surface67). For example, in one example form, the fabric sheet layer74is placed within a mold machine and the inserts70,72are molded onto the fabric, wherein the heat that provides attachment of the inserts70,72provides attachment of the inserts to the fabric sheet layer74. Alternatively or additionally, the inserts may be adhesively or otherwise attached to the fabric sheet layer. Thus, when placing the spacer panel64thereon, the inserts70,72are free to float relative to the spacer panel and the base insole in response to movement or shifting of weight of the wearer. Preferably, the spacer panel64is fitted onto the fabric sheet layer74(and inserts70,72molded thereto) without any form of adhesive or attachment. Optionally, an adhesive or other form of attachment can be provided to affix the spacer panel64to the fabric sheet layer74, for example, wherein an adhesive is applied to one or more portions of the spacer panel64and/or the fabric sheet layer74. Preferably, the gel insert members70,72are not adhered or otherwise attached to the underlying base insole22or shock absorbing inserts56,60, but are allowed to compress and move under load for increased comfort and weight distribution when worn, and to resist shifting of the foot within the shoe (i.e., to substantially lock the foot in position on the insole to prevent shifting forward in the footbed).

In alternate example embodiments, the first and second gel inserts70,72can be affixed in place in or on the spacer panel64, and the fabric sheet layer74can then be affixed to the panel64with an adhesive. For example, an adhesive may be applied to the outer periphery of the first gel insert70and the insert70is fitted within the opening68, thus coupling the outer periphery of the first gel insert70to the outer contour of the opening68. For affixing the second gel insert73to the spacer panel64, an adhesive is applied to an end surface of the second gel insert72and the end surface of the insert72is affixed to the end surface67of the spacer panel64. And, for affixing the fabric sheet layer74, an adhesive is more or less applied across the surface of the sheet layer74and the sheet layer74is affixed to the spacer panel64. Optionally, the adhesive can be selectively applied on the sheet layer74to only adhere at one or more portions of the spacer panel64. Preferably, the adhesive is in the form of a glue, resin, cement, or other type of bonding material. Optionally, the panel64, inserts70,72and fabric sheet layer74can be affixed together by other adhesives, heat bonding, stitching, injection molding, etc. Optionally, the inserts70,72are separately formed (not molded onto the fabric sheet layer74) and can be adhered to the fabric sheet layer74with an adhesive, by stitching, or other attachment means. Optionally, the spacer panel64can be adhered to the sheet layer74prior to adhering the inserts70,72to the spacer panel64and/or sheet layer74. Alternatively, the gel insert members70,72are not adhered or attached to the spacer panel64, but are held in place by being sandwiched in close fit between the surrounding components.

Generally, the insole system20may be either permanently secured to the internal portion of the upper12(accessible through the opening18) of the shoe10, or the insole system20may be added or removed from the shoe by insertion or removal through the shoe's foot opening18. As described above, it is preferred that portions of the insole system20are constructed or assembled with the article of footwear10at different stages of the construction or assembly of the article of footwear10. For example, the chassis24and the shock absorbing insert56are typically assembled when forming the upper12and outsole14, and the second shock absorbing insert60and upper insole62are assembled at a later stage. In one example form, the second shock absorbing insert60and the upper insole62are assembled during the construction of the article of footwear10(permanently secured or replaceable/interchangeable), but after at least constructing the upper12(comprising the chassis24and the first shock absorbing insert56). In another example form, the second shock absorbing insert60and/or the upper insole62can be installed during a post-construction or assembly process or other later time including once the footwear10has been worn by a user. For example, it may be desired to provide a replacement upper insole62and/or the second shock absorbing insert60to replace the current upper insole62and/or second shock absorbing insert60after the article of footwear10has been used. In this manner, the insole system of the present invention can be installed during construction as original equipment within a shoe designed to incorporate the insole system, or can be retrofit into the construction of a standard shoe design, or can be installed in an existing shoe after construction. Optionally, the entire insole system20can be assembled at the same stage and then be permanently secured or replaceable/interchangeable with the article of footwear10during or after the construction process thereof.

In embodiments of the shoe10having the insole system20permanently secured in the shoe10, the base insole22is generally affixed to an internal portion of the upper12by applying an adhesive to the bottom side30of the chassis or base layer24, the internal portions of the upper12, or both. Optionally, stitching, molding or other adhering methods may be used to affix the base insole22to the upper12(and/or midsole as described above). If the second shock absorbing insert60has not been secured to the central well50, the insert60is then secured to the central well50, which is typically accomplished with an adhesive. Optionally, the other adhering methods listed above and others may be used. Typically, the upper insole62is inserted within the opening18(aligning the forefoot portion65with the forefoot portion46, seeFIG. 7) and the midfoot portion66and the affixed heel portion72are then inserted within the central well50and between the peripheral wall52(seeFIG. 8). To permanently secure the upper insole62to the chassis24of the base insole22, adhesive is then applied to the lip or collar53or the exposed portions of the fabric sheet layer74extending beyond the periphery of the midfoot portion66and the second gel insert72, or both. Optionally, other adhering methods may be provided to affix the upper insole62to the base insole22. Optionally, the adhesive can be applied to the lip53and/or fabric sheet layer74prior to placing the upper insole62atop the base insole22. Alternatively or additionally, the adhesive can be applied to the exposed (bottom side of the spacer panel64), which will contact and adhere to the chassis24of the base insole22. Preferably, the first and second gel inserts70,72remain free from engagement with the chassis24and/or central well50, thus allowing the inserts70,72to generally float atop the shock absorbing inserts56,60of the base insole22, respectively. In some example forms, at least some portions of the outer periphery of the spacer panel64and/or the second gel insert72can be secured to the peripheral wall52, or alternatively may be unsecured. Further optionally, the upper insole62and/or shock absorbing insert60are replaceable or interchangeable, to be installed or removed from the article of footwear10by insertion or removal through the opening18. Thus, the upper insole60and/or shock absorbing insert60may be generally seated within or interengage the base insole22and provide a substantially snug fit while also providing for replacing or interchanging therefrom.

In other aspects, the present invention relates to a method of assembling an article of footwear such as for example a womens high heel shoe. Generally, the method comprises providing a shoe upper having an opening configured for receiving a wearer's foot, mounting a shoe outer member to a bottom surface of the shoe upper, affixing a base insole to an interior portion of the upper, and affixing an upper insole to the base insole. Alternatively, the method comprises forming a footwear upper comprising a footbed or midsole therein, mounting an outer sole member to the midsole and/or to the upper, affixing a base insole22to the midsole and/or footbed within the upper12, and affixing an upper insole62to the base insole22. As described above, the outer member can be mounted to the bottom of the upper12, which may comprise the midsole mounted therein. Further, as described above, the base insole22can be affixed to the upper insole62prior to affixing the base insole22to the midsole (and/or internal portions of the upper12). One or more gel insert members are held in place between the base insole and the upper insole, preferably without attachment that would otherwise restrict movement of the gel insert members in compression.