SYSTEMS AND METHODS FOR CUSHIONED FOOTWEAR

A shoe comprises an outsole, a midsole operatively connected to the outsole, an insole operatively connected to the midsole, the midsole and insole each having at least one aperture therein, and a cushion. The cushion includes at least one pillar extending generally upwardly from outsole through the at least one aperture in the midsole and the aperture in the insole. The cushion can further include a radial flange sandwiched between the outsole and the midsole.

FIELD

This disclosure relates to footwear, and more particularly to footwear having cushions therein.

BACKGROUND

A typical shoe comprises a plurality of formed layers connected together. The materials comprised in the formed layers are often chosen for a desired purpose, for example, durability, style, and/or comfort. However, materials often provide singular benefit, requiring wearers to introduce additional layers for additional functionality. To provide this additional functionality, wearers frequently need to purchase additional custom insoles or orthotics.

A variety of heel sole cushions are known in the art. U.S. Patent Pub. No. 2014/0310981 to Abshire et al. describes a cushioning and support layer that cushions and supports a foot and an afferent feedback biomechanical support plate positioned between the cushioning and support layer and the user's foot. U.S. Patent Pub. No. 2007/0033835 to Bray includes an upper sole cushion arrangement at with a lower cover positioned to cover aperture and recessed lip in bottom side of insole base structure. U.S. Patent Pub. No. 2010/095551 to Gupta et al. discloses footwear, footwear inserts, and socks that include a cavity adapted to receive a portion of an individual's heel foot to reduce contact forces.

Such conventional methods and systems of introducing additional layers have generally been the means historically utilized to provide the desired cushioning and comfort. However, to reduce, minimize or eliminate layering, there is a long felt but unsolved need in the art for a shoe having an integrated cushioning element therein. The present disclosure provides a solution that meets this long-felt, unresolved need.

SUMMARY

A shoe comprises an outsole, a midsole operatively connected to the outsole, an insole operatively connected to the midsole, the midsole and insole each having at least one aperture therein, and a cushion. The cushion includes at least one pillar extending generally upwardly from outsole through the at least one aperture in the midsole and the at least one aperture in the insole. The cushion can further include a radial flange sandwiched between the outsole and the midsole.

An upper can be operatively connected to the midsole such that the upper encloses at least a portion of the midsole, the insole, and the at least one pillar. A top surface of the at least one pillar can be flush with a top surface of the insole, or the top surface of the at least one pillar can extend beyond flush with a top surface of the insole. The top surface of the at least one pillar can visible through the at least one aperture in either position.

The cushion can be formed of at least one of a gel, foam, plastic, cork, leather, and/or fluid, having multiple densities. The at least one pillar can have a first density and the radial flange can have second density, where the second density is greater than the first density. The cushion can include a material different from that of the outsole, midsole, insole and/or upper.

A method for constructing a shoe can include forming a last having at least one recess therein, forming a cushion having at least one pillar corresponding to the at least one recess in the last, and forming respective apertures through at least one of a midsole, a connector, and an insole of the shoe, configured and adapted to receive the at least one pillar. The at least one recess of the last can be formed in at least one of a heel portion, a midfoot portion, and/or a forefoot portion such that the at least one pillar extends generally upwardly from an outsole.

The method can include layering the midsole onto the outsole so that the at least one pillar can extend through the at least one aperture in the midsole and that a radial flange of the cushion is sandwiched between the midsole and outsole. The method can also include layering the insole onto the midsole so that the at least one pillar can extend through the at least one aperture in the insole. Further, the method can include attaching an upper to the midsole such that the upper encloses at least a portion of the midsole, the insole and the pillar.

DETAILED DESCRIPTION

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, an illustrative view of an embodiment of a shoe in accordance with the disclosure is shown inFIG.1and is designated generally by reference character100. Other embodiments and/or aspects of this disclosure are shown inFIGS.2-9. Certain embodiments described herein can be used to improve comfort and wearability as compared with traditional cushions.

A shoe100can include an outsole102, a midsole106operatively connected to the outsole102by any suitable means, and an insole108operatively connected to the midsole106(e.g. friction fitted). The midsole106and insole108can each include at least one aperture112therein for receiving at least one corresponding cushion110. The cushion110can include at least one pillar114extending generally upward from outsole102and through the respective at least one aperture112in the midsole106and insole108. The cushion110can further include a radial flange116extending radially outward and circumferential to the pillar114, so that the flange116is sandwiched between the outsole102and the midsole106. The radial flange116can be visible on an exterior101of the shoe100, while the at least one pillar114can be visible through the respective at least one aperture112on an interior103of the shoe100. Similarly, the outsole102can include at least one notch132so that a bottom portion134of the cushion110can be visible from an underside of the exterior101of the shoe100(e.g. as shown inFIG.3). A portion of the cushion110is therefore visible from all sides of the shoe100.

An upper118can be operatively connected to the midsole106such that the upper encloses at least a portion of the midsole106, the insole108, and the at least one pillar114, forming interior103. A top surface120of the at least one pillar114can be flush with a top surface122of the insole108(e.g. as shown inFIG.5). However, it is contemplated that the top surface120of the at least one pillar114can extend beyond flush with the top surface122of the insole108(e.g. as shown inFIG.6, where the at least one pillar114extends beyond the top surface120by an amount dl). It should be appreciated by those skilled in the art that dl can be any suitable amount, for example 1 mm-3 mm or less, however it is possible the amount dl can be determined by the type of shoe100and its use, and can vary between embodiments, or within embodiments, without departing from the scope of this disclosure. In any event, the top surface120of the at least one pillar114can be visible through the at least one aperture112in any position, configured to make direct contact with a foot of a wearer without any intervening fabrics, materials, or components of the shoe100. Direct contact with the at least one pillar114can provide the wearer with improved cushioning and comfort, as well as overall performance of the shoe100.

In certain embodiments, the insole108may continuously extend over the at least one aperture112. In that case, the portion of the insole108covering the aperture112can include a plurality of geometric openings over aperture112for aesthetic purposes, e.g. a plurality of diamond shaped openings, a plurality of honeycomb shaped openings, a plurality of circular or elliptical shaped openings, a plurality of openings in the shape of letters, and the like, or any combination thereof. However, even in this case, the at least one pillar114can still directly contact the foot of a wearer through the plurality of openings in the insole. For example, the at least one pillar114may be able to extend through the geometric openings in the insole108when compressed by a foot.

The cushion100can include at least one of a gel and/or foam material having multiple densities, or the cushion110can include at least one of plastics, cork, leather, fluid (e.g. air) and the like, or any suitable combination thereof. More specifically, a gel material can include hydrogels, organogels, xerogels, nanocomposite hydrogels, or any suitable combination thereof. The at least one pillar114of the cushion110can have a first density and the radial flange116can have second density. More particularly, the radial flange116can be more dense to provide support between the midsole108and the outsole102, whereas the at least one pillar114can be a lower density to provide adequate cushioning. The at least one pillar114can be, for example, the same or a similar density to that of the insole108to provide a feel of continuity throughout the footbed.

It should be appreciated that the at least one pillar114and radial flange116can have the same density, or the respective densities can be dictated by the type of shoe or the gait of the wearer. For example, in an athletic shoe, the at least one pillar114and the radial flange116can have a consistent low density across the entirety of the cushion110, while in a dress shoe, the density can be distributed laterally over a transverse plane. More specifically, in the case of a dress shoe, a medial lateral portion (e.g. from a midline to the outer portion of the foot) of the cushion110(including both pillar114and radial flange116) can have a lower density than the opposed portion of the cushion110. Accordingly, the cushion110is not limited to differing densities between the pillar114and the radial flange116, but the cushion can include different densities across any suitable plane. Further, the cushion110can include a material different from that of the outsole102, midsole106, insole108and/or upper118.

A method for constructing the shoe100can include forming a last124having at least one recess126therein. The cushion110can be formed to match the recess126of the last124. For example, as shown inFIGS.1and7-9, the cushion can have a single pillar114in the heel portion140, or a pillar114in each of the heel portion140, midfoot portion150, and/or forefoot portion160. InFIG.8, the cushion can include a plurality of pillars114scattered throughout the shoe, having a regular and repeating pattern (as shown), or an irregular, non-repeating pattern. Further, as shown inFIG.9, the cushion110can have a single pillar114covering a majority of the footbed. It is contemplated, that while these embodiments are shown separately, it should be appreciated that the cushion110can employ any one, or all of these embodiments in a single shoe100, or any combination thereof as is desired. To form the remainder of the shoe100, respective apertures112corresponding to the at least one pillar114can be formed through the midsole106, the insole108, and a connector130, each respective aperture112configured to receive the corresponding at least one pillar114. The connector130can be any stuitable connector, for example a tuckboard, a strobel sock, a welt, or the like. In certain embodiments, the connector130can include a support portion128(e.g. a shank) for adding additional structural support between the heel portion140and the midfoot portion150.

The method can further include layering the midsole108onto the outsole102so that the at least one pillar114can extend through the at least one aperture112, and the radial flange116is sandwiched between the outsole102and midsole106(e.g. using adhesive). If called for, the connector130can be layered onto the midsole108around the at least one pillar114using adhesive or in any other suitable manner. The last124is placed onto the connector130so that the at least one pillar114is mated with the recess126in the last124. The upper118is molded or otherwise formed around the last124, enclosing the interior103of the shoe100.

The upper118can be attached to the midsole106by any suitable means, for example, using stiches, staples, adhesive, or the like. The outsole102can then be connected to the upper118/midsole106combination using similar means. The last124is then be removed from the formed interior103and the insole108can be placed inside the shoe100atop the connector130so that the respective aperture112in the insole108matches the position of the at least one pillar114. Forming the upper118can create at least one opening136for inserting a foot. It is contemplated that the upper118can include any number of openings136as desired, typically dictated by the style of the shoe100. The method as described herein may be suitable for various types of shoe construction, including but not limited to, cement construction, strobel construction, welt construction, direct attach construction, and/or opanka construction, as appreciated by those having ordinary skill in the art.

Any suitable combination(s) of any disclosed embodiments and/or any suitable portion(s) thereof are contemplated herein as appreciated by those having ordinary skill in the art. The embodiments of the present disclosure, as described above and shown in the drawings, provide for improvement in the art to which they pertain. While the subject disclosure includes reference to certain embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the spirit and scope of the subject disclosure.