Shoe having transparent window for viewing cushion elements

Abstract: A midsole (10 and 22) for an activewear shoe (12) comprises a removable insert (10) and a peripheral member (22). The peripheral member (22) is joined to the perimeter of an upper surface (18) of an outsole (14). A reinforcing layer (28) substantially less thick than the peripheral member (22) is joined to the outsole upper surface (18). A transverse reinfor­ cing segment (30) is integrally formed with the peripheral member (22) to provide stability and support to a wearer of the shoe (12). Segment (30) forms a front receptacle (32) and a heel receptacle (34) dimensioned to receive insert (10). Insert (10) has a transverse slot (42) to match with the transverse segment (30). A plurality of independent cushioning elements (40) depend from a base member (38) of insert (10), and are sized in order to conform to the depth of peripheral member (22). The cushiona­ bility and resiliency of insert (10) may be selected according to the wearer's weight and cushionability preference. A window formed in the sole portion allows to view the cushioning elements (40).

Description: This application along with copending U.S. application Serial No. 207,202 filed June 16, 1988 is a continuation-in-part of co-pending U.S. application Serial No. 153,222 filed February 8, 1988, which in turn is a continuation-in-part of U.S. Patent No. 4,733,483, March 29, 1988 and is related to U.S. application Serial No. 180,529 filed April 12, 1988, which in turn is a continuation-in-part of U.S. application Serial No. 097,806 filed September 17, 1987, (now abandoned), which was a Divisional of U.S. Patent No. 4,733,483, March 29, 1988. TECHNICAL FIELD OF THE INVENTION This invention relates in general to athletic or other activewear shoes, and more particularly relates to shoes having custom midsoles with a transverse reinforcement segment and a removable insert which coacts with said segment to provide improved stability and support. BACKGROUND OF THE INVENTION Athletic or other activewear shoes of a conventional construction generally have three or four separate parts. First, such shoes are provided with an outsole that is made of a durable material and that extends across the lower surface of the shoe. A midsole is joined to the outsole to provide a cushioning layer to the wearer's foot. Usually, an upper formed of leather, synthetics or other materials is joined to the midsole. In many conventional structures, an insole is further provided for disposal between the midsole and the wearer's foot for additional cushioning. The midsoles of these conventional constructions have two undesirable characteristics. First, they have the property of deforming over a large area of surface when a downward force is impressed on them. Second, the midsoles are affixed to the shoes and therefore customers can make no choice in the midsole's cushionability without selecting another shoe. Thus, conventional midsoles do not offer anything in the way of independent suspension or deformation of various areas thereof, and further are suited to only a particular weight class or cushionability preference of wearers. The need for a midsole having a plurality of cushioning elements, each demonstrating an individual suspension and deforming independently from the remaining elements has generally been met by the custom midsole as disclosed in U.S. Patent No. 4,733,483, March 29, 1988, to Lin. However, it has been found that a flat outsole and midsole as disclosed therein have a tendency to create a springboard effect which causes the heel to bounce and vibrate. Unless the midsole fits perfectly into the cavity created within the shoe, there is also a tendency for the midsole to slip therein. Thus, a need has arisen for a midsole that has a plurality of cushioning elements with individual suspension that does not slip or vibrate. EP-A-0 031 936 discloses a plurality of cushioning elements visible through a window in the shoe sole. A spring member is located within the chamber and includes a plurality of elastomer spring elements and a tension rod extending through the spring elements. The tension rod is connected to abutments at opposite ends of the spring elements. One end of the tension rod is accessible on the exterior of the sole for adjusting the spring characteristic of the spring member. German Patent DE-U-8 807 671 to Killtec discloses a sport shoe which has a first cushioning member disposed in the heel portion of the shoe and a second cushioning member disposed in the toe portion of the shoe. The cushioning member in the heel of the shoe comprises an insert having a plurality of cylindrical cushioning elements. The insert is held in a chamber in a midsole element of the shoe. A window, covered by a transparent sheet of material, is formed through the bottom of the shoe and allows the wearer of the shoe to visually inspect these cylindrical cushioning elements. The front and back cushioning members in Killtec are sealed into their respective chambers and cannot be removed. EP-A-0 031 936 and Killtec fail to disclose a reinforcement segment transversely disposed over the outsole and within the midsole, together with a removable midsole insert having first and second groups of curved cushioning elements depending downwardly therefrom on opposite sides of the reinforcement segment and providing distinctive visual design aspects, such that the reinforcement segment inhibits movement of the cushioning elements within the shoe. Moreover, EP-A-0 031 936 and Killtec fail to disclose a midsole having a body, an underside of the body, an upper surface, a toe portion, and a heel portion integral with the toe potion. Further, EP-A-0 031 936 fails to disclose a plurality of independently cushionable, distinctive visual design elements forming at least a major portion of the lower surface of the midsole and positioned in static and nonvariable lateral relationship with respect to each other, upper ends of the design elements joined to fixed, nonvariable spaced locations on the underside of the body of the midsole, lower ends of the elements being free from each other, and bearing against portions of the outsole to provide cushioning to the foot of the wearer, a predetermined and unchanging portion of the elements visible through the entire area of the transparent window at all times such that the distinctive design elements of the midsole may be inspected externally of the shoe, while providing continuous cushioning support to the foot of the wearer in the entire area of the transparent window. SUMMARY OF THE INVENTION The present invention comprises a shoe having a sole portion for the shoe, wherein said sole portion comprises a midsole affixed to an upper surface of an outsole, and wherein said sole portion contains a transparent window, characterized by: a reinforcement segment transversely disposed over said outsole and within said midsole; removable midsole insert overlying said sole portion in order to provide cushioning support to the foot of the wearer, said removable midsole insert having a first and second groups of curved cushioning elements depending downwardly therefrom on opposite sides of said reinforcement segment and providing distinctive visual design aspects, such that said reinforcement segment inhibits movement of said cushioning elements within the shoe; walls defining said window through said sole portion; and transparent plastic material filling said window such that said plastic material seals to make an integral shoe, said transparent plastic material allowing the ability to see through said sole portion to externally observe at least a portion of said cushioning elements having said distinctive visual design aspects overlying said sole portion. Another aspect of the invention comprises an improved shoe wherein internal cushioning elements may be viewed externally of the shoe, comprising an upper having a bottom margin an outsole having a lower surface and an upper surface opposed to said lower surface, said outsole made of a relatively durable and resilient material; a midsole having a body, an underside of said body, an upper surface, a toe portion, a heel portion integral with the toe portion, and being formed completely of an integral material substantially more yieldable and cushionable than said outsole, and with only non-rigid support therein in order to provide consistent, uniform and nonvariable cushioning to the foot of the wearer, a lower surface of said midsole disposed substantially adjacent said upper surface of said outsole, said bottom margin of said upper joined to at least one of said outsole and said midsole; an insole cushioning member disposed in said upper to be at least substantially adjacent to said upper surface of said midsole, at least one orifice formed through said outsole for the visual inspection of a respective portion of said midsole, a transparent window sealingly disposed across said orifice and formed of a yieldable elastomeric material; and a plurality of independently cushionable, distinctive visual design elements forming at least a major portion of said lower surface of said midsole and positioned in static and nonvariable lateral relationship with respect to each other, upper ends of said design elements joined to fixed, nonvariable spaced locations on the underside of said body of said midsole, lower ends of said elements being free from each other, and bearing against portions of said outsole to provide cushioning to the foot of the wearer, a predetermined and unchanging portion of said elements visible through the entire area of said transparent window at all times such that said distinctive design elements of said midsole may be inspected externally of the shoe, while providing continuous cushioning support to the foot of the wearer in the entire area of said transparent window. BRIEF DESCRIPTION OF THE DRAWINGS Various aspects of the invention and their advantages will be more completely understood by reference to the following Detailed Description in conjunction with the appended drawings in which: FIGURE 1 is an isometric view of a shoe construction according to the invention as fitted with a custom midsole therefor, with parts broken away to show interior structure; FIGURE 2 is a top isometric view of a preferred embodiment of a transverse segment of the invention; FIGURE 3 is a bottom isometric view of a preferred embodiment of a custom midsole insert of the invention; FIGURE 4 is a longitudinal section taken substantially along line 4-4 of FIGURE 1; FIGURE 5 is a partial longitudinal section of an alternate embodiment of the present invention; FIGURE 6 is a longitudinal section of an additional alternate embodiment of the present invention; and FIGURE 7 is a partial longitudinal section of a still further alternate embodiment of the present invention. DETAILED DESCRIPTION Referring first to FIGURE 1, an isometric view of a preferred embodiment of a shoe construction according to the invention is shown. A custom midsole insert is indicated generally at 10. Insert 10 is shown as fitted into an active wear shoe indicated generally at 12. While the illustrated shoe 12 is one designed for walking, the invention can also be employed in other types of athletic shoes, such as running, aerobics, or court shoes. The invention also has application in any circumstance where varying midsole cushionability is desired. Shoe 12 is comprised of an outsole 14 that forms the wearing surface of the shoe. Outsole 14 is preferably constructed of a relatively durable, resilient material such as natural rubber. Outsole 14 has an exterior surface that is provided with a suitable tread surface 16. Outsole 14 further has an interior or upper surface 18 which may be smooth and featureless throughout, or may have a central area 20 that is reticulated or webbed in order to save weight. A peripheral area (not shown) of upper surface 18 presents a smooth surface for gluing or other means of attachment. A peripheral midsole member 22 is formed to be glued or otherwise attached to the peripheral area of outsole upper surface 18. Peripheral member 22 is more cushionable and yieldable than outsole 14, and can be conveniently molded of polyurethane foam or ethylene vinyl acetate copolymer (EVA). Peripheral member 22 is, in the illustrated embodiment, endless and extends completely around the periphery of outsole 14. Peripheral member 22 has an interior sidewall 24 and an upper surface 26. While in the illustrated embodiment, peripheral member 22 is endless, this need not necessarily be the case. Member 22 can, for example, take the form of two longitudinal strips, one for each side of the shoe, or could take the form of several sections spaced around the periphery of the shoe. The form taken by peripheral member 22 should in any event perform its dual function of retaining insert 10 and provide structural support for the peripheral area of the shoe. Preferably, a footbed reinforcing layer 28 is affixed as by gluing to outsole upper surface 18. Layer 28 is preferably much thinner than the height of peripheral member 22 so as to allow room for insert 10. Reinforcing layer 28 is sized to substantially coincide with the exposed portion of outsole upper surface 18. Layer 28 is fabricated of a relatively resilient firm and less flexible material in relation to the EVA forming peripheral member 22. For example, layer 28 can be constructed of a leatherized paper or cardboard. The purpose of layer 28 is to replace torsional strength lost by the creation of peripheral midsole member 22. Thus, a midsole/outsole configuration having satisfactory torsional strength is formed for proper lateral support of the wearer's foot while at the same time providing for a central insert 10 having selectable cushionability. Of particular importance to the present invention is a transverse reinforcing segment 30. Segment 30 is preferably integral with peripheral member 22 and formed from the same cushionable material (EVA). Segment 30 is preferably provided with a layer 28 on an upper surface thereof. Segment 30 is particularly useful for providing stability to the insert 10 and support to a wearer of the shoe 12. Without the segment 30, it has been found that vibrations, heel bounce and slippage of the insert 10 have occurred. The peripheral member 22 and the segment 30 form a front receptacle 32 and a heel receptacle 34 (covered in FIGURE 1 by insert 10) that are dimensioned to receive insert 10. Shoe 12 further comprises an upper 36 that can be fashioned of leather, cloth, synthetic materials or a combination of these, and is attached to upper surface 26 of peripheral member 22 by a method later described. Insert 10 comprises an upper base member 38 and a plurality of supporting elements 40 that are preferably formed integrally with base member 38 to depend therefrom. As shown, elements 40 occupy receptacles 32 and 34 when insert 10 is installed into shoe 12. Elements 40 are dimensioned such that their depth matches the depth of sidewall 24 minus the thickness of layer 28, and are formed so as to occupy substantially all of receptacles 32 and 34 from one sidewall 24 to the other. Elements 40 are postioned in static and nonvariable lateral relationship with respect to each other. Peripheral member 22 and removable insert 10 are apportioned such that most of the weight of the wearer will be borne by insert 10. Insert 10 has a transverse slot 42, formed by eliminating elements 40, corresponding to the transverse reinforcing segment 30. Base member 38 has an upper surface 44 onto which a flocking material 46, which is preferably formed of a polyester/nylon material but can be formed of any suitable fabric, is joined as by gluing. As finished out by flocking material 46, insert 10 would not require any insole or liner on top of it to be suitable for wearing. As shown, base member 38 has a central member 48, and a lip member 50 that extends beyond central area 48. Cushioning elements 40 depend from central member 48. Lip member 50 is formed to be coextensive with top surface 26 of peripheral member 22. A uniform cushionable upper surface 44 is therefore presented to the wearer's foot throughout the interior of the shoe. Referring now to FIGURE 2, a top isometric view of the outsole 14, the peripheral member 22 and the transverse segment 30 is shown. The segment 30 is joined to opposite sidewalls 24 of peripheral member 22 transverse to a longitudinal axis of the outsole 14 as indicated by line 52. In a preferred embodiment, segment 30 comprises a first generally vertical transverse surface 54 and a second generally vertical transverse surface 56 spaced apart from first surface 54. A generally horizontal transverse surface 58 connects first surface 54 to second surface 56. The area thus formed by surfaces 54-58 forms a solid block of cushionable material for supporting a wearer of shoe 12. Positioned proximate the segment 30 is a generally transparent window 60 which is molded into a void or aperture 62 formed by walls in the outsole 14. The window 60 may be formed from a clear plastic elastomeric material such as is available from E.I. du Pont de Nemours. For example, the window may be formed from ployurethane, or from polyvinyl chloride, or from a combination of polyurethane and polyvinyl chloride. Moroever, the window may be formed by a hollow see-through container including polyurethane at least partially filled with a fluid. It is preferable to recess the window 60 into outsole 14, for example, 2 millimeters, to prevent scuffing or abrasion to the window 60 which would obscure the view therethrough. The window 60 provides for observation or inspection of the elements 40 of insert 10 from the exterior shoe 12, a predetermined and unchanging portion of elements 40 visible through the entire area of window 60 at all times. It is to be understood that segment 30 and window 60 may be located in different positions and different orientations. For example window 60 may be parallel or oblique to axis 52 rather than transverse thereto. A window 60 may also be positioned along the peripheral member 22 as will be subsequently described in more detail. Additionally, a plurality of transverse segments 30 and a plurality of observation windows 60 may be provided. Referring now to FIGURE 3, a bottom isometric view of insert 10 is shown. In the illustrated embodiment, insert 10 is integrally formed with an insole portion 64. In the embodiment shown in FIGURE 3, upper surface 44 comprises the upper surface of insole portion 64, and the flocking material 46 (FIGURE 1) is joined to this surface. In the embodiment illustrated in FIGURES 1 and 3, elements 40 each take the form of a pillar with a rounded free end. Elements 40 are formed in central area 48 in a closest packing arrangement in order to provide cushionable support throughout central area 48. Elements 40 are formed independently of each other, and are only joined to base 38. In this manner, elements 40 provide in effect a multiple-point independent suspension. This is because elements 40 will be compressed and will yield independently of each other. This is an advantage over midsoles or insoles of solid construction, which have a tendency to yield and compress continuously and uniformly over large areas. The discrete elements 40 on the other hand give an independent, discontinuous support to different portions of the foot that is not obtainable by a midsole or insole of uniform construction. Elements 40 are graduated in size in order to conform to the depth of sidewall 24 (FIGURE 1). In a front area 66 of area 48, a plurality of relatively small elements 68 are formed. Elements 68 will conform to the relatively thin depth of peripheral member 22 in the front region. In heel region 70, a relatively small number of large heel cushioning elements 72 are formed. The larger size of elements 72 adapts them to the larger depth of peripheral member 22 in heel region 70. Further, since there is a larger cushioning depth of material, the larger size of elements 72 prevents undue bending or nonradial deformation, as might otherwise occur if a plurality of long, thin elements were used. A transverse slot 42 is formed into insert 10 by eliminating elements 40 corresponding to the transverse reinforcing segment 30. The transverse slot 42 divides insert 10 into front area 66 and heel region 70 that fit into receptacles 32 and 34 respectively. The division into front area 66 and heel region 70 greatly reduces or eliminates slippage of the insert 10 within the receptacles 32 and 34. The combination of transverse reinforcing segment 30 and transverse slot 42 reduces any bounce or heel vibration caused by a springboard effect of the elements 40. Referring now to FIGURE 4, a longitudinal section taken substantially along line 4-4 of FIGURE 1 is shown. FIGURE 4 particularly illustrates the graduated size of elements 40 from front area 66 to heel region 70. Some of the elements 40 are not shown in section because section line 4-4 did not pass through them, or are shown only partially in section because line 4-4 did not pass through them along their major diameter. Insole portion 64 is shown to have a concave surface 74 in heel region 70 for the support of the heel of the wearer's foot. Upper 36 has a bottom lip member 76 for mating with upper surface 26 of peripheral member 22. Lip member 76 is attached as by gluing to upper surface 26. Then, an element 78 is placed on top of lip member 76. Element 78 is elongate and extends around the periphery of shoe 12, corresponding to upper surface 26. Element 78 can conveniently be formed of the leatherized paper material preferably forming reinforcing layer 28, or from another relatively strong material. Stitching (not shown) is used to join element 78, lip member 76 and peripheral member 22, and optionally outsole 14, together. In operation, shoes 12 and inserts 10 are distributed to retailers as separate items. Each insert 10 has a specific durometer reading that measures its relative yieldability or resiliency. The cushionability of inserts 10 can also be varied by changing the shape and/or spacing of elements 40. A plurality of different inserts 10 having a range of durometer readings are provided for each shoe size, such that any pair or numerous pairs of inserts 10 can be inserted into a respective pair of shoes 12. A particular pair of inserts 10 are selected for a particular customer according to the customer's weight and cushioning preference. Thus, a lightweight person will in general require an insert 10 that is more cushionable and less resilient than a heavier person. Further, the customer may have a particular preference concerning how "soft" or "hard" the shoe feels, and may select a pair of inserts 10 that match his or her preferences in this respect. Finally, there may be medical reasons for selecting a right insert 10 that has a different resiliency and cushionability than a left insert 10, and the invention will permit this selection. Referring now to FIGURES 5, 6 and 7, alternate embodiments of a transparent window constructed according to the invention is illustrated. Referring first to FIGURE 5, a window 82 is illustrated in cross-section. Window 82 comprises a generally transparent material and is positioned in a void or aperture 84 and 86 formed by walls through outsole 14. The window 82 is recessed into the outsole 14 approximately 2 millimeters to help reduce scuffing or abrasion to the transparent material. The voids 84 and 86 are preferably cut through the outsole 14 to remove any obstacles to a clear view of the interior of the shoe. The transparent material comprising window 82 is then formed to match the voids 84 and 86 and have overlaps 88, 90 and 92 to allow for securing to outsole 14. Window 82 is secured by any appropriate method such as gluing to reestablish the integrity of outsole 14. Referring to FIGURES 6 and 7, side window alternatives are shown in elevational view. In FIGURE 6, an irregularly shaped window 96 is formed through a void or aperture 98 defined by walls in peripheral member 22. In FIGURE 7, an oval shaped window 100 is formed through a void 102 in peripheral member 22. Windows 96 and 100 may have overlap areas similar to 88 and 92 (FIGURE 5) to allow for glue attachment or may be configured to clip into place. In summary, a novel midsole with a custom insert has been provided in order to vary the resiliency and cushionability of the midsole according to the wearer's needs. A transverse segment is positioned between the heel and the front portion of the shoe to add stability and support to the wearer. The transverse segment helps reduce heel bounce and slippage found to exist with a shoe insert. Finally, windows are provided in either the outsole or the peripheral member to allow interior observation from exterior the shoe.

Claims: A shoe having a sole portion (14) for the shoe, wherein said sole portion comprises a midsole (22) affixed to an upper surface (18) of an outsole (14), and wherein said sole portion (14) contains a transparent window (60, 82, 96, 100), characterized by: a reinforcement segment (30) transversely disposed over said outsole (14) and within said midsole (22); removable midsole insert (10) overlying said sole portion (14) in order to provide cushioning support to the foot of the wearer, said removable midsole insert (10) having a first and second groups of curved cushioning elements (40) depending downwardly therefrom on opposite sides of said reinforcement segment (30) and providing distinctive visual design aspects, such that said reinforcement segment (30) inhibits movement of said cushioning elements (40) within the shoe; walls (62) defining said window (60, 82, 96, 100) through said sole portion (14); and transparent plastic material filling said window (60, 82, 96, 100) such that said plastic material seals to make an integral shoe, said transparent plastic material allowing the ability to see through said sole portion (14) to externally observe at least a portion of said cushioning elements (40) having said distinctive visual design aspects overlying said sole portion. The shoe of claim 1, wherein said window (60, 82, 96, 100) comprises polyurethane. The shoe of claim 1, wherein said window (60, 82, 96, 100) comprises polyvinyl chloride. The shoe of claim 1, wherein said window (60, 82, 96, 100) comprises a combination of polyurethane and polyvinyl chloride. The shoe of claim 1, wherein said window (60, 82, 96, 100) comprises a hollow see-through container. The shoe of claim 5, wherein said container comprises polyurethane at least partially filled with a fluid. The shoe according to claim 1, characterized in that midsole insert (10) and midsole (22) have a body, an underside of said body, an upper surface (26), a toe portion (66), a heel portion (70) integral with the toe portion (66), and being formed completely of an integral material substantially more yieldable and cushionable than said outsole (14), and with only non-rigid support therein in order to provide consistent, uniform and nonvariable cushioning to the foot of the wearer, a lower surface of said midsole (22) disposed substantially adjacent said upper surface (18) of said outsole (14), said shoe having a bottom margin (76) and an upper (36) joined to at least one of said outsole (14) and midsole (22). The sole according to claim 7, characterized in that a plurality of independently cushionable, distinctive visual design elements (40) form at least a major portion of said lower surface of said midsole insert (10) and positioned in static and nonvariable lateral relationship with respect to each other, upper ends of said design elements (40) joined to fixed, nonvariable spaced locations on the underside of said body of said midsole insert (10), lower ends of said elements (40) being free from each other, and bearing against portions of said outsole (14) to provide cushioning to the foot of the wearer, a predetermined and unchanging portion of said elements (40) visible through the entire area of said transparent window (60, 82, 96, 100) at all times such that said distinctive design elements (40) of said midsole insert (10) may be inspected externally of the shoe, while providing continuous support to the foot of the wearer in the entire area of said transparent window.

Inventors: LIN YUNG MAO, LIN, YUNG MAO
Applicants: AUTRY IND, AUTRY INDUSTRIES, INC
Application year: 1989
Main classification: A43B23
IPC codes: A43B7, A43B13, A43B23