Abstract:
A replaceable tuning wedge-shaped piece of a variety of hardnesses, is inserted in the midsole of shoes for enhancing the rate of compression. As the shoe breaks down or compresses, the tuning wedges will help the midsole rate of compression in each individual&#39;s gait. Such wedges can be made of elastomers, rubbers, plastics, wood, air bladders, Skydex brand thermoplastic polyurethane (TPU) material, D3O® Set Foam, or the like. A method of adjusting the density and compression of the midsoles or platforms of footwear includes using these wedges in shoes. An athletic or casual or dress shoe can include an upper component, a midsole, an outsole, and a void or voids along the midsole borders for housing wedges of different durometers for controlling compression rates of each foot of the individual wearer.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Priority of our U.S. provisional patent application No. 62/085,800, filed 1 Dec. 2014, incorporated herein by reference, is hereby claimed. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable 
       REFERENCE TO A “MICROFICHE APPENDIX” 
       [0003]    Not applicable 
       BACKGROUND OF THE INVENTION 
     Field of the Invention 
       [0004]    The present invention relates to shoes with midsoles or platforms. More particularly, the present invention relates to shoes with midsoles of compressible materials, including midsoles with pronation plugs for over pronation. 
       IMPROVEMENTS TO PRIOR ART 
       [0005]    Shoes manufactured today are basic athletic shoes, using an upper, a midsole, with cushioning characteristics, and control hardnesses, such as pronation plugs, to help control excessive pronation. Wave plates, gels, air and different combinations of rubbers and plastic can be combined to help control these abnormalities. There have been plugs used in the 1980s for rearfoot cushioning, such as in the Adidas 1980 model used in a very hard plastic midsole, so the wearer could add some cushioning. 
       General Background of the Invention 
       [0006]    According to a podiatrist journal, 44% of humans have a different gait in each foot. Shoes typically do not adapt to both feet. 
         [0007]    A typical running shoe has a hardness 50-55 durometers shore A. Conventional shoe construction involves an upper mounted on a midsole, which has an outsole for wear from hitting the ground. 
         [0008]    The prior art discloses midsoles that are made of ethylene-vinyl acetate (EVA) of different durometers. The prior art discloses different hardnesses within the midsole, such as pronation plugs, supination plugs, plastic wave plates, gels, air and other foot controlling devices, that are manufactured into the midsole or platform. 
         [0009]    The following US Patent Numbers are incorporated herein by reference: 
         [0000]    U.S. Pat. No. 873,775; U.S. Pat. No. 3,159,928; U.S. Pat. No. 3,783,373; U.S. Pat. No. 4,223,457; U.S. Pat. No. 4,237,626; U.S. Pat. No. 4,322,895; U.S. Pat. No. 4,429,474; U.S. Pat. No. 4,430,810; U.S. Pat. No. 4,573,279; U.S. Pat. No. 4,624,061; U.S. Pat. No. 4,882,856; U.S. Pat. No. 4,897,936; U.S. Pat. No. 4,942,677; U.S. Pat. No. 5,077,915; U.S. Pat. No. 5,212,878; U.S. Pat. No. 5,533,280; U.S. Pat. No. 5,692,322; U.S. Pat. No. 5,875,568; U.S. Pat. No. 6,023,859; U.S. Pat. No. 6,604,301. 
         [0010]    Shimano at one time (late 1990&#39;s or early 2000&#39;s) sold shoes which include voids for receiving rectangular blocks for adjusting hardnesses of the shoes. However, these blocks created lumps in the shoes, and these shoes may no longer be sold. 
         [0011]    Adidas at one time (around 1980) sold shoes with cylindrical voids for receiving cylinders around 25 mm in diameter and around 40 mm long for adjusting the hardness of the heel. 
       BRIEF SUMMARY OF THE INVENTION 
       [0012]    A goal of the present invention is to achieve footwear that can adapt to each foot of the individual. 
         [0013]    The present invention relates generally to footwear and more particularly, to shoes with shock absorbing midsoles or platforms. 
         [0014]    Manufacturing footwear with a replaceable tuning wedge allows the user to take out the tuning wedge and replace it with a softer or harder durometer tuning wedge to control or alter the densities of each individual&#39;s shoes. In altering the density of the midsole at specific locations, the magnitude and rate of compression resulting from the foot striking the ground is altered. The position or location of the tuning wedges within the midsole or platform adjusts the shoe to control over pronation or supination of the individual&#39;s feet. 
         [0015]    In accordance with the illustrated preferred embodiments of the present invention, replaceable tuning wedges having different durometers can be inserted into a void manufactured within the midsole. Tunable wedges can also be inserted into all shoes with midsoles or platforms without a pre-manufactured void. For example, a plastic wedge can be inserted by cutting a slice in the midsole and inserting the plastic wedge. 
         [0016]    The apparatus of the present invention includes an athletic or casual or dress shoe comprising an upper component, a midsole, an outsole, and wedges of preferably different durometers for controlling compression rates of each foot of the individual wearer. Preferably, there is a void or voids along the midsole borders for housing the wedges. 
         [0017]    The apparatus of the present invention further includes a shoe for controlling compression rates of a wearer&#39;s foot, the shoe comprising an upper, a midsole, an outsole, and one or more wedges of preferably varying durometers. Preferably, there are one or more voids along the midsole, wherein the one or more voids are sized and shaped to accept the one or more wedges. 
         [0018]    The apparatus of the present invention further include apparatus for controlling the compression rate of an individual&#39;s foot, the apparatus having a size and a shape so that one or more can be placed in the individual&#39;s shoes, wherein the apparatus has various durometers. 
         [0000]    A. Shoe and associated Control Devices 
         [0019]    The present invention provides an improved article of footwear including an upper component, a midsole component attached to the upper component, wherein the midsole component is made of a foam material that includes one or more different durometers, and an outsole for wear characteristics. Pre-manufactured midsoles with voids on the sides of said midsole in which different durometer tuning wedges may be inserted to help control or enhance compression and breakdown of the midsole in various areas of the shoe. Voids may be placed in areas such as lateral and medial rear foot and fore foot, along with the arch area, for example. 
         [0020]    Tunable wedges will help an individual who has a different gait pattern in his or her right and left feet. Tunable wedges can be used to help reduce motion created by the breakdown of the midsole, such as the lateral heel breakdown and the medial forefoot breakdown that can lead to iliotibial band issues. It is believed that almost all shoe-related soft tissue injuries can be helped by the tunable wedges of the present invention. 
         [0021]    Inserting the tuning wedges into the void of the midsole or platform can help create a more natural curvature of the heel within the shoe by creating a U shape underneath the wearer&#39;s heel. 
         [0022]    The tuning wedges can also help with the rate of midsole breakdown, thus giving the wearer longer wear with added control. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0023]    For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: 
           [0024]      FIG. 1  is a perspective view of a shoe upper in current athletic shoes, including a heel section, a midfoot section, a fore foot section, an outsole for durability and wear, and tuning wedges, in accordance with a preferred embodiment of the present invention. 
           [0025]      FIG. 2  shows a method of locking the tuning wedge in accordance with a preferred embodiment of the present invention. 
           [0026]      FIG. 3  shows a method of locking the tuning wedge in accordance with a preferred embodiment of the present invention. 
           [0027]      FIG. 4  shows a method of locking the tuning wedge in accordance with a preferred embodiment of the present invention. 
           [0028]      FIG. 5  shows a method of locking the tuning wedge in a preferred embodiment of the present invention. 
           [0029]      FIG. 6  shows tuning wedges inserted into a midsole, showing the U shape it creates around wearer&#39;s heel in accordance with a preferred embodiment of the present invention. 
           [0030]      FIG. 7  shows tuning wedges inserted into a midsole, showing the U shape it creates around wearer&#39;s heel, and a sensor contained within a wedge, in accordance with a preferred embodiment of the present invention. 
           [0031]      FIG. 8  shows tuning wedges inserted into a midsole, showing the U shape it creates around wearer&#39;s forefoot, and a sensor contained within a wedge, in accordance with a preferred embodiment of the present invention. 
           [0032]      FIG. 9  shows an outer side of a shoe with tuning wedges inserted into a midsole in accordance with a preferred embodiment of the present invention. 
           [0033]      FIG. 10  shows an inner side of a shoe with tuning wedges being inserted into a midsole in accordance with a preferred embodiment of the present invention. 
           [0034]      FIG. 11  shows an outer side of a shoe with voids in a midsole for receiving tuning wedges in accordance with a preferred embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0035]      FIG. 1  shows a shoe  20  having an upper  10  that is preferably made of a suitable material such as nylon, leather, or synthetic leather, for example, in accordance with the present invention. A midsole or platform  11  is attached to the upper  10  and preferably made of ethylene-vinyl acetate or EVA foam, plastics, leather or types of rubber, for example, for cushioning and controlling the individual&#39;s gait. An outsole  12  is preferably attached to the midsole  11  for wear and traction according to the individual&#39;s needs. A void  13  and/or a void  24  may be within the midsole  11 , manufactured or created, preferably in a wedge shape to house wedges  14 ,  114 ,  214 ,  314  of the proper durometers of the individual wearer&#39;s right and left feet. The wedges  14 ,  114 ,  214 ,  314  of different durometers preferably get seated into the void  13  and/or void  24  of the midsole for compression control and gait control. 
         [0036]    Shoe  20  includes an upper  10 , a heel section  34 , a midfoot section  35 , a forefoot section  36 , an outsole  12  for durability and wear, and voids  13  and  24  for receiving tuning wedges, in accordance with a preferred embodiment of the present invention. See  FIGS. 1 and 10 . 
         [0037]    As shown in  FIGS. 6 and 7 , there is a void  13  on each side of shoe  20 . Likewise, there is a void  24  on each side of shoe  20  (the one on the left is the mirror image of the one on the right). 
         [0038]    Materials, hardnesses, dimensions, and angles for the wedges can be for example as follows. Wedges  14 ,  15 ,  16 ,  17 ,  18 ,  40 ,  114 ,  140 ,  214 ,  240 ,  314 ,  340 ,  414 ,  440  can be made of the following materials: Elastomers, rubbers, plastics, wood, air wedge, air bladders, Skydex brand thermoplastic polyurethane (TPU) material, D3O® material used in motorcycle jackets or equivalent material which gets harder on impact, or plastic/rubber. The air wedges could be made of TPU. Wedges  14 ,  114 ,  214 ,  314 , and  440  can for example have the following hardnesses: 
       Wedges  14 ,  40 : 
       [0039]    30-60 Durometer Shore A, more preferably 35-55 Durometer Shore A, and most preferably 40-50 Durometer Shore A—for example, about 45 Durometer Shore A; 
       Wedge  114 ,  140 : 
       [0040]    40-70 Durometer Shore A, more preferably 45-65 Durometer Shore A, and most preferably 50-60 Durometer Shore A—for example, about 55 Durometer Shore A; 
       Wedge  214 ,  240 : 
       [0041]    50-80, 55-75, 60-70, for example 65 
         [0042]    50-80 Durometer Shore A, more preferably 55-75 Durometer Shore A, and most preferably 60-70 Durometer Shore A—for example, about 65 Durometer Shore A; and 
       Wedge  314 ,  340 : 
       [0043]    60-90 Durometer Shore A, more preferably 65-85 Durometer Shore A, and most preferably 70-80 Durometer Shore A—for example, about 75 Durometer Shore A; 
       Wedge  414 : 
       [0044]    Any of the hardnesses of any of the above wedges. 
       Wedge  440 : 
       [0045]    Any of the hardnesses of any of the above wedges. 
       Wedge  18 : 
       [0046]    Any of the hardnesses of any of the above wedges. 
         [0047]    A typical set of wedges for use by store owners to adjust shoes of the present invention might be as follows: 
         [0000]    multiple wedges having a hardness of 45 durometer;
 
multiple wedges having a hardness of 55 durometer
 
multiple wedges having a hardness of 65 durometer;
 
multiple wedges having a hardness of 75 durometer
 
Wedges  14 ,  15 ,  16 ,  17 ,  40 ,  114 ,  140 ,  214 ,  240 ,  314 ,  340 ,  414 ,  440  can have the following dimensions, for example:
 
Width W: preferably from 10 mm to 60 mm, more preferably from 15 mm to 55 mm, most preferably from 20 mm to 50 mm, for example around 35 mm for men&#39;s sizes 10-16 and for women&#39;s size 11-13, around 25-30 mm for men&#39;s sizes 7-9 and women&#39;s sizes 6-10. The width of the forefoot wedges can be the same as the rearfoot wedges, or the two widths can be different. The forefoot wedge width is preferably 40%-100% of the rearfoot wedge width, more preferably 45-90%, and most preferably 55-80% of the rearfoot wedge width. Height H: preferably from 3 mm to 23 mm, more preferably from 4 mm to 22 mm, most preferably from 5 mm-21 mm, for example around 6 mm-10 mm for the forefoot wedge ( 14 ,  114 ,  214 ,  314 ,  414 ) for men&#39;s sizes 7-9 and women&#39;s sizes 6-10 and for example around 10 mm-15 mm for the rearfoot wedge ( 40 ,  140 ,  240 ,  340 ,  440 ) for men&#39;s sizes 7-9 and women&#39;s sizes 6-10; for example around 10 mm-15 mm for the forefoot wedge ( 14 ,  114 ,  214 ,  314 ,  414 ) for men&#39;s sizes 10-16 and women&#39;s sizes 11-13 and for example around 15 mm-20 mm for the rearfoot wedge ( 40 ,  140 ,  240 ,  340 ,  440 ) for men&#39;s sizes 10-16 and women&#39;s sizes 11-13;
 
Depth D: preferably from 10 mm to 50 mm, more preferably from 15 mm to 45 mm, most preferably from 20 mm to 40 mm, for example around 25 mm-30 mm for men&#39;s sizes 7-9 and women&#39;s sizes 6-10, for example around 30-35 mm for men&#39;s sizes 10-16 and for women&#39;s size 11-13. The depth can be the same for forefoot and rearfoot wedges, or they can vary. It is expected that they will normally be the same.
 
         [0048]    It is possible to have more than 4 wedges per shoe and to have the wedges have a total area approximately equal to that of the midsole  11 ; however, typically, four wedges are used in each shoe  20  and together they may typically have a total area (width W×depth D×4 wedges) of from 5% to 30% of the surface area of midsole  11 , more preferably from 10% to 25% of surface area of midsole  11 , and most preferably from 15-20% to for example, 16% of surface area of midsole  11 . 
         [0049]    Angle A may be from 5 degrees to 30 degrees, more preferably from 8 degrees to 25 degrees, most preferably from 10 degrees to 20 degrees, for example around 15 degrees. 
         [0050]    Referring to  FIG. 5 , wedge  18  may have dimensions as follows: depth D; height H; a first width, W 1 ; a second width, W 2 ; an angle of wedge, A; and an angle of flare, A 2 . The wedges may substantially rectangular in vertical cross section. In some embodiments, there may be four wedges per shoe. Angle A, depth D and height H of wedge  18  can be the same as for any of wedges  14 ,  15 ,  16 ,  17 ,  18 ,  40 ,  114 ,  140 ,  214 ,  240 ,  314 ,  340 ,  414 ,  440 . First width W 1  of wedge  18  can be the same as width W for any of wedges  14 ,  15 ,  16 ,  17 ,  18 ,  40 ,  114 ,  140 ,  214 ,  240 ,  314 ,  340 ,  440 . Second width W 2  of wedge  18  can be for example 105-140%, more preferably 110-125%, and most preferably 110-120% of first width W 1  of wedge  18 . Angle of flare A 2  of wedge  18  is determined by the W 1  and W 2  and preferably both angles A 2  on a wedge are the same. In some applications, some or all wedges  14 ,  15 ,  16 ,  17 ,  18 ,  40 ,  114 ,  140 ,  214 ,  240 ,  314 ,  340 ,  414 ,  440  may be made of D3O® material (such as D3O® Set Foam 001 ST.1, density range 400-500, standard density 450, hardness range Shore 00 60-75) that will get harder upon impact, or other materials that react to impact, such as UA Speedform by Dow Chemical. 
         [0051]    Preferably, in many cases, wedges used in the forefoot will be thinner than wedges in the rearfoot. For example, if wedges in the forefoot are around 7 mm high, the wedges in the rearfoot can be around 13 mm high. 
         [0052]    The shoes will preferably be made with voids for the wedges, and sold with wedges having the same material (including hardness) as the midsole. A store would then test the shoes on the user and replace none, one, some, or all of the wedges with wedges of other hardnesses, based on observations by the shoe store operator or based on readings from sensors. 
         [0053]    In a preferred embodiment, there is preferably an attachment characteristic for seating said wedges. Exemplary attachment characteristics for use in some embodiments are shown in  FIGS. 2-4 . In  FIG. 2 , the attachment characteristic includes mating projection device  26  configured to couple with a receiving groove  27 . Referring to  FIG. 3 , the attachment characteristic includes mating serrations  28  configured to couple with receiving mating serrations  29 . The exemplary attachment characteristics in  FIG. 3  also include a mating projection device  30  configured to couple with a receiving groove  31 . Referring to  FIG. 4 , the attachment characteristic may include a mating projection device  32  configured to mate with a receiving groove  33 . One having ordinary skill in the art will recognize that  FIG. 1  shows an exemplary embodiment having four voids (one at each end as shown in  FIG. 1  and one on each side as shown in  FIGS. 6 and 7 ) for use with four wedges. However, alternative embodiments may have greater or fewer than four voids. 
         [0054]    The midsole  11  may be configured for gait control and cushioning for the wearer. One or more voids  13  or seats in the midsole  11  may be wedge shaped, for example, for controlling the compression rate in that section of the midsole. A wedge b  14  of a harder durometer that may control the forefoot section of the midsole, for example. Wedges  14  with different durometers may be seated into the voids creating the right gait control for each individual wearer, as shown in  FIG. 1 . Exemplary attachment characteristics to seat each wedge and to secure the wedge from falling out are show in  FIGS. 2-5 . The wedges used in a single shoe or in a pair of shoes may all be of the same hardness, or perhaps in some cases each will be of a different hardness from all others used in the pair of shoes, or anything in between. 
         [0055]      FIGS. 2-5  show preferred methods of seating the tuning wedges  15 ,  16 ,  17  and  18  within the void. The tuning wedges  14 ,  40 ,  114 ,  140 ,  214 ,  240 ,  314 , and  340  in  FIG. 1  show another preferred method of seating the tuning wedges within the void  13 ,  24 . As shown in  FIGS. 2-4 , the wedges  15 ,  16 , and  17  may be configured to mate with mating surfaces  21 ,  22 , and  23  of the midsole  11 , respectively. Alternatively, the shoes without a void may be tuned by placing different durometer materials in desired locations of the midsole. In such a case, the wedges could look like wedge  18 . Wedge  18  is wider at the thin part so it can be pinched and it stays in a slit which can be cut with a knife. A wedge can have the shape of wedge  18  and include a sensor  19  therein. 
         [0056]      FIGS. 6 and 7  show tuning wedges  14  seated within the midsole  11 , preferably creating a U shaped compression pattern  25  from the weight of the wearer. Referring to  FIG. 7 , a pressure sensor  19 , such as a piezo electronic sensor or strain gauge, may be placed in the wedge  440  and configured to measure compression rate or other inputs. This will alert the user as to whether the compression rate is too low to be effective in preventing pronation or supination. The sensor  19  may be configured to give feedback on a display or to connect with a computing device, such as a mobile phone, via Bluetooth or other wired or wireless networking connection. One having ordinary skill in the art would recognize that the sensor may be placed in a part of the shoe other than the wedge in an alternative embodiment. The sensor could be, for example, an Omega brand LCKD or LCMKD load cell commercially available from Omega corporation at www.omega.com. In shoe  20  shown in  FIG. 7 , there is a wedge  440  having a sensor  19  and a wedge  240  not having a sensor. In  FIG. 8 , there is a wedge  414  having a sensor  19  and a wedge  14  not having a sensor. Each wedge used in a pair of shoes may have a sensor, and each wedge may not, or any combination of wedges with sensors and without sensors can be used. 
         [0057]    Having multiple sensors gives additional information that one sensor does not give. For example, with an outside and inside sensor, when and how much pressure is applied during the foot strike can be measured. Generally, one sensor is better than no sensors, but multiple sensors (including one on each wedge used in each shoe) are sometimes preferred. 
         [0058]    The tuning wedges of the present invention can be modified as the midsole breaks down, which allows shoe stores to continue to tune the individual&#39;s gait throughout the life of the shoe. 
         [0059]    While it is preferred to use a unitary wedge in each void, one could fill the void with multiple wedges that together approximate the shape of the void. 
         [0060]    Though not preferred, one could glue the wedges in place. 
         [0061]    This wedge system can be used with virtually any type of shoe or boot or sandal. 
       PARTS LIST 
       [0062]    The following is a list of parts and materials suitable for use in the present invention: 
         [0000]    
       
         
               
               
               
             
           
               
                   
                   
               
               
                   
                 Parts  
                   
               
               
                   
                 Number 
                 Description 
               
               
                   
                   
               
             
             
               
                   
                  10 
                 upper 
               
               
                   
                  11 
                 midsole or platform 
               
               
                   
                  12 
                 outsole 
               
               
                   
                  13 
                 void 
               
               
                   
                  14 
                 wedge 
               
               
                   
                  15 
                 wedge 
               
               
                   
                  16 
                 wedge 
               
               
                   
                  17 
                 wedge 
               
               
                   
                  18 
                 wedge 
               
               
                   
                  19 
                 sensor 
               
               
                   
                  20 
                 shoe 
               
               
                   
                  21 
                 mating surface 
               
               
                   
                  22 
                 mating surface 
               
               
                   
                  23 
                 mating surface 
               
               
                   
                  24 
                 void 
               
               
                   
                  25 
                 weight of the wearer 
               
               
                   
                  26 
                 mating projection device 
               
               
                   
                  27 
                 receiving groove 
               
               
                   
                  28 
                 mating serrations 
               
               
                   
                  29 
                 receiving mating serrations 
               
               
                   
                  30 
                 mating projection device 
               
               
                   
                  31 
                 receiving groove 
               
               
                   
                  32 
                 mating projection device 
               
               
                   
                  33 
                 receiving groove 
               
               
                   
                  34 
                 heel section 
               
               
                   
                  35 
                 midfoot section 
               
               
                   
                  36 
                 forefoot section 
               
               
                   
                  40 
                 wedge 
               
               
                   
                 114 
                 wedge 
               
               
                   
                 140 
                 wedge 
               
               
                   
                 214 
                 wedge 
               
               
                   
                 240 
                 wedge 
               
               
                   
                 314 
                 wedge 
               
               
                   
                 340 
                 wedge 
               
               
                   
                 414 
                 wedge including sensor 19 
               
               
                   
                 440 
                 wedge including sensor 19 
               
               
                   
                 W 
                 width 
               
               
                   
                 D 
                 depth 
               
               
                   
                 H 
                 height 
               
               
                   
                 A 
                 angle 
               
               
                   
                 W1 
                 width 
               
               
                   
                 W2 
                 width 
               
               
                   
                 A2 
                 angle of flare 
               
               
                   
                   
               
             
          
         
       
     
         [0063]    All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise. 
         [0064]    The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.