Abstract:
Footwear with enhanced wearing comfortability, stability and orthotic foot support are disclosed. The footwear comprises built-in intrinsic midsole, anatomically shaped footbed having a functional arch concavity on a medial side, and deep heel cup. The built-in intrinsic midsole provides ideal foot support and function. Raised sidewalls accentuate a deep heel cup, which controls and matches the natural anatomic shape of the foot. The midsole is made by direct single density injection with integrated orthotic contour. The direct injection midsole to upper creates a strong bond, and resolves a potential of delaminating soles. Furthermore, it eliminates the need and cost of cementing, and improves instant fit/comfort.

Description:
FIELD OF THE DISCLOSURE 
       [0001]    The present disclosure is generally related to footwear products. The disclosure has particular utility in connection with performance walking shoes, and will be described in connection with such utility, although often utilities are contemplated. 
       BACKGROUND OF THE DISCLOSURE 
       [0002]    Growing awareness about healthy and active lifestyles, rising demand for comfortable footwear, increased demand for innovative design and technology, growing population, and rising disposable income levels all contribute to a steady increase in the size of the footwear market. 
         [0003]    Innovations have been made to push the boundary for wearing comfort, fit, finish, controls and/or stability of footwear products. U.S. Patent application 2011/0000102 discloses a customisable insert consisting of an integrated insole and midsole customised to match the internal profile of an item of footwear. U.S. Patent application 2014/0250727 discloses a layered composition comprising three or more layers suitable for combined midsole/insole production. The combined midsole/insole is cut from a layered composition having a strobel layer, a cushioning layer, and a textile layer, all of which are needle-punched or laminated together to form the layered composition. U.S. Pat. No. 7,010,869 discloses footwear with an insertable midsole orthotic. The shoe sole includes a concavely rounded side or underneath portion, which may be formed in part by the insertable midsole orthotic. The insertable midsole orthotic permits replacement of midsole material which has degraded or has worn out in order to maintain optimal characteristics of the shoe sole and allows customization for the individual wearer to provide tailored cushioning or support characteristics for the purpose of orthopedic, podiatric, corrective, prescriptive, therapeutic and/or prosthetic purposes. 
         [0004]    It would be desirable to provide footwear with orthotic structure support for enhanced wearing comfortability, stability and foot support. 
       SUMMARY OF THE DISCLOSURE 
       [0005]    Embodiments of the present disclosure provide footwear with enhanced wearing comfortability, stability and orthotic foot support. The footwear comprises built-in intrinsic midsole, anatomically shaped footbed with a functional arch concavity on the medial side, and a deep heel cup. The built-in intrinsic midsole provides ideal foot support and function, allowing the foot to arch and collapse during walking and running, in a natural manner. Raised sidewalls accentuate the deep heel cup, which controls and matches the natural anatomic shape of the foot. 
         [0006]    In one embodiment, the midsole comprises a dual density midsole made by direct compression co-molding and combining the outsole, with an integrated orthotic contour such as the Vionic® Orthaheel Lisa orthotic thong sandal available from Vionic Group LLC, the assignee of the subject application, but having a functional arch concavity on the medial side, and a deep heel cup as described hereafter. Optionally, the midsole also may include 1 st  ray relief such as found in the Vionic Orthoheel Active orthotic insole also available from Vionic Group LLC. Direct injection molding of the midsole to the outsole creates a strong bond, and resolves any potential issue with delaminating soles. Furthermore, it eliminates the need and cost of cementing, and improves instant fit/comfort. Alternatively, the midsole may be dual density compression molded, with similar results. 
         [0007]    In another embodiment, the unibody midsole comprises an outsole for protection/traction and a midsole for shock absorption that incorporates an orthotic contour and a functional arch concavity on the medial side, and a deep heel cup for relief and foot support. The unibody midsole eliminates the need for a separate orthotic insole into footwear and thus avoids any potential relative movement between the insole insert and the footwear when a user is at aggressive movement. The unibody midsole integrates components into one dynamic form. The biomechanically and anatomically shaped foot bed with a functional arch concavity on the medial side facilitates a more efficient gait. 
         [0008]    In yet another embodiment, the unibody midsole orients the user closer to the ground surface. The midsole further comprises functional arch concavity on the medial side, which promotes biomechanical function and comfort for a user, allowing the foot to arch and collapse during walking and running in a natural manner. 
         [0009]    In yet another embodiment, the footwear has one-piece upper overlay construction with a relaxed toe box, and minimal lining. The midfoot and heel counter are reinforced to maintain integrity of the footwear. The one-piece upper combines polyurethane (PU) overlay(s) with woven/mesh construction for enhanced breathability when worn by a user. 
         [0010]    Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
           [0012]      FIG. 1  is a cross-sectional view of a midsole with intrinsic orthotic in accordance with an embodiment of the present disclosure. 
           [0013]      FIG. 2  is a prospective view of an anatomic footbed matches natural contours in accordance with an embodiment of the present disclosure. 
           [0014]      FIG. 3A  is a section view comparison between a shoe with a traditional midsole and  FIG. 3B  an orthotic insert and a shoe with a unibody midsole incorporating intrinsic orthotic, in accordance with an embodiment of the present disclosure. 
           [0015]      FIG. 4  is an exploded view of a traditional shoe in accordance with prior art. 
           [0016]      FIG. 5  is an exploded view of a shoe with unibody midsole, in accordance with one embodiment of the present disclosure. 
           [0017]      FIG. 6  is an exploded view of a shoe with unibody midsole, in accordance with another embodiment of the present disclosure. 
           [0018]      FIG. 7  is a bottom view of a unibody midsole in accordance with an embodiment of the present disclosure. 
           [0019]      FIG. 8  is a flow chart of a method for making a unibody midsole in accordance with an embodiment of the present disclosure. 
           [0020]      FIG. 9A  is a cross-sectional view of a traditional midsole in accordance with prior art. 
           [0021]      FIG. 9B  is a cross-sectional view of a traditional midsole with orthotic device in accordance with prior art. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    In the following description, for the purpose of explanation, specific details are set forth in order to provide understanding of the present invention. However, the present invention may be implemented without some of these details. The embodiments of the present invention described below may be incorporated into a number of different means, components, apparatus, circuits and devices. Structures and devices shown in diagram are illustrative of exemplary embodiments of the present invention. Connections between components may be modified, re-formatted via intermediary components. When the specification makes reference to “one embodiment” or to “an embodiment”, it is intended to mean that a particular feature, structure, characteristic, or function described in connection with the embodiment being discussed is included in at least one contemplated embodiment of the present invention. Thus, the appearance of the phrase, “in one embodiment” in different places in the specification does not constitute a plurality of references to a single embodiment of the present invention. 
         [0023]    Various embodiments of the invention are related to a unibody midsole for walking shoes with enhanced wearing comfortability, stability and orthotic foot support. The built-in intrinsic midsole provides ideal foot support and function. Raised sidewalls on the midsole accentuate a deep heel cup, which controls and matches the natural anatomic shape of the foot. The midsole may integrate anatomically shaped footbed, a functional arch concavity on the medial side, and deep heel cup. 
         [0024]      FIG. 9A  is a cross-sectional view of a traditional midsole in accordance with prior art. The traditional shoe midsole construction utilizes a midsole  100  with essentially a flat top surface, which provides little support to the foot and may cause foot arch fatigue after long time wearing.  FIG. 9B  is a cross-sectional view of a traditional midsole with orthotic device in accordance with prior art. The traditional shoe midsole  110  is retrofitted with supportive orthotic device  111 , which may be constructed as an insertable insole. The orthotic retrofitted midsole remains flat at the heel portion, and therefore does not match the natural anatomic shape of a foot. 
         [0025]      FIG. 1  is a cross-sectional view of a midsole with intrinsic orthotic in accordance with an embodiment of the present disclosure.  FIG. 2  shows a prospective view of an anatomic footbed matches natural contours in accordance with embodiments of the present disclosure. The midsole  120  is a unibody piece with intrinsic orthotic  122  for ideal foot support and function. Raised sidewalls  123  accentuate a deep heel cup  121 , which controls and matches the natural anatomic shape of the foot. Midsole  120  has a foot supporting upper surface contour at  125  to provide a functional arch concavity on the medial side, which allows the foot arch to collapse during walking and running, in a natural manner. The unibody structure also avoids any potential sheer movement between the shoe midsole  110  and the supportive orthotic device  111  for traditional shoes, especially when a wearer is having aggressive movement. As shown in  FIG. 2 , the midsole may also have an optional perforated foam layer to increase air flow and moisture wicking. 
         [0026]    The midsole may be made from TPU (Thermoplastic polyurethane), PU (polyethylene), EVA (Ethylene-vinyl acetate) or other materials. In one embodiment, the unibody midsole is constructed with a single density midsole for a simplified manufacturing process. In another embodiment, the unibody midsole is constructed with a dual density midsole with different density combinations for proper function, stability, and comfort. 
         [0027]      FIGS. 3A and 3B  are section view comparisons between a shoe with a traditional midsole and an orthotic insert ( FIG. 3A ) and a shoe with a unibody midsole incorporating an intrinsic orthotic and functional arch components on the medial side, in accordance with embodiments of the present disclosure ( FIG. 3B ). For the shoe  310  shown  FIG. 3A , an orthotic is retrofitted to a midsole to provide support and function. However, the heel cup area remains flat. The unstable stacking of components brings the wearer higher above ground surface and thus lowers the stability of the wearer. Furthermore, non-matching contours and shapes in the heel are less comfortable for the wearer. In  FIG. 3B , the shoe has a unibody midsole incorporating an intrinsic orthotic for an anatomically shaped footbed providing instant fit and comfort and a functional arch concavity  325  on the medial side. Furthermore, the heel cup  121  transitions seamlessly into an heel counter  322 , thus providing an improved anatomic fit. 
         [0028]      FIG. 4  illustrates an exploded view of a traditional shoe in accordance with prior art. A traditional shoe typically comprises an upper  410 , an insole  420 , a midsole  430  and an outsole  440 . The insole  420  may incorporate orthotic technology improve support and fit of the shoe. The multi-layer lamination of the traditional shoe structure not only adds manufacturing complexity and cost, but also pushes a user further away from ground surface thus reduces stability of the user due to raised position. Multi-layer structure may also cause de-lamination between the layers after long term wearing and thus adversely affect the reliability of the shoe. Furthermore, gaps between the insole and the midsole may be prone to germ or bacterial growth, especially when the shoe is used in high humidity regions. 
         [0029]      FIG. 5  is an exploded view of a shoe with an unibody midsole, in accordance with one embodiment of the present disclosure. As a comparison to  FIG. 4 , the shoe in  FIG. 5  only comprises an upper  510  and a unibody midsole  520 . The midsole may be constructed into a dynamic form with an orthotic biomechanic and anatomical engineered footbed. Fewer components also simplify manufacturing process, eliminate de-lamination issues and cause less waste. In some embodiments, the unibody midsole  520  has a medial contour  522  (or a contoured arch) higher than the heel cup  523  and the front contour  524  (or the rest of the footbed). The higher medial contour  522 , however, is concave under the medial arch, whereby to accentuates a functional arch, and thus provide better structure support for a user&#39;s foot, and yet permit the foot arch to collapse during walking and running, in a natural manner. 
         [0030]      FIG. 6  is an exploded view of a shoe with an unibody midsole, in accordance with another embodiment of the present disclosure. The shoe  600  comprises an unibody midsole  610 , an upper  620  and an optional molded strobel sock  630 . The midsole  610  incorporates a deep or concaved heel cup  611  and a contoured arch support  612  including a functional arch concavity on the medial side, to form an orthotic biomechanic and anatomical engineered footbed  615 . In a preferred embodiment the module  610  also includes an area  640  of reduced support positioned to underlie the first metatarsal head of the wearer. Area  640  may comprise an area of reduced durometer, or a hollow or concavity, e.g., in accordance with the teaching of U.S. Pat. Nos. 4,597,195 and 8,166,674, and U.S. Design Pat. No. D723,256, the contents of which are incorporated herein by reference. The heel cup  611  transitions seamlessly into a heel counter  621  of the upper  620 , thus providing an improved anatomic fit. In some embodiments, the midsole  610  comprises a raised sidewall  613  fully around the footbed  615 . The sidewall  613  forms a closed contour. The sidewall  613  not only helps accentuate the heel cup, but also facilitates the sealing of the upper to the midsole. The upper is a one-piece design. In some embodiments, the upper is a breathable mesh upper for enhanced wearing comfort. In some embodiments, the molded strobel sock  630  is made with perforated memory foam layer for additional cushioning, air flow and moisture wicking. The strobel sock  630  is preferably made with a surface contour  631  fully matched the footbed  615  for maximum fit. 
         [0031]      FIG. 7  is a bottom surface of a unibody midsole in accordance with embodiments of the present disclosure. The midsole  700  incorporates a medial concavity  710  on the bottom surface  705  to allow localized functionality. The bottom surface  705  has a plurality of grooves  720  to allow deformation of the midsole during wearing movement. The grooves  720  may be straight line grooves, crossed groves, or grooves with other patterns. At least one insert  740  is attached to the bottom surface to enhance friction stability, shock absorption and wear against ground surface. In some embodiments, the insert is a carbon rubber or a blown rubber. The midsole  700  may also incorporate tuned heel pitch and transitional contour on the bottom surface  705  to support additional functionalities. In some embodiments, the midsole  700  has reinforcement  715  on the bottom surface  705  and beneath the contoured arch support  612  for increased lateral torsional support. 
         [0032]      FIG. 8  is a flow chart of a method for making an unibody midsole in accordance with embodiments of the present disclosure. The method begins at step  810  by provide a unibody midsole with an anatomically shaped footbed integrated orthotic contour having a functional arch concavity on the medial side, and deep heel cup. At step  820 , a molded strobel sock is optionally attached to the footbed of the midsole. At step  830 , the midsole is directly injected or bonded to a one-piece upper to create a strong bond. In some embodiments, inset panels are attached to the bottom surface of the midsole for added flexibility, friction stability and shock absorption. It shall be noted that the above steps are performed under specific conditions using a specific embodiment or embodiments. Accordingly, neither these steps nor their results shall be used to limit the scope of the disclosure. Furthermore, it shall be noted that the method for making an unibody midsole may be implemented by performing certain steps optionally, extra steps beyond the illustration of  FIG. 8 , performing certain steps in different orders, and/or performing certain steps concurrently. [ 33 ] It should be emphasized that the above-described embodiments of the present disclosure, particularly, any “preferred” embodiments, are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present disclosure and protected by the following claims.