Patent Publication Number: US-8991070-B2

Title: Shoe and method of making same

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a nonprovisional application of U.S. Provisional Application No. 61/226,013, filed 16 Jul. 2009 and entitled “Shoe and Method of Making Same.” The disclosure of this provisional application is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to shoes, and, in particular, to a shoe including an integrated sling operable to move within the shoe, as well as to a method of forming a shoe. 
     SUMMARY OF THE INVENTION 
     The present invention is directed toward a shoe with a sling or lining member integrated into the shoe. The shoe includes an upper and a sole that define an interior shoe cavity operable to receive a foot. The sling includes a receptacle and a fastener assembly. The sling is secured to the collar such that the receptacle is suspended with the shoe cavity, moving freely therein. The fastener assembly is configured to wrap around the leg/ankle of a foot. The fastener assembly includes a central web and one or more fastener members. In operation, the central web extends above the shoe collar to generally cover the Achilles tendon of the foot, while the fastener members are wrapped around the ankle of the foot and secured to each other on the side of the ankle opposite the central web. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  illustrates a front perspective view of a shoe including a sling in accordance with an embodiment of the invention. 
         FIG. 1B  illustrates a rear perspective view of the shoe shown in  FIG. 1A . 
         FIG. 1C  illustrates a side perspective view of the shoe shown in  FIG. 1A . 
         FIG. 2  illustrates an isolated view of the sling in accordance with an embodiment of the invention. 
         FIG. 3  illustrates a front cross-sectional view of the shoe of  FIG. 1A , showing the sling connected to the collar of the upper. 
         FIG. 4  is a flow diagram showing the steps of forming the shoe shown in  FIG. 1A . 
         FIGS. 5A and 5B  illustrate the formation of the upper. 
         FIG. 5C  illustrates an exploded view of the shoe of  FIG. 1A , showing the interrelationship of components forming the shoe. 
         FIG. 6  illustrates the shoe of  FIG. 1A  positioned on the foot of a wearer. 
         FIG. 7  illustrates a side view of shoe in accordance with another embodiment of the invention. 
         FIG. 8  illustrates a side view of shoe in accordance with another embodiment of the invention. 
       Like reference numbers have been utilized to identify like components throughout the figures. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIGS. 1A-1C  illustrate a shoe in accordance with an embodiment of the invention. As illustrated, the shoe  100  includes an upper  105  and a sole  110 . The front or forefoot portion  115  of the upper  105  includes a toe cap  120  disposed at its front and a throat  125  disposed rearward of the toe cap. The intermediate portion  130  of the upper  105  is defined by the vamp  135  (i.e., the section of the upper disposed rearward of the throat  125  that covers the front of the foot as far back as the quarter). The rear or heel portion  140  of the upper  105  substantially envelops the heel of the foot. The heel portion  140  includes the quarter  145  with a heel cap  147  and an optional counter  150  (a generally vertical strip of material aligned with the longitudinal axis of the shoe that is configured to strengthen the quarter). 
     An ankle collar or cuff  155  is formed into the top of the upper  105 , extending forward from the heel portion  140  to the front portion  115 , terminating proximate the throat  125 . The ankle collar  155  defines a foot opening  160  that permits the passage of foot into the shoe. The ankle collar  155  further serves as the point of attachment for a stretchable sling (discussed in greater detail below). 
     With the above-described configuration, the upper  105  and the sole  110  cooperate to define a foot or shoe cavity  315  ( FIG. 3 ) that receives the foot of the wearer. 
     The upper  105  is secured to the sole  110  around its bottom edge  545  ( FIG. 5B ) along a joint or feather  165 , e.g., by stitching, adhesive bonding, a welt (a strip of material that joins the upper to the sole), etc. The sole  110  defines an interior surface or insole  300  ( FIG. 3 ) that faces the bottom of the foot and an exterior surface or outsole  305 ( FIG. 3 ) that faces the walking surface. The shoe  100  may further include a pad coupled to the insole  300  to provide additional cushioning to the shoe. 
     The rear section of the sole  110  may include a heel  170  configured to support the heel of the foot, raising the rear of the shoe  100  in relation to the front. The heel  170  may possess any shape and any dimensions suitable for its described purpose. The heel  170  typically includes a top piece that touches ground, a heel seat connected to outsole, and a front-facing surface or breast. 
     In one embodiment, the sole  110  is configured as a full sole, extending continuously from the heel cap  147  to toe cap  120 . In another embodiment, the sole  110  may be configured as a split sole, wherein a first sole section is disposed within the heel portion  140  and a second sole section disposed within the forefoot portion  115  (i.e., no sole is positioned along the part of the shoe located under the arch of the foot). 
     The shoe  100  further includes a flexible/stretchable sling or liner permanently secured to the upper  105 . In the embodiment shown in  FIG. 2 , the sling  200  possesses a unitary structure including a foot receptacle  210  and a fastener assembly  220 . The foot receptacle  210  is configured to generally conform to the shape of the shoe cavity  315 . The foot receptacle  210  includes a bottom or base  225  and a side wall  230  extending upward from the base. The base  225 , which defines a generally horizontal surface in contact with the bottom of the foot, is substantially coextensive with the insole  300  of the sole  105 . The side wall  230  may be connected to the base  225  along a seam  235  (e.g., via stitching), and may be angularly or orthogonally oriented with respect to the base  225 . With this configuration, the foot receptacle  210  is configured to be generally coextensive with the cavity  315  of the shoe  100 , further defines a sling cavity  240  ( FIG. 3 ) that receives the foot of a wearer. 
     The sling  200  may further include an exterior flap  245  extending from the rim  247  of the receptacle  210 . The flap  245  extends downward from the perimeter of the receptacle  210  such that it overlaps the receptacle&#39;s upper portion. With this configuration, the flap  245  generally defines a pocket  249  configured to receive and capture an elastic member or band  560  ( FIG. 5C ). The elastic member is coupled to the collar  155  of the sole  105  to provide a resilient opening that partially closes on the foot, helping to secure to shoe  100  thereto. In operation, the band  560  is positioned within the pocket  249 . The flap  245  is secured to the receptacle  210 , which, in turn, is secured to the upper  105  along a line falling just below the collar  155 . 
     The fastener assembly  220  is configured to wrap around the leg/ankle of the wearer. The fastener includes a central web  250  configured to extend upward from collar  155  proximate the heel portion  140  of the upper  105  (e.g., being centrally aligned with the counter  150  (seen best in  FIG. 6 )). The central web  250  may further include a first lateral portion  252 A disposed along a first lateral side of the web and a second lateral portion  252 B disposed along a second lateral side of the web. With this configuration, the central web  250  and lateral portions  252 A,  252 B partially surround the rear potion of the opening  160  defined by collar  155  (being positioned along the heel cap  147 ). The central web  250  may possess any shape and dimensions suitable for its described purpose. Preferably, the central web  250  is configured to cover at least a portion of the Achilles tendon of the wearer. 
     A first fastener member  255 A may extend from the first lateral portion  252 A of the central web  250 , while a second fastener member  255 B may extend from the second lateral portion  252 B of the central web. Each fastener member  255 A,  255 B extends distally from the central web  250  to define a distal portion  260 A,  260 B disposed a predetermined distance from the web. Each fastener member  255 A,  255 B may be configured to extend laterally from the central web  250  at an angle oriented generally orthogonal to the longitudinal axis of the shoe  100 . Alternatively, the fastener member  255 A,  255 B may extend from the central web  250  at other desired angles. Each fastener member  255 A,  255 B is configured to wrap around the lateral side of the leg/ankle and be fastened to each other along the side of the ankle/leg generally opposite to the central web  250 . 
     Referring to the embodiment shown in  FIG. 3 , the sling  200  may be secured to the upper  105  such the receptacle  210  is suspended and/or draped within the shoe cavity  315 . Specifically, the upper edge of the receptacle sidewall  230  is fixed to collar  155 , but the base  225  is permitted to move within the shoe cavity  315 . By way of example, the upper portion of the receptacle  210  may be secured to the collar  155  via stitching, adhesive, etc. With this configuration, only the upper portion or edge of the side wall  230  is secured about the circumference of the collar  155 , thereby enabling the receptacle  210  to hang freely from the collar while remaining positioned within the shoe cavity  315 . Stated another way, the base  225  of the receptacle  210  is not permanently or temporarily secured to the sole  110  or the upper  105 ; consequently, the base of the receptacle moves freely move relative to the sole  110  (e.g., along the surface of the insole  300 ). With this configuration, the portion of the sling  200  that cradles the foot is adapted to move within the shoe cavity, while remaining securely coupled to the upper  105 . 
     In other embodiments, the sling  200  may be secured to the shoe  100  (i.e., to the upper  105  and/or the sole  110 ) at other predetermined locations including, but not limited to, the forward point of the shoe (e.g., along the toe cap  120 ). 
     As best seen in  FIG. 3 , the uppermost portion  265  of the receptacle side wall  230  may be further configured extend slightly above the collar  155  of the upper  105  to provide additionally comfort to the wearer (to prevent chafing of the collar  105  against the foot). 
     The materials forming the shoe  100  are not particularly limited, and include natural and synthetic materials. By way of example, the upper  105  may be formed of flexible material such as leather such (e.g., patent leather or suede). The sling  200  may be formed of soft, elastic (stretchable) material such as LYCRA. The sole  110  may be formed from generally rigid and/or durable materials such as rubber or wood. 
     The method of forming the shoe  100  is now explained with reference to FIGS.  4  and  5 A- 5 C. At Step  410 , the upper  105  is formed. Referring to  FIG. 5A , the upper  105  may include a first segment of material  500 A and a second segment of material  500 B. Each material segment  500 A,  500 B possesses an interior surface  505  (i.e., a surface that faces the interior of the shoe  100 ) and an exterior surface  510  (i.e., a surface that faces outward). The first material segment  500 A may be a generally arcuate segment including a first or forward transverse side  515 A, a second or rearward transverse side  515 B, a first or sole-facing longitudinal side  520 A, and a second or collar-forming longitudinal side  520 B. The portion of the first segment  500 A including the first transverse edge  515 A may be a hooked end  522  that defines a generally J-shaped structure. 
     The second material segment  500 B may include a third or forward transverse end  525 A, a fourth or rearward transverse end  525 B, a third or sole-facing longitudinal side  530 A, and a fourth or collar-forming longitudinal side  530 B. 
     To form the upper, the transverse ends  515 A,  515 B,  525 A,  525 B of the material segments  500 A,  500 B may be connected together by scribing or skiving complementary portions of the interior-facing  505  or exterior-facing  510  surfaces and securing the scribed edges together utilizing an adhesive and/or stitching. In one embodiment, the interior surface  505  of the first material segment  500 A is scribed along its first transverse side  515 A. Similarly, the exterior surface  510  of the second material segment  500 B is scribed along the third transverse side  520 A. This creates an inverse joint  532  having a size of, e.g., about 5-6 mm. The first  515 A and third  525 A transverse sides are then sealed together utilizing an adhesive (e.g., a hot melt polyurethane adhesive). In addition, the second  515 B and fourth  525 B transverse sides may be connected along seam  532  to form the heel portion  140  of the upper  105 , defining the central counter position. Once sealed, the upper  105  may be generally in the form of an oval having a top or collar edge  540  and a bottom or sole edge  545  is formed. 
     At Step  420 , the collar  155  may be formed. By way of example, the collar edge of the upper  105  may be folded along fold lines  550  to form a folded over band or cuff. 
     At Step  430 , the sling  200  is formed. By way of example a piece of stretchable material may be configured into the base  225 , side wall  230 , and fastener assembly  215  portions (e.g. by cutting a single piece of fabric or cutting multiple pieces of fabric together via stitching, etc.). The sling  200  may then be secured to the collar  105  of the upper at Step  440 . Specifically, the outer surface of the exterior flap  245  extending from the rim of the receptacle  210  is secured to the interior surface  505  of the upper  105 , and the receptacle is positioned within the upper. Optionally, the elastic band  560  may be inserted into the pocket  249  formed between the downward flap  245  and the receptacle exterior wall at Step  450 . The pocket  249  may be sealed shut in a manner that secures the sling  200  to the upper  105  (e.g., by stitching) as described above. The elastic band  560  assists in stabilizing the shoe  100  on the foot, more securely connecting it to the foot of the wearer. 
     At step  460 , the sole  110  is secured to the bottom edge  545  of the upper  105  utilizing conventional techniques (e.g., via stitching, adhesive, etc.) to form the joint  165 . Once formed, the upper  105  is positioned above the sole  110 , defining one or more of the toe cap, throat, vamp, quarter, heel cap portions of the shoe  100  as described above. 
     In one embodiment, reinforcement material may be added to selected portions of the interior surface  505  of the upper  105 . For example, reinforcing material (e.g., fabric such as canvas) may be secured to the interior surface  505  of the toe cap  120  of the upper  105  utilizing adhesive. In addition, reinforcing material may be secured to the interior side of the heel (to form the counter), e.g., by sewing and/or adhesive, and then optionally hammered until smooth. Reinforcement material may also be connected to the bottom edge  545  of the upper  105  (e.g., via adhesive and stitching). 
     Referring to  FIG. 6 , in operation, a user inserts a foot  600  into the shoe  100 , through the opening  160  defined by the collar  155  and into the sling cavity  240 . As the foot is positioned within the shoe, the foot receptacle  210  of the sling stretches and conforms to the foot  600 , providing a customized fit to the wearer. In addition, the upper portion of the receptacle  210  remains fixed to the collar  155  while the base  225  moves freely with the user&#39;s foot. 
     Once the foot is inserted into the shoe, fastener assembly  220  is secured to the ankle/leg. Specifically, the central web  250  is positioned such that it covers the Achilles tendon of the foot. The first fastener member  255 A is wrapped around one side of the ankle/leg, while the second fastener member  255 B is wrapped around the other side of the ankle/leg. The distal portions  260 A,  260 B of the fasteners  255 A,  255 B are then secured to each other (e.g., mechanically secured by tying), being fastened along the front of the leg/ankle, generally opposite the central web position. Securing the fastening members further helps to secure the shoe  100  to the foot  600 . 
     The above-described method provides a shoe having an internal, integrated sling or lining member with increased comfort characteristics. The sling not only provides additional comfort for the wearer, reducing friction between the foot and the interior surface of the shoe upper and sole, but also stabilizes the shoe on the foot. The sling permits the wearer to completely flex the foot in all required directions while securing the shoe tightly to the foot. The sling is easy to secure, and flexes to accommodate the movement of the foot. 
     While the present invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. For example, the materials forming the shoe  200  may include any suitable for its described purpose. The type of shoe  100  in which the sling  200  is integrated is not particularly limited. That is, the method may be utilized to form shoes other than the shoes illustrated. Referring to  FIGS. 7 and 8 , other embodiments of the shoe includes low-heeled  700  ( FIG. 7 ) and high-heeled shoes  800  ( FIG. 8 ). 
     In addition, the sling  200  may include only the receptacle  210  portion, with the fastener assembly  215  being omitted. Thus, the  200  sling would terminate along its upper rim. The sling  200  may be formed of a unitary piece of fabric, or may be formed of multiple pieces of fabric secured together. For example, the receptacle  210  and the fastener assembly  215  may be formed as separate components and combined via sewing, adhesive, etc. Similarly, individual components of each of the receptacle  210  (e.g., the base and side wall) and the fastener assembly  215  (e.g., the fastener members  255 A,  255 B and the central web  250 ) may be formed as a unitary structure or may be individual units secure together. 
     Any number of segments of material pieces  500 A,  500 B may be utilized to form the upper  105 . While the illustrated embodiments show two segments of material, the upper  105  may be formed of a single segment of material. 
     Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. It is to be understood that terms such as “top”, “bottom”, “front”, “rear”, “side”, “height”, “length”, “width”, “upper”, “lower”, “interior”, “exterior”, and the like as may be used herein, merely describe points of reference and do not limit the present invention to any particular orientation or configuration.