Patent Publication Number: US-2015068066-A1

Title: Footwear assemblies having reinforced insole portions and associated methods

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 13/110,739, titled “FOOTWEAR ASSEMBLIES HAVING REINFORCED INSOLE PORTIONS AND ASSOCIATED METHODS”, filed May 18, 2011, which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure is directed generally to footwear assemblies having insoles securely attached to corresponding uppers and midsole and/or outsoles. 
     BACKGROUND 
     Articles of footwear have been designed for in a wide variety of physical activities including walking, running, hiking, trekking, hunting, backpacking, and indoor and outdoor activities. For example, hiking and work boots are typically designed to provide a wearer with suitable comfort and support for hiking or walking on uneven or rough terrain. Conventional hiking or work boots, however, can be relatively heavy. Every time a wearer takes a step, such as while walking or hiking, the wearer must lift the weight of the boot. After hundreds or thousands of steps, that additional weight can be fatiguing on the wearer&#39;s legs. Accordingly, it is highly desirable to minimize the weight of the footwear without overly compromising the stability and support of the footwear. 
     U.S. Pat. Nos. 6,484,420 and 6,757,990 disclose a significant advancement in footwear technology to achieve a lightweight footwear assembly while maintaining a very stable platform. U.S. Pat. Nos. 6,484,420 and 6,757,990 are incorporated herein in their entirety by reference. This footwear incorporates a construction wherein at least a portion of the lateral and medial peripheral flanges of the upper are stitched to the insole in the phalangeal and heel portions but they are not stitched to the insole through the arch portion. Additionally, the lateral and medial peripheral flange of the upper is wrapped around the lateral peripheral edge of the insole in the arch portion and the medial peripheral flange of the upper is wrapped around the medial peripheral edge of the insole in the arch portion. Moreover, the lateral and medial peripheral flanges are secured to the bottom surface of the arch portion of the insole. This construction provides a very lightweight and stable platform, although there are areas where improvements may be made for selected footwear. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of a footwear assembly configured in accordance with an embodiment of the disclosure. 
         FIG. 2  is an isometric partially exploded view of the footwear assembly of  FIG. 1 . 
         FIG. 3A  is a cross-sectional end view taken substantially along lines  3 A- 3 A of  FIG. 1 . 
         FIG. 3B  is a cross-sectional end view taken substantially along lines  3 B- 3 B of  FIG. 1 . 
         FIG. 3C  is a cross-sectional end view similar to  FIG. 3A  showing an alternate embodiment. 
         FIG. 4  is a bottom view of a portion of a footwear assembly configured in accordance with another embodiment of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Footwear assemblies with securely attached and reinforced insoles, and associated methods for using and making such assemblies, are described in detail herein in accordance with embodiments of the present disclosure. In one embodiment, for example, a footwear assembly includes an upper coupled to a multi-piece insole having a first insole board positioned underneath and attached to a second insole board in the heel area of the footwear. The first insole board includes a first surface (e.g., a top surface) opposite a second surface (e.g., a bottom surface). The top surface is configured to face the second insole board and a user&#39;s foot when inserted in the upper. In the heel area, the peripheral portion of the upper at least partially wraps around the edge of the first insole board and is stitched to the bottom surface of the first insole board. The second insole board is stacked on top of at least a portion of the first insole board in the heel area. In one embodiment, the peripheral edge portion of the upper in the heel area is wrapped around and stitched to the first insole board, but the stitching does not extend through the second insole board. Instead, the heel area of the second insole board is adhered or otherwise anchored to the top surface of the first insole board, to which the upper is stitched. Moreover, at the arch area, the peripheral portion of the upper is wrapped around and adhered to the bottom surface of the first or second insole boards, such that stitching along the upper does not extend into the arch area of the footwear. 
     In one embodiment, a heel counter is provided in the heel area of the footwear. A bottom flange portion of the heel counter is sandwiched between at least the peripheral areas of the first and second insole boards. Sidewalls of the heel counter extend upwardly from the bottom flange portion and help define a heel cup area in the footwear. In at least one embodiment, the flange of the heel cup can be adhered to the top of the first insole board. In another embodiment, the flange of the heel cup can be stitched to the top of the first insole board with the same stitching that secures the peripheral edge portion of the upper to the bottom surface of the first insole board. Moreover, at the forefoot area, the peripheral edge portions of the upper are flared outwardly and stitched to the upper surface of the second insole board forward of the arch area, but not in the arch area. 
     In another embodiment, a footwear assembly includes an upper, a sole assembly including an insole and a midsole, and an outsole. The insole is positioned between the upper and the midsole, and the midsole is positioned between the insole and the outsole. The upper is coupled to the sole assembly. At a heel portion of the footwear assembly, a lower edge portion of the upper is stitched to a lower surface of the insole facing the midsole. At a forefoot portion of the footwear assembly, the lower edge portion of the upper is stitched to an upper surface of the insole opposite the midsole. Moreover, the upper is not stitched to the insole at an arch portion of the footwear assembly. 
     Certain details are set forth in the following description and in  FIGS. 1-4  to provide a thorough and enabling description of various embodiments of the disclosure. Other details describing well-known structures and components often associated with footwear assemblies and methods of forming such assemblies, however, are not set forth below to avoid unnecessarily obscuring the description of various embodiments of the disclosure. Many of the details, dimensions, angles, relative sizes of components, and/or other features shown in the Figures are merely illustrative of particular embodiments of the disclosure. Accordingly, other embodiments can have other details, dimensions, angles, sizes, and/or features without departing from the spirit and scope of the present disclosure. In addition, further embodiments of the disclosure may be practiced without several of the details described below, while still other embodiments of the disclosure may be practiced with additional details and/or features. In the Figures, identical reference numbers identify identical, or at least generally similar, elements. To facilitate the discussion of any particular element, the most significant digit or digits of any reference number refer to the Figure in which that element is first introduced. For example, element  100  is first introduced and discussed with reference to  FIG. 1 . Moreover, one of ordinary skill in the art will appreciate that any relative positional terms such as above, below, over, under, etc. do not necessarily require a specific orientation of the footwear assemblies as described herein. Rather, these or similar terms are intended to describe the relative position of various features of the disclosure described herein. 
       FIG. 1  is a side view of a footwear assembly  100  (“assembly  100 ”) configured in accordance with an embodiment of the disclosure. As will be appreciated by one of ordinary skill in the art, the assembly  100  can include any article of footwear (e.g., a boot, shoe, sandal, etc.) and is not limited to the boot shown in  FIG. 1 . In the illustrated embodiment, the assembly  100  includes an upper  102  attached to a sole assembly  104 . The sole assembly  104  includes an outsole  106  coupled to a midsole  108 , as well as an insole attached to the upper  102  and the midsole  108  as described in detail below with reference to  FIGS. 2-4 . The sole assembly  104  also includes an arch portion  110  positioned between a heel portion  112  and a forefoot portion  114 . As described in detail below, the sole assembly  104 , and in particular the heel portion  112  of the sole assembly  104 , is configured to provide increased support and stability, as well as secure attachment to the upper  102 . 
       FIG. 2  is an isometric partially exploded view of the footwear assembly  100  of  FIG. 1  illustrating several features of the sole assembly  104 . More specifically, the sole assembly  104  includes the outsole  106  coupled to the midsole  108 , as well as the insole  230  and upper  102  coupled to the midsole  108 . In the illustrated embodiment, the outsole  106  includes an outsole arch portion  218  between an outsole heel portion  216  and an outsole forefoot portion  219 . The outsole  106  also includes an exterior tread portion  217  that can include any suitable tread pattern for providing traction while walking or running on various terrain. The outsole  106  can be made from rubber (e.g., natural or synthetic), leather, or other suitable footwear materials or combinations of materials. 
     According to additional features of the illustrated embodiment, the midsole  108  is positioned adjacent to the outsole  106  and includes a full-length first midsole portion  220  and a separate second midsole portion  228 . The first midsole portion  220  includes an arch portion  224  between a heel portion  222  and a forefoot portion  226 . The first midsole&#39;s heel portion  222  can include a cushioned heel section  223  that provides additional support or cushioning in the heel portion  222 . For example, the cushioned heel section  223  can be made from the same material or a different material from the first midsole heel portion  222 , and can protrude or extend away from the first midsole heel portion  222  to provide an increased thickness. In other embodiments, however, the cushioned heel section  223  can be omitted. 
     The second midsole portion  228  is configured to be generally aligned with or otherwise overlap the first midsole forefoot portion  226  of the first midsole portion  220  to provide additional support and/or cushioning at the first midsole forefoot portion  226 . Although the first and second midsole portions  220 ,  228  are shown as separate components, in other embodiments these portions of the midsole  108  can be integrally formed. Moreover, in still further embodiments, the midsole  108  can be integrally formed with the outsole  106  or omitted from the sole assembly  104 . The midsole  108  can be formed from rubber, ethylene vinyl acetate (EVA), closed-cell foam material, and/or other suitable footwear materials. As such, the midsole  108  can provide support and comfort while for a user by dispersing the user&#39;s weight and providing stability and/or shock absorption. 
     The insole  230  is positioned adjacent to the midsole  108  and configured to be positioned directly below a user&#39;s foot when inserted into the assembly  100 . In the illustrated embodiment, the insole  230  is a multi-piece insole that includes first and second insole boards  232  and  240 , respectively. In the illustrated embodiment, a sturdy heel counter  236  is provided in the heel area and is at least partially sandwiched between the first and second insole boards  232  and  240 . The first insole board  232  is configured to be positioned in the heel area of the assembly  100  and includes a generally U-shaped configuration. More specifically, the first insole board  232  can be a stiffener or support that includes a first or lower surface  233  opposite a second or upper surface  231 . The lower surface  233  faces the midsole  108  and/or outsole  106 , and the upper surface  231  faces the heel counter  236 . The first insole board  232  further includes a first insole inner opening  235  at least partially defined between corresponding legs or end portions  234  of the U-shaped configuration (identified individually as a first leg  234   a  and a second leg  234   b ). In other embodiments, however, the inner opening  235  of the first insole board  232  can be smaller or fully enclosed. In still further embodiments, the first insole board  232  can be a structure without any interior opening. 
     The heel counter  236  is a separate structure positioned adjacent to the upper surface  231  of the first insole board  232  and attached to the first insole board  232 . The heel counter  236  is configured to provide stiffness and/or support in the heel area of the assembly  100 . For example, the heel counter  236  can be a heel cup structure including a tapered sidewall  238  extending at least partially around rear and side sections of the heel counter  236 . The heel counter  236  can be an internal heel counter covered by the heel portion of the upper. In another embodiment, the heel counter  236  can be an external heel counter forming an exterior heel portion of the footwear, such that the external heel counter is visible. In yet another embodiment, the heel counter  236  can be a multi piece structure including an internal heel counter and a separate external counter. In the illustrated embodiment the heel counter  236  is an internal heel counter having a generally U-shaped configuration substantially matching and aligned with the U-shaped first insole board  232 . More specifically, for example, the heel counter  236  can include a second insole inner opening  237  at least partially defined between corresponding legs or end portions  239  (identified individually as a first leg  239   a  and a second leg  239   b ). In other embodiments, however, the second insole inner opening  237  of the can be smaller or fully enclosed. In still further embodiments, the heel counter  236  can be a structure without any interior opening. 
     The second insole board  240  of the illustrated embodiment is a full-length insole component configured to provide added support. The second insole board  240  includes an arch portion  244  positioned between a forefoot portion  246  and a heel portion  242 . In certain embodiments, the heel portion  242  of the second insole board  240  can include an opening  243  sized generally similar to and aligned with the inner openings  235 ,  237  of the first insole portions  232  and the heel counter  236 , respectively. As such, these openings in each of the portions of the insole  230  can at least partially surround the cushioned section  223  of the first midsole heel portion  222  in the midsole  108 . More specifically, the cushioned section  223  of the midsole  108  projecting from the first midsole heel portion  222  can at least partially extend through the corresponding openings  235 ,  237 , and/or  243  in the insole  230 . In other embodiments, however, the cushioned section  223  and the corresponding openings in the insole  230  can be removed from the assembly  100  (e.g., the first and second insole boards  232 ,  240  can be a structure without an interior opening). Moreover, in certain embodiments the first, second, and/or third portions  232 ,  236 , and  240  of the insole  230  can be made from paper board, non-woven board, plastic, thermoplastic polyurethane (TPU), and/or other materials suitable for an insole in a footwear assembly. 
     According to additional features of the illustrated embodiment, the upper  102  includes a peripheral edge portion  250  extending around a lower section of the upper  102 . The upper  102  also includes an arch portion  254  between a heel portion  252  and a forefoot portion  256 . As described in detail below, the peripheral edge portion  250  of the upper  102  is configured to be securely attached to the insole  230 . 
       FIG. 3A  is a cross-sectional end view of the assembly  100  taken substantially along lines  3 A- 3 A of  FIG. 1  and illustrating several features of the heel portion  112  of the sole assembly  104 . According to features of the embodiment illustrated in  FIG. 3A , the outsole  106  is secured (e.g., adhered) directly to the midsole  108 , the midsole  108  is secured (e.g., adhered) directly to each of the insole  230  and the upper  102 . In addition, the insole  230  is also secured (e.g., stitched and/or adhered) directly to the upper  102 . More specifically, the heel portion  252  of the upper&#39;s peripheral edge portion  250  is positioned between the first insole board  232  of the insole  230  and the first midsole portion  220  of the midsole  108 . 
     As also shown in the illustrated embodiment, the heel portion  252  of the upper peripheral edge portion  250  is stitched, sewn, or otherwise directly attached to the insole  230 . In particular, the heel portion  252  at least partially wraps inwardly around the edges of the first insole board  232  and is stitched or sewn directly to each of the first insole board  232 . In one embodiment shown in  FIG. 3C , the bottom flange of the heel counter  236  is cemented to the top surface of the first insole board. In another embodiment, the bottom flange of the heel counter  236  is stitched to the first insole board  232  and to the heel portion  252  of the upper peripheral edge portion  250  with the heel portion stitching  360 . As such, the heel portion  252  of the upper peripheral edge portion  250  is positioned immediately adjacent to the lower surface  233  of the first insole board  232 . The upper peripheral edge portion  250  is also sewn or stitched directly to at least the first insole board  232  and optionally to the heel counter  236  with the heel portion stitching  360 . Accordingly, the upper peripheral edge portion  250  is positioned beneath the first insole board  232 , and the heel portion stitching  360  attaches the heel portion  252  of the upper peripheral edge portion  250  to each of the first insole board  232  (and optionally the heel counter  236 ). Moreover, the heel portion stitching  360  is not externally visible at the heel portion  112  of the assembly  100 . Wrapping the upper peripheral edge portion  250  around the lower surface  233  of the first insole board  232 , as well as applying the heel portion stitching  360  to the upper peripheral edge portion  250  and the first insole board  232 , helps maintain the structural stability of the overall footwear assembly  100 . 
     In the illustrated embodiment showing the internal heel counter  236 , the first insole board  232  is sandwiched between and stitched or otherwise attached to the bottom flange of the internal heel counter and the upper peripheral edge portion  250 . In an embodiment wherein the heel counter  236  is an external heel counter, the bottom flange of the heel counter is under the upper peripheral edge portion  250  such that the upper peripheral edge portion  250  is sandwiched between and stitched to the heel counter and the first insole board  232 . In another embodiment wherein the heel counter  236  includes an internal heel counter and an external heel counter, the bottom flange of the external heel counter is below and stitched to the upper peripheral edge portion  250  and to the first insole board  232 . The stitching can also extend through the bottom flange of the internal heel counter. Alternatively, the internal heel counter can be adhered, bonded, or otherwise securely fixed to the top of first insole board. In yet another embodiment, the internal heel counter can be stitched to the first insole board  232  and the upper peripheral edge portion  250  as shown in  FIG. 3A , and the external heel counter may be adhered, bonded, or otherwise securely fixed in place below the first insole board. 
     According to additional features of the illustrated embodiment, the upper peripheral edge portion  250  is not stitched or sewn directly to the second insole board  240  in the heel portion  112  of the sole assembly  104 , nor is the upper peripheral edge portion  250  stitched or sewn directly to the midsole  108  in the heel portion  112  of the sole assembly  104 . Instead, the second insole board  240  can be glued or otherwise adhered to the first insole board  232  and/or the heel counter  236 . Moreover, and as explained below with reference to  FIG. 4 , the upper peripheral edge portion  250  is not stitched to the arch portion of the footwear assembly  100 . Rather, the upper peripheral edge portion  250  can at least partially wrap inwardly around the arch portion and be glued or otherwise adhered to the arch portion of the insole  230  and/or the midsole  108 . In this manner, the attachment of the upper  102  to the insole  230  and the midsole  108  can help to maintain the heel cup configuration while maintaining the structural stability of the components of the overall platform. 
     According to additional features of the embodiment illustrated in  FIG. 3A , the midsole  108  extends at least partially through a portion of the insole  230 . More specifically, the cushioned heel section  223  of the first midsole heel portion  222  of the first midsole portion  220  extends through at least a portion of the corresponding openings of each of the first and second insole boards  232  and  240 , as well as the heel counter  238 . As such, the insole  230  can at least partially surrounds the cushioned portion  233  of the first midsole heel portion  222 . In other embodiments and as noted above, the cushioned portion  233  of the midsole  108  can be omitted. 
       FIG. 3B  is a cross-sectional end view of the assembly  100  taken substantially along lines  3 B- 3 B of  FIG. 1  and illustrating several features of the forefoot portion  114  of the sole assembly  104 . For example, as shown in  FIG. 3B , the outsole  106  is secured (e.g., adhered) directly to the midsole  108 , and each of the midsole  108  and the insole  230  is secured (e.g., adhered and/or stitched) to the upper  102 . More specifically, the forefoot portion  256  of the upper peripheral edge portion  250  flares outwardly and is stitched to the top surface of the second insole board  240 . For instance, as shown in  FIG. 3B , the upper peripheral edge portion  250  is positioned over corresponding peripheries of the forefoot portion  246  of the second insole board  240 , as well as the second midsole portion  228  and the forefoot portion  226  of the first midsole portion  220 . 
     Moreover, the forefoot portion  256  of the upper peripheral edge portion  250  is stitched, sewn, or otherwise directly attached to the insole  230  and the midsole  108  with the forefoot portion stitching  362 . In particular, the forefoot portion  256  is sewn or stitched directly to the top surface of the second insole board  240 , as well as to the second midsole portion  236 . Accordingly, in the illustrated embodiment the forefoot portion stitching  362  is sewn or otherwise applied to each of the upper peripheral edge portion  250 , the second insole board  240 , and the second midsole portion  228 . The forefoot portion stitching  362 , however, is not applied to the arch portion  244  of the second insole board  240 . Moreover, the upper peripheral edge portion  250  is not stitched or sewn directly to the first midsole portion  226  in the forefoot portion  114  of the sole assembly  104 . In addition, the forefoot portion stitching  362  may be externally visible at the forefoot portion  114  of the assembly  100 , over the outwardly flared forefoot portion  256  of the upper peripheral edge portion  250  at the top or upper surface of the second insole board  240 . 
       FIG. 4  is a bottom view of a portion of a footwear assembly  400  (“assembly  400 ”) configured in accordance with another embodiment of the disclosure. The assembly  400  includes several features generally similar in structure and function to the corresponding features of the assembly  100  described above with reference to  FIGS. 1-3 . For example, the assembly  400  illustrated in  FIG. 4  includes an upper  402  coupled to a generally U-shaped first insole board  423  and a second insole  430  that extends between the heel and toe areas. The upper  402  and the first and/or second insole boards  432  and  430  are configured to be coupled to a suitable midsole and/or outsole assembly, such as the midsole  108  and outsole  106  described above with reference to  FIGS. 1-3C . 
     In the embodiment illustrated in  FIG. 4 , however, a corresponding midsole and/or outsole have been removed from the assembly  400  to illustrate several features of a lower or bottom surfaces  433  of the first and second insole boards  432  and  430 . As also shown in  FIG. 4 , the first insole board  432  is a U-shaped structure stitched to the upper in the heel portion of the footwear, and the second insole board  430  is a substantially full length component having an arch insole portion  443  positioned between an insole forefoot portion  441  and an insole heel portion  445 . Although not shown in  FIG. 4 , in other embodiments the insole  430  can include one or more openings to accommodate additional features of a sole assembly, such as cushioning features or other desired features. 
     As shown in  FIG. 4 , the upper  402  includes a peripheral edge portion  450  extending around a lower section of the upper  402 . The peripheral edge portion  450  includes a heel portion  452  and a forefoot portion  456 . The heel portion  452  extends over and at least partially wraps inwardly around at least a portion of the lower surface of the insole heel portions  445  of at least the first insole board  432 . The forefoot portion  456  of the peripheral edge portion  450 , however, flares outwardly and is stitched or otherwise coupled to a top or upper surface of the forefoot portion  441  of the second insole board  430 . As such, the peripheral edge portion  450  of the forefoot portion  456  of the upper  402  is not generally visible in  FIG. 4 . 
     According to additional features of the illustrated embodiment, the upper  402  is stitched to the heel and forefoot portions  445 ,  441  of the first and second insole boards  432  and  430 , but the upper  402  is not stitched to the arch portion  443  of the insole  430 . More specifically, the assembly  400  includes heel portion stitching  460  and forefoot portion stitching  462 . The heel portion stitching  460  extends through each of the upper peripheral edge heel portion  452  and the first insole board  432 . For example, the upper peripheral edge heel portion  452 , which extends over or partially wraps inwardly around the bottom surface of the first insole board  432 , before being sewn to the insole board with the heel portion stitching  460 . In addition, the upper peripheral edge forefoot portion  456 , which flares outwardly on the top surface of the second insole board  430 , is sewn to the top surface of the insole forefoot portion  441  with the forefoot portion stitching  462 . In at least one embodiment, the upper peripheral edge forefoot portion  456  can be wrapped around the edge of the insole board&#39;s forefoot portion, after being stitched to the top surface, and adhered to the bottom surface. At the arch portion  443  of the second insole board  430 , however, the peripheral edge portion of the upper  402  is not sewn or stitched to the second insole board  430 . Rather, the peripheral edge portion of the upper  402  can be glued or otherwise adhered to the second insole board  430  at the arch portion  443  of the insole  430 . 
     From the foregoing, it will be appreciated that specific embodiments of the disclosure have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the disclosure. For example, although many of the Figures described above illustrate the midsoles and insoles as having multiple separate components, in other footwear assemblies the midsoles and insoles can include more or less components, including, for instance, integral or one-piece configurations. Further, while various advantages associated with certain embodiments of the disclosure have been described above in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the disclosure.