US20110247239A1 - Shoe Having A Midsole With Heel Support - Google Patents
Shoe Having A Midsole With Heel Support Download PDFInfo
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- US20110247239A1 US20110247239A1 US13/122,703 US200913122703A US2011247239A1 US 20110247239 A1 US20110247239 A1 US 20110247239A1 US 200913122703 A US200913122703 A US 200913122703A US 2011247239 A1 US2011247239 A1 US 2011247239A1
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- Prior art keywords
- midsole
- shoe
- heel
- hardness
- component
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Classifications
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B13/00—Soles; Sole-and-heel integral units
- A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
- A43B13/18—Resilient soles
- A43B13/187—Resiliency achieved by the features of the material, e.g. foam, non liquid materials
- A43B13/188—Differential cushioning regions
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B13/00—Soles; Sole-and-heel integral units
- A43B13/02—Soles; Sole-and-heel integral units characterised by the material
- A43B13/12—Soles with several layers of different materials
- A43B13/125—Soles with several layers of different materials characterised by the midsole or middle layer
- A43B13/127—Soles with several layers of different materials characterised by the midsole or middle layer the midsole being multilayer
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B7/00—Footwear with health or hygienic arrangements
- A43B7/14—Footwear with health or hygienic arrangements with foot-supporting parts
- A43B7/16—Footwear with health or hygienic arrangements with foot-supporting parts with elevated heel parts inside
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B9/00—Footwear characterised by the assembling of the individual parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D35/00—Producing footwear
- B29D35/12—Producing parts thereof, e.g. soles, heels, uppers, by a moulding technique
- B29D35/14—Multilayered parts
- B29D35/142—Soles
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
- A43B23/02—Uppers; Boot legs
- A43B23/0205—Uppers; Boot legs characterised by the material
- A43B23/0235—Different layers of different material
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
- A43B23/02—Uppers; Boot legs
- A43B23/04—Uppers made of one piece; Uppers with inserted gussets
Definitions
- the present invention relates to athletic footwear. More particularly, the present invention relates to a shoe having a midsole with heel support.
- Shoes especially shoe uppers, have traditionally been assembled from a relatively large number of three dimensional components. Both the large number and the three dimensional nature of these components have required a great deal of labor to assemble a single shoe. Decreasing the labor required to manufacture a shoe by a meaningful amount is not possible with standard shoe designs.
- the present invention relates to shoes having a midsole configured to provide heel support for a wearer.
- Midsoles in accordance with the present invention may permit the elimination or reduction of a heel counter in an upper and may further facilitate the attachment of an upper and midsole.
- FIG. 1A illustrates the initial layering step for upper creation in accordance with the present invention
- FIG. 1B illustrates examples of upper components associated with the layering step depicted in FIG. 1A , in accordance with the present invention
- FIG. 2 illustrates the heat press step for upper creation in accordance with the present invention
- FIG. 3 illustrates the step for upper creation involving cutting out a pattern perimeter in accordance with the present invention
- FIG. 4 is a top plan view of upper components designed for uni-body construction of shoes in accordance with an embodiment of the present invention
- FIG. 5 illustrates the step for uni-body shoe construction involving attachment of an upper component to the flange of a midsole unit in accordance with an embodiment of the present invention
- FIG. 6 illustrates the step for uni-body shoe construction involving heel formation and attachment of an upper component to the flange of a midsole unit in accordance with an embodiment of the present invention
- FIG. 7 further illustrates the step for heel formation and attachment of an upper component to the flange of a midsole unit in accordance with an embodiment of the present invention
- FIGS. 8A and 8B are perspective views of a finished uni-body construction running shoe in accordance with various embodiments of the present invention.
- FIGS. 9A-D are lateral side elevational views of examples of uni-body running shoes in accordance with an embodiment of the present invention.
- FIG. 9E is a lateral side elevational view of the midsole and outsole sections of uni-body running shoes in accordance with an embodiment of the present invention.
- FIG. 10 is a lateral side elevational view of a finished uni-body construction basketball shoe in accordance with an embodiment of the present invention.
- FIG. 11A is a cross-sectional view of the sole unit associated with the basketball shoe depicted in FIG. 10 ;
- FIG. 11B is a lateral side profile view of the sole unit associated with the basketball shoe depicted in FIG. 10 ;
- FIG. 11C is a top plan view of the outsole associated with the basketball shoe depicted in FIG. 10 ;
- FIG. 11D is a medial side profile view of the sole unit associated with the basketball shoe depicted in FIG. 10 ;
- FIGS. 11E-G are cross-sectional views of the of forefoot, midfoot and heel portions of the sole unit associated with the basketball shoe depicted in FIG. 10 ;
- Shoes in accordance with the present invention are designed to enable the efficient manufacturing of customized shoes.
- Shoe model options in accordance with the present invention may include, for example, a running shoe model and a basketball shoe model, although other shoes in accordance with the present invention may be constructed.
- upper forms of shoes are manufactured by a flat forming process, whereby the upper pattern is kept in a two-dimensional shape for most of the upper assembly and then stitched, glued, molded or otherwise affixed into a three dimensional form in the final stage of upper assembly.
- Shoes having midsoles providing heel support in accordance with the present invention may utilize traditional uppers fabricated from a plurality of pieces, although the specific example described herein further includes a flat formed upper to achieve additional construction efficiencies.
- the flat forming process minimizes the amount of labor intensive stitching traditionally needed to assemble a three dimensional upper form.
- the upper forms are then coupled with midsole structures designed to permit efficient shoe production.
- the uni-body midsole structures may be comprised of dual-hardness phylon, molded into a three dimensional shape designed to provide heel support. This uni-body midsole design eliminates the need to incorporate a heel counter into the upper form, thereby reducing the number of processes traditionally required to assemble a three-dimensional upper form.
- the uni-body midsoles are also designed with one or more flange to enable attachment of the upper form. This flange(s) may assist in converting the upper from a two-dimensional to a three-dimensional form.
- step 100 shoe upper components and hot-melt films (not shown) may be cut and arranged in between a lining layer 105 and an external layer 110 .
- the upper components layered in between lining layer 105 and external layer 110 may include, internal foams 115 , 117 , 119 , a lining foam 120 , and reinforcement pieces 125 , 127 , 129 .
- Lining layer 105 may include a moisture-wicking textile for removing excess moisture from the area immediately surrounding the foot. Suitable materials for lining layer 105 include polyester and recycled polyester. Other suitable materials for lining layer 105 will become readily apparent to those skilled in the art, given the benefit of this disclosure.
- step 100 internal foams 115 , 117 and 119 of different shapes and sizes as illustrated in FIG. 1A may be placed upon lining layer 105 .
- Internal foams 115 , 117 and 119 may be cut into shapes consistent with conventional shoe design and may include, a collar, vamp, quarter and tongue.
- Internal foam elements 115 , 117 , and 119 enhance the structure and comfort of the upper and can be formed of material such as polyurethane foam.
- Lining foam 120 is layered over the internal foams 115 , 117 and 119 in step 100 .
- Lining foam 120 forms a barrier between lining layer 105 and external layer 110 , and enhances the comfort and three-dimensional form of the shoe.
- lining foam 120 may be replaced by a forming foam or other reinforcement materials conventionally used in shoe upper manufacture.
- reinforcement pieces 125 , 127 , and 129 of different shapes and sizes as illustrated in FIG. 1A may be placed upon lining foam 120 .
- Reinforcement pieces 125 , 127 and 129 may be cut into shapes consistent with conventional shoe design and may include vamp and eyestay reinforcements.
- External layer 110 is placed above the reinforcement pieces 125 , 127 and 129 in layering step 100 .
- External layer 110 forms the outer surface of the upper and may include textile elements for resisting abrasion and providing breathability. To enable the a customer to customize the appearance of the upper, external layer 110 may be altered by various dying, digital printing, embossing and embroidering techniques.
- Suitable materials for external layer 110 include synthetic leather and polyester mesh, although other materials including natural materials, may be used in accordance with the present invention. Other suitable materials for external layer 110 will become readily apparent to those skilled in the art, given the benefit of this disclosure.
- hot-melt films may be layered amongst the upper components between lining layer 105 and external layer 110 . Upon heat pressing, these films act to adhesively bond the upper components between lining layer 105 and external layer 110 .
- the hot-melt films may be composed of materials such as thermoplastic polyurethane (TPU) film.
- TPU film(s) may be integral to one or more sides of the other layers, such as lining layer 105 and/or external layer 110 .
- Upper components 150 may be cut into shapes consistent with conventional shoe design and may include, a collar, vamp, quarter and tongue. Since the uni-body, dual hardness midsoles associated with the present invention provide sufficient heel support to eliminate the need for a heel counter in the upper form, upper components 150 may not include traditional plastic, thermoplastic resin, TPU or nylon heel counter elements.
- the heat press step 200 for upper creation in accordance with the present invention is illustrated.
- the layers from step 100 may be heat pressed together to form a basic laminated upper form, designated generally as 205 .
- Upper form 205 is formed when the layers from step 100 are heated under pressure.
- the specific temperature, pressure and time needed to laminate the upper form may vary according to the upper component being treated. For example, proper lamination of the quarter upper component may occur when treated at a pressure of 25 bars at 135 degrees Celsius for thirty seconds, and proper lamination of the tongue upper component may occur when treated at a pressure of 25 bars at 130 degrees Celsius for forty-five seconds.
- step 300 the pattern perimeter of basic laminated upper form 205 may be cut out to form upper component 305 .
- Step 300 may be performed using any type of cutting device such as a cutting die, shears and the like.
- the upper component 400 includes a tongue 405 and a upper form 410 .
- the upper form 410 and tongue 405 may be made by the layering step 100 , heat pressing step 200 and cutting step 300 as illustrated in FIGS. 1-3 .
- the no sew techniques of steps 100 , 200 and 300 facilitate the flat construction of upper form 410 and tongue 405 .
- Tongue 405 may be attached to upper form 410 to create upper component 400 by stitching, chemical adhesive, welding (RF or ultrasonic), or any other attachment technique or technology.
- Upper component 400 may be finished with customization requirements.
- upper component 400 may include all the embossing and printing aesthetics required by a particular customer.
- step 500 for uni-body shoe construction involving attachment of an upper component to the flange of a midsole unit in accordance with an embodiment of the present invention is illustrated.
- upper component 400 may be aligned with a midsole unit 505 .
- the upper component 400 may be attached to the flange 510 of midsole unit 505 in step 500 .
- upper component 400 may be attached to flange 510 using conventional shoe manufacture techniques like stitching, gluing or a combination thereof.
- Attachment flange 510 may be around the entire perimeter of midsole 505 or may be at a plurality of points or regions around the perimeter of midsole 505 .
- Flange 510 may be of a different hardness than other portions of midsole unit 505 .
- the design of the midsole unit 505 eliminates the need to incorporate a heel counter into the upper component 400 .
- the depth of the interior heel region 507 , of midsole 505 may form a rigid or semi-rigid area in the heel region that may hold the foot in place.
- the heel region 507 may extend around at least a portion of a wearer's heel in an as worn position, or when the wearer is wearing the shoe.
- the structural support provided by heel region 507 of the midsole 505 may eliminate the need for an internal heel counter in the upper component 400 .
- Heel region 507 may, for example, be harder than the rest of the midsole unit 505 .
- midsole 505 reduces the labor intensive steps generally needed for upper formation, particularly for the heel formation steps.
- upper component 605 may be attached to the flange 625 of midsole unit 620 .
- upper component 605 may be attached to the flange 625 by gluing, stitching or welding.
- Upper component 605 includes heel elements 610 and 615 . Heel elements 610 and 615 may be formed as a part of the laminated upper component 605 using methods 100 , 200 and 300 .
- heel element 610 may be folded as depicted in FIG. 6 and attached to the flange 625 of midsole 620 .
- the midsole unit 620 extends substantially under a wearer's foot in an as worn position, or when the wearer is actually wearing the shoe. This portion of the midsole that extends under a wearer's foot may have a hardness different from other portions of the midsole, including the heel region. For instance, the hardness of the midsole portion extending underneath the wearer's foot may be less than the hardness of the heel region, and vice versa.
- step 700 a further step 700 for heel formation and attachment of an upper component to the flange of a midsole unit in accordance with an embodiment of the present invention is illustrated.
- upper component 705 is attached to midsole element 720 (e.g., midsole bed region).
- Upper component 705 includes heel elements 710 and 715 , with heel element 710 being attached to sole unit 720 as illustrated in FIG. 6 .
- heel element 715 is folded onto heel element 710 as depicted in FIG. 7 .
- Heel element 715 may be attached to heel element 710 and to sole unit 720 by stitching, gluing, or welding. Other methods of attachment of upper component 705 to midsole element 720 will become readily apparent to those skilled in the art, given the benefit of this disclosure.
- Running shoe 800 includes an upper 805 attached to a sole unit 810 .
- Sole unit 810 is comprised of midsole 815 attached to an outsole 820 .
- the outsole 820 may be affixed to the midsole opposing the upper.
- FIGS. 6-8A illustrate an upper 805 wherein one heel element is wrapped around the other heel element (e.g., a first heel element and a second heel element), shown clearly by heel elements 610 and 615 in FIG. 6
- FIG. 8B illustrates an embodiment where the two heel elements are flush against one another so that stitching or some other method can be utilized to secure the two heel elements together, shown as reference number 865 .
- Running shoe 850 includes an upper 855 attached to a sole unit 860 . Sole unit 860 is comprised of midsole 870 attached to an outsole 875 .
- FIGS. 9A-D four lateral side elevational views of uni-body running shoes in accordance with an embodiment of the present invention, are illustrated and designated generally as 900 , 910 , 920 and 930 respectively.
- FIGS. 9A-D illustrate different options available in accordance with the present invention.
- a shoe can include a standard graphic design as depicted in FIG. 9A or the shoe can be decorated with varsity designs as depicted in FIG. 9B .
- the sole unit 950 includes midsole 955 and outsole 970 .
- Midsole 955 is comprised of a hard layer 960 and a soft layer 965 .
- Suitable materials for midsole 955 may include dual hardness phylon, although other materials may be used for midsole 1010 .
- Suitable materials for outsole 970 may include carbon rubber or blown rubber, although other materials may be used for outsole 970 .
- the dual layers of midsole 955 enable variation of the midsole.
- midsole 955 may have a blue hard layer 960 (e.g., upper midsole portion) and a white soft layer 965 (e.g., lower midsole portion).
- a blue hard layer 960 e.g., upper midsole portion
- a white soft layer 965 e.g., lower midsole portion
- the hardness of different midsoles can be varied to enhance performance for a particular shoe design or shoe type. For example, running shoes may require a softer midsole to provide a high degree of cushioning, while basketball soles may be harder to provide stability.
- an upper component may then be aligned with the midsole component.
- the upper component may include one or more heel elements (e.g., a first heel element and a second heel element), and the midsole component may have a heel region that extends around at least a portion of the wearer's heel, as described above.
- the upper component may then be affixed to the midsole component, and the heel elements may be secured to each other.
- the heel elements may cover at least a portion of the heel region.
- one heel element is wrapped around, or overlaps, the other heel element.
- the two heel elements meet up are the middle of the heel of the shoe such that a second heel element does not overlap the first heel element, and are stitched or otherwise secured together.
- the heel elements are flush against one another, as shown by reference numeral 865 in FIG. 8B .
- Basketball shoe 1000 may include, a sole unit 1005 attached to an upper 1030 .
- the sole unit 1005 may include a midsole 1010 and an outsole 1025 , with midsole 1010 comprised of a first layer 1015 and second layer 1020 .
- Midsole 1010 may be formed using a dual hardness phylon, although other materials may be used for midsole 1010 .
- Upper 1030 may be attached to sole 1005 by stitching as shown in FIG. 10 or by gluing.
- Upper 1030 includes a tongue 1035 and collar fastening element 1040 .
- the collar fastening element 1040 secures upper 1030 to the foot.
- Sole unit 1100 includes an outsole 1105 and a midsole 1110 , with midsole 1010 comprised of a first layer 1115 and second layer 1120 .
- the second layer may be located underneath the first midsole layer in an as worn position.
- the midsole 1110 may be formed by heat treating a plurality of pre-formed phylon biscuits.
- the plurality of biscuits may be formed in an injection process that includes heating phylon pellets until molten and injecting them into pre-forms (e.g., molding cavities) within an injection mold.
- the plurality of biscuits includes at least a first biscuit that has a first density and a second biscuit that has a second density, or a first and second color.
- the method may further include the steps of arranging the biscuits into a receiving area (e.g., molding cavity) of the heat press, and integrating the plurality of biscuits to form the midsole by activating the heat press.
- the midsole layer 1115 may therefore have a different hardness and or color than the second midsole layer 1120 .
- midsole layer 1115 is comprised of soft injection phylon and midsole layer 1120 is comprised of hard injection phylon.
- FIGS. 11A , 11 E-G four cross sectional views of the sole unit associated with the uni-body basketball shoe depicted in FIG. 10 , in accordance with an embodiment of the present invention are illustrated.
- the distribution of the dual density phylon layers 1115 and 1120 across the forefoot 1125 , midfoot 1130 and heel 1135 regions of the sole unit is illustrated in FIGS. 11E-G .
Abstract
Shoes having midsoles with heel support, specifically designed to facilitate production via efficient shoe manufacturing methods and systems are described. In embodiments, the shoe upper is designed by way of a flat forming process. Additionally, in embodiments upper forms may be coupled with dual hardness midsole structures that provide heel support and eliminate the need for a heel counter in the shoe upper.
Description
- This application claims the benefit of U.S. Provisional Patent Application No. 61/194,302, filed Sep. 26, 2008, entitled “Shoe Having a Midsole with Heel Support.”
- The present invention relates to athletic footwear. More particularly, the present invention relates to a shoe having a midsole with heel support.
- Shoes, especially shoe uppers, have traditionally been assembled from a relatively large number of three dimensional components. Both the large number and the three dimensional nature of these components have required a great deal of labor to assemble a single shoe. Decreasing the labor required to manufacture a shoe by a meaningful amount is not possible with standard shoe designs.
- The present invention relates to shoes having a midsole configured to provide heel support for a wearer. Midsoles in accordance with the present invention may permit the elimination or reduction of a heel counter in an upper and may further facilitate the attachment of an upper and midsole. These shoe designs and/or manufacturing methods reduce the specialized individual labor required for shoe production, while avoiding high costs associated with highly automated manufacturing equipment.
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FIG. 1A illustrates the initial layering step for upper creation in accordance with the present invention; -
FIG. 1B illustrates examples of upper components associated with the layering step depicted inFIG. 1A , in accordance with the present invention; -
FIG. 2 illustrates the heat press step for upper creation in accordance with the present invention; -
FIG. 3 illustrates the step for upper creation involving cutting out a pattern perimeter in accordance with the present invention; -
FIG. 4 is a top plan view of upper components designed for uni-body construction of shoes in accordance with an embodiment of the present invention; -
FIG. 5 illustrates the step for uni-body shoe construction involving attachment of an upper component to the flange of a midsole unit in accordance with an embodiment of the present invention; -
FIG. 6 illustrates the step for uni-body shoe construction involving heel formation and attachment of an upper component to the flange of a midsole unit in accordance with an embodiment of the present invention; -
FIG. 7 further illustrates the step for heel formation and attachment of an upper component to the flange of a midsole unit in accordance with an embodiment of the present invention; -
FIGS. 8A and 8B are perspective views of a finished uni-body construction running shoe in accordance with various embodiments of the present invention; -
FIGS. 9A-D are lateral side elevational views of examples of uni-body running shoes in accordance with an embodiment of the present invention; -
FIG. 9E is a lateral side elevational view of the midsole and outsole sections of uni-body running shoes in accordance with an embodiment of the present invention; -
FIG. 10 is a lateral side elevational view of a finished uni-body construction basketball shoe in accordance with an embodiment of the present invention; -
FIG. 11A is a cross-sectional view of the sole unit associated with the basketball shoe depicted inFIG. 10 ; -
FIG. 11B is a lateral side profile view of the sole unit associated with the basketball shoe depicted inFIG. 10 ; -
FIG. 11C is a top plan view of the outsole associated with the basketball shoe depicted inFIG. 10 ; -
FIG. 11D is a medial side profile view of the sole unit associated with the basketball shoe depicted inFIG. 10 ; -
FIGS. 11E-G are cross-sectional views of the of forefoot, midfoot and heel portions of the sole unit associated with the basketball shoe depicted inFIG. 10 ; - Shoes in accordance with the present invention are designed to enable the efficient manufacturing of customized shoes. Shoe model options in accordance with the present invention may include, for example, a running shoe model and a basketball shoe model, although other shoes in accordance with the present invention may be constructed. In accordance with the present invention, upper forms of shoes are manufactured by a flat forming process, whereby the upper pattern is kept in a two-dimensional shape for most of the upper assembly and then stitched, glued, molded or otherwise affixed into a three dimensional form in the final stage of upper assembly. Shoes having midsoles providing heel support in accordance with the present invention may utilize traditional uppers fabricated from a plurality of pieces, although the specific example described herein further includes a flat formed upper to achieve additional construction efficiencies. The flat forming process minimizes the amount of labor intensive stitching traditionally needed to assemble a three dimensional upper form.
- The upper forms are then coupled with midsole structures designed to permit efficient shoe production. The uni-body midsole structures may be comprised of dual-hardness phylon, molded into a three dimensional shape designed to provide heel support. This uni-body midsole design eliminates the need to incorporate a heel counter into the upper form, thereby reducing the number of processes traditionally required to assemble a three-dimensional upper form. The uni-body midsoles are also designed with one or more flange to enable attachment of the upper form. This flange(s) may assist in converting the upper from a two-dimensional to a three-dimensional form.
- Referring now to
FIG. 1A , theinitial layering step 100 for upper creation in accordance with the present invention is illustrated. Instep 100, shoe upper components and hot-melt films (not shown) may be cut and arranged in between alining layer 105 and anexternal layer 110. The upper components layered in betweenlining layer 105 andexternal layer 110 may include,internal foams lining foam 120, andreinforcement pieces Lining layer 105 may include a moisture-wicking textile for removing excess moisture from the area immediately surrounding the foot. Suitable materials forlining layer 105 include polyester and recycled polyester. Other suitable materials forlining layer 105 will become readily apparent to those skilled in the art, given the benefit of this disclosure. - In
step 100,internal foams FIG. 1A may be placed uponlining layer 105.Internal foams Internal foam elements -
Lining foam 120 is layered over theinternal foams step 100. Liningfoam 120 forms a barrier betweenlining layer 105 andexternal layer 110, and enhances the comfort and three-dimensional form of the shoe. In alternative embodiments of the invention, liningfoam 120 may be replaced by a forming foam or other reinforcement materials conventionally used in shoe upper manufacture. - In
step 100,reinforcement pieces FIG. 1A may be placed upon liningfoam 120.Reinforcement pieces External layer 110 is placed above thereinforcement pieces layering step 100.External layer 110 forms the outer surface of the upper and may include textile elements for resisting abrasion and providing breathability. To enable the a customer to customize the appearance of the upper,external layer 110 may be altered by various dying, digital printing, embossing and embroidering techniques. Suitable materials forexternal layer 110 include synthetic leather and polyester mesh, although other materials including natural materials, may be used in accordance with the present invention. Other suitable materials forexternal layer 110 will become readily apparent to those skilled in the art, given the benefit of this disclosure. - In
step 100, hot-melt films (not shown) may be layered amongst the upper components betweenlining layer 105 andexternal layer 110. Upon heat pressing, these films act to adhesively bond the upper components betweenlining layer 105 andexternal layer 110. The hot-melt films may be composed of materials such as thermoplastic polyurethane (TPU) film. The TPU film(s) may be integral to one or more sides of the other layers, such aslining layer 105 and/orexternal layer 110. - Referring now to
FIG. 1B , examples of various upper components associated with thelayering step 100 are illustrated and designated generally asreference number 150.Upper components 150 may be cut into shapes consistent with conventional shoe design and may include, a collar, vamp, quarter and tongue. Since the uni-body, dual hardness midsoles associated with the present invention provide sufficient heel support to eliminate the need for a heel counter in the upper form,upper components 150 may not include traditional plastic, thermoplastic resin, TPU or nylon heel counter elements. - Referring now to
FIG. 2 , theheat press step 200 for upper creation in accordance with the present invention is illustrated. Inheat press step 200, the layers fromstep 100 may be heat pressed together to form a basic laminated upper form, designated generally as 205.Upper form 205 is formed when the layers fromstep 100 are heated under pressure. The specific temperature, pressure and time needed to laminate the upper form may vary according to the upper component being treated. For example, proper lamination of the quarter upper component may occur when treated at a pressure of 25 bars at 135 degrees Celsius for thirty seconds, and proper lamination of the tongue upper component may occur when treated at a pressure of 25 bars at 130 degrees Celsius for forty-five seconds. - Referring now to
FIG. 3 , thethird step 300 for upper creation in accordance with the present invention is illustrated. Instep 300, the pattern perimeter of basic laminatedupper form 205 may be cut out to formupper component 305. Step 300 may be performed using any type of cutting device such as a cutting die, shears and the like. - Referring now to
FIG. 4 , a top plan view of upper components designed for uni-body construction of shoes in accordance with an embodiment of the present invention is illustrated, and designated generally asreference number 400. Theupper component 400 includes atongue 405 and aupper form 410. Theupper form 410 andtongue 405 may be made by thelayering step 100,heat pressing step 200 and cuttingstep 300 as illustrated inFIGS. 1-3 . The no sew techniques ofsteps upper form 410 andtongue 405.Tongue 405 may be attached toupper form 410 to createupper component 400 by stitching, chemical adhesive, welding (RF or ultrasonic), or any other attachment technique or technology.Upper component 400 may be finished with customization requirements. For example,upper component 400 may include all the embossing and printing aesthetics required by a particular customer. - Referring now to
FIG. 5 , astep 500 for uni-body shoe construction involving attachment of an upper component to the flange of a midsole unit in accordance with an embodiment of the present invention is illustrated. Instep 500,upper component 400 may be aligned with amidsole unit 505. Theupper component 400 may be attached to theflange 510 ofmidsole unit 505 instep 500. For example,upper component 400 may be attached toflange 510 using conventional shoe manufacture techniques like stitching, gluing or a combination thereof.Attachment flange 510 may be around the entire perimeter ofmidsole 505 or may be at a plurality of points or regions around the perimeter ofmidsole 505.Flange 510 may be of a different hardness than other portions ofmidsole unit 505. - The design of the
midsole unit 505 eliminates the need to incorporate a heel counter into theupper component 400. The depth of theinterior heel region 507, ofmidsole 505, may form a rigid or semi-rigid area in the heel region that may hold the foot in place. Theheel region 507 may extend around at least a portion of a wearer's heel in an as worn position, or when the wearer is wearing the shoe. Thus, the structural support provided byheel region 507 of themidsole 505 may eliminate the need for an internal heel counter in theupper component 400.Heel region 507 may, for example, be harder than the rest of themidsole unit 505. Absence of an internal heel counter inupper component 400 removes the traditional steps of molding the plastic, or other material used to form the heel counter, cooling the molded plastic to harden the heel counter and stitching an external layer of upper materials such as synthetic leather over the heal counter. Therefore,midsole 505 reduces the labor intensive steps generally needed for upper formation, particularly for the heel formation steps. - Referring now to
FIG. 6 , astep 600 for uni-body shoe construction involving heel formation and attachment of an upper component to the flange of a midsole unit in accordance with an embodiment of the present invention is illustrated. Instep 600,upper component 605 may be attached to theflange 625 ofmidsole unit 620. For example,upper component 605 may be attached to theflange 625 by gluing, stitching or welding.Upper component 605 includesheel elements elements upper component 605 usingmethods step 600,heel element 610 may be folded as depicted inFIG. 6 and attached to theflange 625 ofmidsole 620. By combining theheel formation step 600 with attaching the upper component to themidsole step 500, the amount of stitching traditionally used to form a three dimensional heel component is reduced, thereby allowing for more efficient shoe production. Further, as shown inFIG. 6 , themidsole unit 620 extends substantially under a wearer's foot in an as worn position, or when the wearer is actually wearing the shoe. This portion of the midsole that extends under a wearer's foot may have a hardness different from other portions of the midsole, including the heel region. For instance, the hardness of the midsole portion extending underneath the wearer's foot may be less than the hardness of the heel region, and vice versa. - Referring now to
FIG. 7 , afurther step 700 for heel formation and attachment of an upper component to the flange of a midsole unit in accordance with an embodiment of the present invention is illustrated. Instep 700,upper component 705 is attached to midsole element 720 (e.g., midsole bed region).Upper component 705 includesheel elements heel element 710 being attached tosole unit 720 as illustrated inFIG. 6 . Instep 700,heel element 715 is folded ontoheel element 710 as depicted inFIG. 7 .Heel element 715 may be attached toheel element 710 and tosole unit 720 by stitching, gluing, or welding. Other methods of attachment ofupper component 705 tomidsole element 720 will become readily apparent to those skilled in the art, given the benefit of this disclosure. - Referring now to
FIG. 8A , a perspective view of a finished uni-body construction running shoe in accordance with an embodiment of the present invention is illustrated and designated generally withreference number 800. Runningshoe 800 includes an upper 805 attached to asole unit 810.Sole unit 810 is comprised ofmidsole 815 attached to anoutsole 820. Theoutsole 820 may be affixed to the midsole opposing the upper. - While
FIGS. 6-8A illustrate an upper 805 wherein one heel element is wrapped around the other heel element (e.g., a first heel element and a second heel element), shown clearly byheel elements FIG. 6 ,FIG. 8B illustrates an embodiment where the two heel elements are flush against one another so that stitching or some other method can be utilized to secure the two heel elements together, shown asreference number 865. Runningshoe 850 includes an upper 855 attached to asole unit 860.Sole unit 860 is comprised ofmidsole 870 attached to anoutsole 875. - Referring now to
FIGS. 9A-D , four lateral side elevational views of uni-body running shoes in accordance with an embodiment of the present invention, are illustrated and designated generally as 900, 910, 920 and 930 respectively.FIGS. 9A-D illustrate different options available in accordance with the present invention. For example, a shoe can include a standard graphic design as depicted inFIG. 9A or the shoe can be decorated with varsity designs as depicted inFIG. 9B . - Referring now to
FIG. 9E , a lateral side elevational view of the midsole and outsole sections of uni-body running shoes, in accordance with an embodiment of the present invention is illustrated and designated generally as 950. Thesole unit 950 includesmidsole 955 andoutsole 970.Midsole 955 is comprised of ahard layer 960 and asoft layer 965. Suitable materials formidsole 955 may include dual hardness phylon, although other materials may be used formidsole 1010. Suitable materials foroutsole 970 may include carbon rubber or blown rubber, although other materials may be used foroutsole 970. The dual layers ofmidsole 955 enable variation of the midsole. For example,midsole 955 may have a blue hard layer 960 (e.g., upper midsole portion) and a white soft layer 965 (e.g., lower midsole portion). In addition to the color of themidsole 955, the hardness of different midsoles can be varied to enhance performance for a particular shoe design or shoe type. For example, running shoes may require a softer midsole to provide a high degree of cushioning, while basketball soles may be harder to provide stability. - Manufacturing a shoe similar to that shown in various figures, in particular
FIG. 9A , requires a plurality of steps, including, but not limited to, securing an upper midsole portion to a lower midsole portion. As mentioned above, these different portions may have a different hardness from one another, which may take into account variances such as a shoe type, a shoe design, or performance issues, all of which may be customized by the buyer of the shoe. an upper component may then be aligned with the midsole component. The upper component may include one or more heel elements (e.g., a first heel element and a second heel element), and the midsole component may have a heel region that extends around at least a portion of the wearer's heel, as described above. The upper component may then be affixed to the midsole component, and the heel elements may be secured to each other. The heel elements may cover at least a portion of the heel region. In one embodiment, one heel element is wrapped around, or overlaps, the other heel element. In another embodiment, the two heel elements meet up are the middle of the heel of the shoe such that a second heel element does not overlap the first heel element, and are stitched or otherwise secured together. In this embodiment, the heel elements are flush against one another, as shown byreference numeral 865 inFIG. 8B . - Referring now to
FIG. 10 , a lateral side elevational view of a finished uni-body construction basketball shoe, in accordance with an embodiment of the present invention is illustrated and designated generally as numeral 1000.Basketball shoe 1000 may include, a sole unit 1005 attached to an upper 1030. The sole unit 1005 may include amidsole 1010 and anoutsole 1025, withmidsole 1010 comprised of afirst layer 1015 andsecond layer 1020.Midsole 1010 may be formed using a dual hardness phylon, although other materials may be used formidsole 1010. Upper 1030 may be attached to sole 1005 by stitching as shown inFIG. 10 or by gluing.Upper 1030 includes atongue 1035 andcollar fastening element 1040. Thecollar fastening element 1040 secures upper 1030 to the foot. - Referring now to
FIGS. 11B-D , three views of thesole unit 1100 associated with the uni-body basketball shoe depicted inFIG. 10 , in accordance with an embodiment of the present invention are illustrated.Sole unit 1100 includes anoutsole 1105 and amidsole 1110, withmidsole 1010 comprised of afirst layer 1115 andsecond layer 1120. The second layer may be located underneath the first midsole layer in an as worn position. Themidsole 1110 may be formed by heat treating a plurality of pre-formed phylon biscuits. The plurality of biscuits may be formed in an injection process that includes heating phylon pellets until molten and injecting them into pre-forms (e.g., molding cavities) within an injection mold. Typically, the plurality of biscuits includes at least a first biscuit that has a first density and a second biscuit that has a second density, or a first and second color. The method may further include the steps of arranging the biscuits into a receiving area (e.g., molding cavity) of the heat press, and integrating the plurality of biscuits to form the midsole by activating the heat press. Themidsole layer 1115 may therefore have a different hardness and or color than thesecond midsole layer 1120. For example, as depicted inFIGS. 11A-G ,midsole layer 1115 is comprised of soft injection phylon andmidsole layer 1120 is comprised of hard injection phylon. - Referring now to
FIGS. 11A , 11E-G, four cross sectional views of the sole unit associated with the uni-body basketball shoe depicted inFIG. 10 , in accordance with an embodiment of the present invention are illustrated. The distribution of the dualdensity phylon layers forefoot 1125,midfoot 1130 andheel 1135 regions of the sole unit is illustrated inFIGS. 11E-G .
Claims (20)
1. A shoe designed to facilitate a system for manufacturing shoes customized to an order placed by a customer, the shoe comprising: an upper, a midsole affixed to the upper, the midsole comprising: a heel region extending around at least a portion of a wearer's heel in an as worn position, the heel region having a first hardness, and a midsole bed region extending substantially under a wearer's foot in an as worn position, the midsole bed region having a second hardness; and an outsole affixed to the midsole opposing the upper.
2. The shoe of claim 1 , wherein the upper is manufactured by way of a flat forming process whereby the upper is maintained in a two-dimensional shape during its manufacture.
3. The shoe of claim 1 , wherein a hardness of the heel region is greater than the hardness of the midsole bed region.
4. The shoe of claim 1 , wherein the upper includes a first heel element and a second heel element that is wrapped around the first heel element and secured into place.
5. The shoe of claim 1 , wherein a hardness of the midsole bed region depends on a shoe type.
6. The shoe of claim 1 , wherein the midsole bed region is formed by heat treating a plurality of pre-formed phylon biscuits.
7. The shoe of claim 1 , wherein the midsole bed region is comprised of an upper midsole portion having a first hardness and a lower midsole portion having a second hardness wherein the upper and lower midsole portions are affixed.
8. A shoe having a midsole with heel support manufactured according to a method comprising: securing an upper midsole portion having a first hardness to a lower midsole portion having a second hardness; aligning an upper component having a first heel element and a second heel element with a midsole component having the upper midsole portion and the lower midsole portion, wherein the midsole component has a heel region extending around at least a portion of a wearer's heel; affixing the upper component to the midsole component; and securing the first heel element to the second heel element, wherein the first heel element and the second heel element cover at least a portion of the heel region.
9. The shoe of claim 8 , wherein the midsole component is affixed to the upper component by way of a flange secured to the midsole component.
10. The shoe of claim 9 , wherein the flange extends at least partially around a perimeter of the midsole component.
11. The shoe of claim 9 , wherein the flange has a different hardness than other portions of the midsole component.
12. The shoe of claim 8 , wherein the heel region has a greater hardness than other portions of the midsole component.
13. The shoe of claim 8 , wherein the first heel element overlaps at least a portion of the second heel element.
14. The shoe of claim 8 , wherein the first heel element and the second heel element do not overlap such that they are flush and are secured together by way of one or more stitches.
15. The shoe of claim 8 , wherein the midsole component is made of a dual hardness phylon.
16. The shoe of claim 8 , further comprising securing the midsole component to an outsole component.
17. A shoe designed to facilitate a system for manufacturing shoes customized to an order placed by a customer, the shoe comprising: a midsole affixed to an upper, the midsole comprising: a first midsole layer that includes a heel region that extends around at least a portion of a wearer's heel in an as worn position; a second midsole layer that is affixed to the first midsole layer and that is underneath the first midsole layer in an as worn position; and an attachment flange that covers at least a portion of a perimeter of the first midsole layer and that is located above the first midsole layer in an as worn position.
18. The shoe of claim 17 , wherein the first midsole layer has a first hardness and the second midsole layer has a second hardness.
19. The shoe of claim 17 , wherein a hardness of the heel region is greater than the hardness of other regions of the midsole.
20. The shoe of claim 17 , wherein the upper is affixed to the attachment flange by way of one or more of gluing, stitching, or welding.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/122,703 US20110247239A1 (en) | 2008-09-26 | 2009-09-28 | Shoe Having A Midsole With Heel Support |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US19430208P | 2008-09-26 | 2008-09-26 | |
PCT/US2009/058624 WO2010037033A1 (en) | 2008-09-26 | 2009-09-28 | Shoe having a midsole with heel support |
US13/122,703 US20110247239A1 (en) | 2008-09-26 | 2009-09-28 | Shoe Having A Midsole With Heel Support |
Publications (1)
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US20110247239A1 true US20110247239A1 (en) | 2011-10-13 |
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Family Applications (1)
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US13/122,703 Abandoned US20110247239A1 (en) | 2008-09-26 | 2009-09-28 | Shoe Having A Midsole With Heel Support |
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US (1) | US20110247239A1 (en) |
EP (1) | EP2337469B1 (en) |
JP (2) | JP2012504025A (en) |
CN (1) | CN102223817B (en) |
BR (1) | BRPI0919469A2 (en) |
WO (1) | WO2010037033A1 (en) |
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US8747711B1 (en) | 2013-10-18 | 2014-06-10 | Nike, Inc. | Method of manufacturing rubber and polyolefin sole assembly |
USD816957S1 (en) * | 2017-08-15 | 2018-05-08 | Nike, Inc. | Shoe |
US20190069635A1 (en) * | 2012-04-13 | 2019-03-07 | Adidas Ag | Shoe upper |
US11116275B2 (en) | 2013-04-19 | 2021-09-14 | Adidas Ag | Shoe |
US20220192318A1 (en) * | 2020-12-22 | 2022-06-23 | Chung-Hao Chang | Moisture-permeable waterproof shoe |
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TWI637702B (en) | 2015-05-29 | 2018-10-11 | 耐克創新有限合夥公司 | Footwear manufacturing with an origin |
JP6536818B2 (en) * | 2015-11-19 | 2019-07-03 | 高橋 幸二 | Shoe using high resilience resin foam material in insole and manufacturing method thereof |
CN108813801A (en) * | 2018-07-09 | 2018-11-16 | 特步(中国)有限公司 | A kind of multi-density sole and preparation method thereof |
CN109517264A (en) * | 2019-01-10 | 2019-03-26 | 余新军 | A kind of polychrome footwear material moulding process |
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Also Published As
Publication number | Publication date |
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EP2337469A4 (en) | 2014-01-15 |
WO2010037033A1 (en) | 2010-04-01 |
JP2015180259A (en) | 2015-10-15 |
CN102223817A (en) | 2011-10-19 |
JP6161653B2 (en) | 2017-07-12 |
EP2337469A1 (en) | 2011-06-29 |
JP2012504025A (en) | 2012-02-16 |
EP2337469B1 (en) | 2017-08-30 |
BRPI0919469A2 (en) | 2017-05-30 |
CN102223817B (en) | 2015-04-08 |
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