US20120233881A1

US20120233881A1 - Foot-bed for a shoe

Info

Publication number: US20120233881A1
Application number: US13/422,946
Authority: US
Inventors: William P. Orien
Original assignee: Individual
Current assignee: Individual
Priority date: 2011-03-17
Filing date: 2012-03-16
Publication date: 2012-09-20

Abstract

Exemplary embodiments of the invention provide a shoe assembly having at least an outsole and an upper, and a foot-bed removeably provided with the shoe assembly, the foot-bed includes a plurality of layers or regions with the densities of the material forming the plurality of layers or regions differing from each other, and a layer of the foot-bed being formed by spaced-apart regions extending upwardly from one or more of the other layers.

Description

This application claims the benefit of U.S. Provisional Application No. 61/453,784 filed Mar. 17, 2011, for FOOT-BED FOR A SHOE which is incorporated in its entirety herein by reference.

BACKGROUND

1. Field of the Invention
The present invention relates to shoes, and more particularly to the foot-bed of an athletic shoe that includes a variety of regions that can have different shapes, material, and/or density characteristics.
2. Description of Related Art
Since almost all sporting activities require a person to utilize athletic shoes during the activity, an important piece of equipment is often the footwear worn by the user. Athletic shoes, such as those designed for tennis, running, basketball, hiking, cross-training, walking and other activities, typically include a durable rubber outsole that contacts the ground surface, a cushioning midsole overlying the outsole, an upper secured to a top surface of the midsole.
The midsole generally provides cushioning and support to the shoe wearer's foot. Construction of the upper involves stitching and gluing together multiple pieces of material that constitutes the upper. The upper takes the approximate shape of the shoe wearer's foot. Typically, the upper is bonded to a surface of the midsole and a surface of the midsole is bonded to a surface of the outsole. Athletic shoes can also include a foot-bed or sock-liner which is also made of a resilient material. The foot-bed or sock-liner also provides cushioning and stability and given that it comes in direct contact with the foot, is critical to the perceived fit, comfort, etc for the user. Most foot-beds are inserted after the shoe is completed and mayor may not be cemented down.
Foot, ankle and knee injuries sustained by runners and joggers suggests that the several of the most important factors associated with such injuries are excessive or prolonged pronation, lack of shock absorption on impact, lateral foot instability and lack of support for increased efficiency and stride propulsion. While running or walking, the outside part of the heel makes initial contact with the ground and the foot rolls inward so as to make complete contact with the ground to support the user's body weight. The rolling of the foot distributes the forces of the impact throughout the foot, this rolling movement is called pronation.
However, a disadvantage of many related art athletic shoes is that the upper surface of the midsoles and foot-beds are not sufficiently contoured or shaped to support different regions of the bottom surface of the user's foot. That is, in the prior art, the midsoles and foot-beds are not structured to enhance the comfort of various regions of the foot while also increasing the performance of the midsole and foot-bed for the user.
Over time, the midsoles and foot-beds become worn quickly through compaction of the foam material. As the foot-bed is an important cushioning component of an athletic shoe, the compaction of the foot-bed material greatly reduces the cushioning capacity of the shoe. The compression of the foot-bed also affects fit as the more the foam compresses, the more volume there is within the shoe. Accordingly, in the related art shoe, the problems associated with impact, stability and performance are further exasperated by this change in shape of the midsole and foot-bed.
In the related art, it would then be necessary to replace the shoes in order to maintain a desired performance characteristic of the shoe because the midsoles are bonded to the remaining elements of the shoe. Another disadvantage of many related art athletic shoes is that there is no opportunity for customization. For example, a user may wish to have a different feel and performance from their shoes when practicing and/or training for a sport compared to when the user is playing in a competitive match in that sport. Also, midsoles that provide adequate shock absorption for a shoe wearer in one type of activity may be inappropriate for a completely different type of activity.
Accordingly, there is a need for a foot-bed for an athletic shoe that has a construction that includes differently contoured regions that contact various different regions of the foot, in order to enhance the impact absorption and stability while also increasing performance for the user.

SUMMARY

In an example of the invention, various regions or portions of the foot-bed/insole are provided with different structural and/or performance features. For example, portions of the heel region, portions of the forefoot region, portions of the toe region and/or portions of the arch region of the foot-bed/insole can be provided with areas of different heights, angles, densities, thickness, material, and/or shape to vary the characteristics of the foot-bed/insole.
In an embodiment, the foot-bed/insole includes at least three different layers that each have different densities. In an example, the bottom most layer of the foot-bed/insole is made of material having the greatest density, a second layer substantially formed on top of the bottom layer is made of a second material less dense than the bottom layer, and one or more regions of the midsole formed on top of the bottom layer and/or second layer have densities less than the bottom layer and/or second layer.
In a further example, the bottom layer can have a thickness that varies across the width of the bottom layer from a medial side to a lateral side of the foot-bed. In an example, the thickness of the bottom layer is thicker on a medial side of the foot-bed than on the lateral side of the foot-bed to thereby provide an angled surface for a bottom of the user's foot to contact during use. In an example, the angle created by the varying thickness of the bottom layer is between 1 degree and 25 degrees.
In another example of the invention, the bottom and second layers are formed substantially of a single layer of material and the one or more regions on the second layer are spaced apart on different structural regions provided at different locations on top of the second layer.
In an embodiment of the invention, each of at least a portion of the bottom layer, at least a portion of the second layer and at least a portion of one or more of the regions formed on the second layer of the foot-bed/insole contact a user's foot when the user is wearing the shoe.
In one example, one of the layers, preferably the second layer, includes a portion that has a thickness less than the remaining portion of that layer. In a preferred embodiment, the portion having the smaller thickness is located in the first metatarsal region of the foot.
An example of the invention includes at least one lateral cushioning and/or support wedges. In this way, the construction of foot-bed/insole allows the ability to place support and cushioning in a variety of places in the shoe. The support and cushioning layers can be for example, foam, gel, air, TPE, carbon fiber, etc.
The athletic shoe of the present invention includes a first foot-bed/insole layer which is formed of material having a first density, the first foot-bed/insole layer forms at least a substantial portion of the bottom layer of the foot-bed/insole. A second layer of the foot-bed/insole is provided on top of or lateral to the first layer and has a different density than the first midsole layer and the one or more other regions are made of a material having a different density than the first and second foot-bed/insole layers.
In an example of the invention, a foot-bed/insole is formed at least in part by a foam material. One or more other regions of the midsole are formed by a gel material and/or TPE (Superfoam™) that can be of any shape, size or pattern and can be placed at any portion of the midsole.
As discussed previously, a user may wish to change the feel and performance from a pair of shoes depending on the type and/or level of activity being performed. It is an object of the present invention to provide a shoe having a construction that enables the shoe wearer to remove and replace the foot-bed/insole of the shoe. Providing the wearer of a shoe with the ability to replace or switch parts of the shoe and to achieve the desired performance and maintain the support and structural integrity of the shoe is advantageous to a user.
The ability of changing the thickness and density of individual pads can accommodate different foot types as well as different activities. Rather than subscribing to a “one design fits all” paradigm, customization will produce significant improvement in performance and protection from injuries.
As should be apparent, the invention can provide a number of advantageous features and benefits. It is to be understood that, in practicing the invention, an embodiment can be constructed to include one or more features or benefits of embodiments disclosed herein, but not others. Accordingly, it is to be understood that the preferred embodiments discussed herein are provided as examples and are not to be construed as limiting, particularly since embodiments can be formed to practice the invention that do not include each of the features of the disclosed examples.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood from reading the description which follows and from examining the accompanying figures. These are provided solely as nonlimiting examples of the invention. In the drawings:

FIG. 1 is a shoe according to an example of the invention;

FIG. 2 is a top view of a foot-bed according to an example of the invention;

FIG. 3 shows a sectional view of a foot-bed of a shoe according to an example of the invention;

FIG. 4 is a bottom view showing an example of a foot-bed that is inserted into the upper of the shoe;

FIGS. 5A-5D are sectional views of the foot-bed shown in FIG. 3;

FIGS. 6A and 6B are perspective views of an embodiment of the invention; and

FIG. 7 shows runner's varus.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference characters will be used throughout the drawings to refer to the same or like parts.
FIG. 1 illustrates an example of a shoe 10 of the present invention. The shoe 10, in the illustrated example, is an athletic shoe. Such shoes can be designed for tennis, running, walking, basketball, or other activities. Of course, it should be appreciated that the shoe of exemplary embodiments can be any type of shoe for any use desired by the wearer, which might benefit from a foot-bed/insole that includes a plurality of regions with different structural features that contact the bottom of a user's foot and enhance the interaction between the foot and the foot-bed/insole.
In one or more illustrated examples, a replaceable portion of the shoe 10 is provided in the foot-bed/insole region of the shoe. The different replaceable foot-bed portions could be provided that have material, layers, shape, size, location, density, and/or other characteristics that can be different in one or more portions of the foot-bed compared to other portions of the foot-bed so that a foot-bed/insole can be provided that will offer the user a desired performance characteristic as well as cushioning and stability during use.
As shown in FIG. 1, the shoe 10 includes an upper portion 15 that covers the upper portion of the wearer's foot. By example, the upper portion 15 may be made of leather, a synthetic or natural fiber material or any combination of known materials that are stitched and/or glued together. The upper 15 takes the approximate shape of the shoe wearer's foot. The upper 15 can be secured directly to the midsole 20/outsole 21 around substantially a bottom peripheral edge. A mid-sole 20, as part of a sole assembly, is provided and is typically made of a lightweight material that provides cushioning during use. The shoe outsole 21 has a traction area which extends from a heel end to a forward toe portion and extends across a width of the shoe. Preferably, the outsole 21 is of a durable but resilient material, such as rubber, that provides good traction for the shoe wearer. The bottom surface of the outsole 21 may include an arrangement of grooves and channels that provide improved traction and flexibility. The use of such grooves and channels in the outsoles of athletic footwear is known in the art.
FIG. 7 of the present application illustrates runner's varus in a rear view of a right leg of the runner. Upon contact of the runner's foot with the ground, a force F is imparted to the region of the heel associated with the heel strike. As shown in FIG. 7, typically the lateral side of the heel contacts the ground and therefore the contact force enters the foot at this location. After contact with the ground, there is a demand for rapid rotation of the foot to pronate, so that the outsole and the foot can get flat on the ground. It is essential for the outsole to get flat on the ground in order to provide stability and support for the runner. As shown in FIG. 7, in order for the foot to get flat on the ground, the foot must pronate excessively as shown by arrow A.
However, the foot-bed according to examples of the present invention compensates for runner's varus and reduces the amount of rotary force that causes the foot to pronate excessively at heel strike. That is, the features of the foot-bed of one or more examples of the invention provides structure to prevent excessive pronation of the foot and decelerates the internal hip rotation as well as assisting in the external rotation of the hip, to power the foot and leg into propulsion. As such, the outsole is flat on the ground but the foot inside of the shoe is not.
According to one of the advantageous aspects of the illustrated example, the shoe 10 includes a removable foot-bed 30, shown in FIGS. 2-6 for example, that may be easily interchangeable and replaceable with other removable foot-beds 30. The foot-bed 30 of one or more embodiments is positioned within an interior of the upper 15. As with typical athletic shoes, due to its resiliency and compressibility, the foot-bed 30 serves as an important cushioning and support component of the shoe 10 of the present invention. Preferably, the foot-bed 30 is not bonded to the upper 15 or outsole 21, thus enabling removal of the foot-bed 30 from the interior of the upper 15. At least a portion of at least one layer of the foot-bed 30, is preferably made of one or more of a resilient material, such as ethylene vinyl acetate (EVA), thermoplastic elastomers (TPE), and thermoplastic polyurethane (TPU), which provides cushioning and support to the shoe wearer's foot. However, other resilient materials exhibiting similar cushioning and supporting characteristics could be used without departing from the scope of the invention.
A user may wish to alter the performance of the shoe 10 depending on the particular activity. However, unlike related art athletic shoes, the foot-bed 30 in the shoe 10 of the present invention is positioned within an interior of the upper 15 above the base portion of the upper and is able to be removed from the interior of the upper 15. Accordingly, the user can replace the currently used foot-bed 30 with a more desirable foot-bed 30. That is, when a foot-bed 30 becomes worn out or damaged, or when the user prefers a different performance characteristic, the user can replace the foot-bed 30 with a new one instead of having to buy a complete new shoe. The drawings show a right or left foot-bed 30 but it should be appreciated that the particular structural features of the foot-beds will be placed appropriately for a right or left shoe.
In various exemplary embodiments of the invention shown in the figures, one set of foot-beds 30 may vary from another set of foot-beds 30 by having different structural support/cushioning elements. The different structural support/cushioning elements can be different layers and/or regions within/on top of/below other layers of the foot-bed made from different material and/or having different structural characteristics such as densities depending on the location on the foot-bed. In one or more embodiments of the invention, the foot-bed/insole 30 can be constructed as a plurality of molded components or layers that are then cemented, glued or otherwise bonded to one another.
The bottom layer 25 and layer 26 formed thereon can have substantially the same or different shapes and sizes. In an embodiment shown in FIG. 4, the bottom layer 25 is provided such that the bottom layer 25 extends beneath the other layers to support the other layers. Layer 26 formed on the bottom layer 25 can have the same shape as layer 25 or be formed to extend over only a portion of bottom layer 25. Further, layers 25 and 26 can have different thicknesses or substantially the same thickness as each other, as well as varying thicknesses along their length and/or width.
In an example of the invention, the bottom layer 25 varies in thickness across its width. In one embodiment, the layer 25 has a smaller thickness on the lateral side than a thickness on the medial side of the foot-bed. The different thickness in layer 25 can extend the entire length of the foot-bed or can be formed along a portion of foot-bed 25 with a remaining portion of layer 25 of the foot-bed having a substantially constant thickness. As best shown in FIGS. 5A-5D, the bottom layer 25 increases in thickness from the lateral side to the medial side at a substantially constant gradient. In one or more embodiments, the angle formed by the change in thickness of bottom layer 25 is from approximately 5 degrees to approximately 25 degrees. In an embodiment, the angle formed is from approximately 10 degrees to approximately 20 degrees. In a preferred embodiment, the angle formed is approximately 15 degrees.
Accordingly, the foot-bed according to examples of the present invention compensates for runner's varus and reduces the amount of rotary force that causes the foot to pronate excessively at heel strike. That is, the angle formed by having the bottom layer 25 vary in increasing thickness from the lateral side to the medial side, prevents excessive pronation of the foot upon contact with the ground. Therefore, according to embodiments, the outsole will be flat on the ground but the foot inside of the shoe is not due to the incline of the surface upon which the foot rests.
It should be appreciated that the layer 26 could be formed to have a varying width from the lateral side to the medial side instead of or in addition to the layer 25 having a varying width. Further, it should be appreciated that both the bottom layer 25 and the next layer 26 could have a width that is substantially constant from the lateral side to the medial side, and also a width that is substantially similar between layer 25 and 26. Accordingly, in an example, a shoe that is designed primarily for walking instead of running, can be provided with a uniform width from a lateral side of the foot-bed 30 to a medial side of the foot-bed 30.
In an exemplary embodiment of the invention shown in FIGS. 2 and 3 for example, a foot-bed 30 can include the layer 26 secured to the bottom layer 25 and provided generally on top of the bottom layer 25. On top of layer 25 and/or layer 26 are provided a plurality of spaced apart regions, discussed in detail below, that form different regions to enhance the support, comfort and/or stability aspects of the foot-bed 30. These regions can be made from material different from the material that forms the bottom layer 25 and layer 26. In an example of the invention, these regions are made from one or more materials that are less dense than the other layers 25, 26 of the foot-bed.
In an example of the invention, the bottom layer 25 is made from a material having a first density, layer 26 is made from a material having a second density different from the first density of layer 25, and the regions formed on top of layer 25 and/or layer 26 are made from one or more materials having a density different from each of the bottom layer 25 and layer 26. In a preferred embodiment, layer 25 is made from a material having the greatest density, layer 26 is made from a material that is less dense than the bottom layer 25, and the one or more regions formed on the layer 25 and/or layer 26 are made from material less dense than both layers 25 and 26. For example, bottom layer 25 can be made from EVA while layer 26 is made from EVA with a textile cover, and regions formed on top of layer 26 is formed from TPE. Accordingly, one or more embodiments of the invention provides at least a tri-density replaceable foot-bed 30 that will offer the user a desired performance characteristic as well as cushioning and stability during use.
As shown in FIGS. 2, 3, 5D and 6A-B for example, the foot-bed 30 may include a lateral heel wedge or member 40 that can extend above the top surface 31 of layer 26 of the foot-bed 30. The heel member 40 may be made of a material, for example EVA, that exhibits characteristics of support that can be different from material provided in one or more other areas of the foot-bed 30. That is, in an example of the invention, the heel member 40 can be made of a material having a density that is greater than an area 31 of layer 26 of the foot-bed 30 immediately adjacent to the heel member.
The use of various types of resilient regions adds another opportunity for customization of the shoe to provide a combination of support as well as structural stability. For example, forming the heel member 40 of a material with a higher density, the heel member 40 can enhance the performance for the user and provide the user greater stability during use. That is, since the heel member 40 is made from material more firm than other areas of the foot-bed that contact the user's foot, the force exerted by the user on the heel member 40 when running for example, is not absorbed as much as with a less dense material, and the reactionary force acting on the foot of the user is greater.
As shown in FIGS. 2 and 3, the heel member 40 can be formed as an extension of bottom layer 25 of the foot-bed 30. That is, the heel member 40 can be made from the same material as the bottom layer 25 but unlike the remainder of the bottom layer 25, the heel member 40 will contact the user's foot to provide support. Bottom layer 25 and heel wedge 40 according to an example of the invention can be made from a high density material in order to provide adequate support for the user's foot. The bottom layer 25 and heel wedge 40 can be made of for example, TPU, EVA or carbon fiber for example, but other materials can be used as desired. In an example of the invention, the bottom layer 25 can be made of carbon fiber, which due to its high strength-to-weight ratio, makes it an ideal material when an activity requires low weight but still must provide adequate support for the user. In one example, the bottom layer 25 is made from higher density material as compared to the remaining portions of the foot-bed 30. In a further example of the invention, the heel member 40 is provided as a portion of another layer of the foot-bed 30, for example as a portion of a layer 26 provided on top of bottom layer 25.
The heel member 40 is shown extending generally along a side of the foot-bed 30. However, embodiments of the invention include a heel member 40 formed around all or a portion of the heel. The heel member 40 can be provided along approximately 270 degrees of the heel, for example extend asymmetrically around the heel portion with respect to a medial side surface and lateral side surface. In an example, the heel member 40 can be made of a polymer, such as ethylene vinyl acetate (EVA) or similar type material that provides some flexibility and shock absorbing properties. The heel member 40 can provide extra support for higher endurance when participating in an activity and can also provide extra impact protection for the heel.
As best shown in FIG. 5D and 6A-B, the heel member 40 can extend above the surface 31 of layer 26 of the foot-bed 30. In an example, a top portion the heel member 40 can extend approximately 12 to 24 mm above the surface 31. In a preferred embodiment, the heel member 40 extends 16 mm above the surface 31. It should be appreciated one or more other embodiments includes a heel member 40 that can extend any distance above the surface 31. Further, a top surface of the heel member 40 that will contact the users foot can have a substantially curved surface from the top portion to the surface 31. For example, the heel member 40 can have a sloped upper surface so that a height of the heel member 40 varies along its length.
Alternatively, the heel member 40 can be shaped from two or more substantially planar regions provided at an angle with respect to each other. In an example of the invention, a first planar region of the heel member 40 can extend from the highest portion of the heel member 40 at an angle towards surface 31. A second planar region of the heel member 40 can be formed extending upwardly substantially perpendicular to surface 31 and intersecting with the first planar region. As such, one or more regions of the heel member 40 can extend different distances above the surface 31.
It should be appreciated that one or more of the plurality of spaced apart regions that extend above the top of layer 26 can have a substantially constant curved surface or be formed with substantially planar portions along with curved portions to enhance the support, comfort and/or stability aspects of the foot-bed 30.
As further shown in FIG. 2, 3, 5C, and 6A-B, according to one of the advantageous aspects of an illustrated example, a pad portion 50 of the foot-bed 30 can extend upwardly with respect to a surface 31 of the foot-bed generally in an arch region of a user's foot. The unique construction of foot-bed allows placement of cushioning pads similar to pad 50 in any desirable place on the foot-bed 30. As shown in the sectional view of FIG. 5C, the pad 50 is provided on top of bottom layer 25. It should be appreciated that the pad 50 can be provided on top of layer 25 or on top of layer 26.
As best shown in FIG. 5C, the pad portion 50 extends above the surface 31 of layer 26 of foot-bed 30. In an example, the pad portion 50 extends 8 mm to 34 mm above the surface 31. In one example of the invention, a pad portion 50 for a low arch would have an 18 mm height above surface 31, for a medium arch the pad portion 50 would have a 22 mm height, and a high arch would have a 26 mm height. It should be appreciated that the pad portion 50 can extend any distance above the surface 31. In an example, different areas of the pad portion 50 can extend different distances above the surface 31. For example, the pad portion 50 can have a sloped upper surface so that a height of the pad portion 50 varies along a length of the pad portion 50.
It should be understood that the shape of the pad 50 can be any shape or size and is generally shaped to at least substantially match corresponding shape of an arch of a user. In an example, the pad 50 is shaped similar to a plateau at a top portion with gently sloping side surfaces extending downwardly in three direction until intersecting with the top surface 31 of layer 26. The top plateau surface of pad 50 can be substantially planar. In an example, a plane formed by the top plateau surface can be substantially parallel to ground contacting surface of the shoe 10. In a further example, the top plateau surface can be angled with respect to the ground contacting surface. For example, the top plateau surface can be angled such that either the side towards the medial side or the side towards the lateral side is higher than the other. Further, it should be appreciated that the top plateau surface can be pitched at an angle forward towards the front of the foot-bed 30 or backward in the heel direction of the foot-bed.
In a further example of the invention, the pad 50 includes a top surface that will contact the users foot that is formed from one or more substantially planar regions provided at an angle with respect to each other. In an example, the pad 50 can be shaped to have an upper planar surface formed to contact a substantial portion of the arch of the user's foot. In an example, the upper surface 51 is formed as generally a planar region with respect to beveled edge surfaces 52, 53 of the pad 50 that each form a border with the upper surface 51 and extend to the surface 31 of the layer 26 of foot-bed 30. The border between upper surface 51 and edge surfaces 52, 53 can be any shape, such as curved or substantially linear, and can also be the same or different between surface 51 and edge 52 and surface 51 and edge 53. Therefore, in an example of the invention, the pad 50 forms a tri-plane pad region.
In an example, a plane formed by edge surface 52 faces in a direction away from a heel area 58 and towards a toe area 57 of the foot-bed 30. A plane formed by the edge surface 53 faces in a direction towards the heel area 58 of the foot-bed. In this example, the triplane formed by the pad 50 contacts the user's foot, more particularly the arch area of the foot, and provides cushioning and support for the user. In a further example of the invention, the upper surface 51 of the pad 50 can form beveled edges with the surfaces 52 and 53 that have different shapes from each other. That is, in an example, the edge 52 can be provided substantially perpendicular to a longitudinal axis of the foot-bed 30. However, edge 53 can extend from an edge of the foot-bed substantially perpendicular to a longitudinal axis of the foot-bed in a curved manner and connect substantially parallel with the longitudinal axis of the foot-bed 30 with edge 52. In this example, edges 52 and 53 would meet at substantially a right angle.
It should be appreciated that edges 52 and 53 of the pad portion 50 can be substantially planar along their lengths or be curved. The pad portion 50 can have any desirable pattern and shape and can extend along a bottom portion of the foot-bed 30 as well as up and along side surfaces of the foot-bed to enhance the structural integrity.
In an embodiment, the pad portion 50 is made of material that is less dense than the bottom layer 25 and a layer 26 formed on top of the bottom layer 25. The pad portion 50 can be made of for example, TPE, foam, gel, or rubber, but other materials can be used as desired that provide cushioning, stability and/or support. In an example of the invention, the material for the pad portion 50 accommodates users with different arch heights. As such, the pad portion 50 with these density characteristics provides for a cushioning feel to the user in the arch area, which allows for proper positioning of the foot within the shoe, good shock absorption as well as a comfortable feel for the user.
Accordingly, as best shown in FIG. 2, in an area of the user's heel, an embodiment of the invention provides for the heel member 40 located on a lateral side of the foot, a pad portion 50 located on a medial side, and a portion of the layer 26 provided between the heel member 40 and pad portion 50, with each of these elements made from different materials with different properties, for example density. For example, the heel member 40 can be made of EVA, the pad portion can be made of TPE, and the layer 26 can be made from EVA with a textile cover. In this way, the support and performance of the foot-bed 30 is advantageously enhanced by the different materials in different regions having different shapes and sizes. As such, while the outsole is flat on the ground, the foot in contact with the features of the foot-bed inside of the shoe, such as the heel member 40 and pad portion 50, is not resting on a plane parallel to the ground surface. Accordingly, the foot-bed according to examples of the invention compensates for runner's varus and reduces the amount of rotary force that causes the foot to pronate excessively at heel strike.
Additionally, in an example of the invention, the pad 50 can be made from a variety of different materials having different densities to alter the performance of the foot bed. Therefore, the foot bed characteristics can be modified by not only changing the height of the pad portion 50, but also the density of the material used for the pad 50. For example, the top plateau portion of the foot-bed can be formed from a first material while one or more of the side surfaces 52, 53 can be made from a different material.
An exemplary foot-bed 30 of the invention includes the layers 25, 26 as well as an onlay portion 55 that is included as an additional support and stability element of the foot-bed. The onlay portion 55 can be any shape and can be placed along at least a portion of the foot-bed 30 along a lateral edge of the foot-bed, as best shown in FIGS. 2 and 6A-B. As shown in the example of FIG. 2, the onlay portion 55 is provided on the lateral side of the foot-bed 30 spaced apart from the pad portion 50 and support platform 60 provided on the medial side of foot-bed 30. In an example, the onlay portion 55 can extend a distance to the center region of the foot-bed 30 from the lateral edge, and also extend in a longitudinal direction of the foot-bed in a curved manner from an area near the pad portion 50 towards the metatarsal depression portion 45. For example the onlay portion 55 can be a radiating circular pattern or a substantially rectangular shape.
As shown in FIGS. 5B and 6A-B, the onlay portion 55 can extend above the surface 31 of layer 26 of foot-bed 30. In an example, the onlay portion 55 extends 2 mm to 12 mm, preferably 5 mm above the surface 31. It should be appreciated that the onlay portion 55 can extend any distance above the surface 31. Further, the onlay portion 55 can have different areas that extend different distances above the surface 31. For example, the onlay portion 55 can have a sloped upper surface so that the height varies along its length. The onlay portion 55 can be made of for example, TPE, foam, gel, or rubber, but other materials can be used as desired that provide cushioning, stability and/or support. As shown in the sectional view of FIG. 5B, the onlay portion 55 is provided on top of bottom layer 25. It should be appreciated that the onlay portion 55 can be provided on top of layer 25 or on top of layer 26.
As best shown in FIGS. 2, 3 and 6A-B, in addition to regions such as the heel portion 40, pad portion 50, onlay portion 55 and support platform 60 that extend above the upper surface 31 of the foot-bed 30, one or more examples of the invention include a depression 45 provided in the layer 26 of the foot-bed 30. The depression 45 is a region in the layer 26 of the foot-bed 30 that extends below surface 31 shown in FIG. 3. The depression 45 is generally located in the first metatarsal region of the foot, which is located in the body of the foot at the base end of the big toe. The depression 45 is shown as a substantially circular shape with a diameter wide enough so that the first metatarsal area of the foot can generally reside therein. Any other shape and size is within the spirit and scope of the present invention.
In an example, the depression 45 is located close to the support platform 60 in a direction of the heel 58 of the foot-bed. The depression 45 extends below the surface 31 of layer 26 approximately 2 mm to 8 mm, preferably 4 mm below the surface 31. It should be appreciated that the depression 45 can extend any distance below the surface 31. Additionally, different areas of the depression 45 can extend below the surface 31 different distances. In an example, edges 46 of the depression 45 can be sloped, and a bottom surface of the depression 45 can be formed as a planar bottom surface.
In a further example of the invention, the foot-bed 30 best shown in FIGS. 2 and 5A, is a foot-bed that includes a support platform 60 provided along a portion of the foot-bed, for example from an area near the toe end 57 of the foot-bed to an area adjacent the metatarsal depression region 45. The support platform 60 is provided near the big toe or hallux region of the user's foot. Utilizing the support platform 60 in this region enhances the support and comfort provided to this area of the user's foot. As shown in the sectional view of FIG. 5A, the support platform 60 is provided on top of bottom layer 25. It should be appreciated that the support platform 60 can be provided on top of layer 25 or on top of layer 26.
As shown in FIGS. 2 and 6A-B, the support platform 60 generally extends along an outer edge area of the foot-bed 30 and is shaped to generally conform to the shape of the toe. In an example, the width of support platform 60 is similar to a width of a toe. The support platform 60 can extend from at or short of the toe end 57 to the metatarsal depression region 45. As shown in FIG. 2, in an example, an edge of platform 60 near the metatarsal depression region 45 is curved to generally match the curve edge of the metatarsal region 45. The support platform 60 extends above the surface 31 of layer 26. In an example, the support portion 60 extends from approximately 2 mm to approximately 12 mm, preferably 4 mm above surface 31. It should be appreciated that the shape, size and height of the support platform 60 can be any dimension depending on the desired location, performance and/or support characteristics. For example, the platform 60 can have a generally sloped shape. Alternatively, the platform 60 could have a plateau in a central region and have planar or sloped sides down to surface 31 of layer 26.
Similar to the pad 50, and onlay 55, the support platform 60 can be made of for example, TPE, foam, gel, rubber, and/or TPU, but other materials can be used as desired that can be used for cushioning, stability and/or support. The gel can be Si18 gel, or gel-like material that provides long lasting shock absorption and a pillow-like feel. Additionally, it should be appreciated that the support platform 60 can extend along part of or the entire top surface of layer 26 of the foot-bed 30 in the forefoot and/or toe area to provide a desired amount of cushioning to the foot of the user.
It should be appreciated that one or more of the heel member 40, pad 50, onlay portion 55, and/or support platform 60 can also extend across the width of the foot-bed 30 as well as extend along a substantial length of the foot-bed 30. For example, the heel member 40, pad 50, onlay portion 55, and/or support platform 60 can extend along any desirable length and width of the foot bed 30. The position of one or more of the heel member 40, pad 50, onlay portion 55, and/or support platform 60 with respect to one or more of the others can be varied as desired depending on the type of activity envisioned by the user upon purchase of the footwear.
It should be appreciated that one or more of the heel member 40, pad portion 50, onlay portion 55, and/or support platform 60 can have a bottom surface that rests on either the layer 25 and/or the layer 26, and/or have at least a portion formed integrally with layer 25 and/or layer 26.
In an example of the invention, one or more of the features of the heel member 40, pad portion 50, onlay portion 55, and/or support platform 60 can be omitted from the foot-bed 30, while the other features are provided as part of the foot-bed 30, without departing from the spirit and scope of the invention.
In a further example, a foot-bed for one of the user's shoes can have a first combination of the features of the heel member 40, pad portion 50, onlay portion 55, and/or support platform 60, while a second one of the user's shoes can have a different combination of features of the heel member 40, pad portion 50, onlay portion 55, and/or support platform 60. Further, an example provides for one or more of the dimensions and/or placement of the features in one shoe can vary from the dimensions and/or placement of the features in a second shoe.
Additionally, one or more of the heel member 40, pad 50, onlay portion 55, and/or support platform 60 can extend up and/or down along the side surfaces of the foot-bed 30. Further, an embodiment of the invention includes one or more of the heel member 40, pad 50, onlay portion 55, and/or support platform 60 to be provided directly on the bottom layer 25 instead of on layer 26. Additionally, one or more of the heel member 40, pad 50, onlay portion 55, and/or support platform 60 can be made of the same or different material from each other, and also they can themselves be made from more than one material.
It should be appreciated that further examples of the invention provide for the foot-bed 30 of a particular set to be asymmetrical. That is, one or more structural support and performance elements of a foot-bed 30 used for a right shoe can be different in location, size, shape, height, density, texture, and/or material for example, from a foot-bed 30 used in a left shoe.
Further, it should be appreciated that the exemplary embodiments of the invention are not limited to the exemplary replaceable foot-bed shown and described above. While this invention has been described in conjunction with exemplary embodiments outlined above, various alternatives, modifications, variations and/or improvements, whether known or that are, or may be, presently unforeseen, may become apparent. Accordingly, the exemplary embodiments of the invention, as set forth above are intended to be illustrative, not limiting. The various changes may be made without departing from the spirit and scope of the invention. Therefore, the replaceable foot-bed of a shoe and the systems and methods of replacing the foot-bed according to exemplary embodiments of this invention are intended to embrace all now known or later-developed alternatives, modifications, variations and/or improvements.

Claims

1. A shoe, comprising:

an upper adapted to receive a foot;

an outsole secured to the upper, the outsole including a ground engaging surface; and

a foot-bed configured to be removably inserted into the upper,

wherein the foot-bed includes a plurality of layers, a first layer being made from a material having a first density, a second layer being made from a material having a second density that is different than the first density.

2. The shoe according to claim 1, wherein the foot-bed includes a third layer formed on a portion of the second layer, the third layer having a third density that is different from the first and second density, the third density being less dense than each of the first and second densities.

3. The shoe according to claim 1, wherein a third layer is provided on top of the second layer and extends above a top surface of the second layer, the third layer including a plurality of spaced apart regions each formed on top of the second layer.

4. The shoe according to claim 3, wherein the third layer includes a first region provided along a medial edge of the foot-bed substantially corresponding to an arch area of a foot, the first region being spaced apart from a second region located along a lateral edge of the foot-bed.

5. The shoe according to claim 4, wherein the third layer includes a third region provided along the medial edge of the foot-bed in an area of the foot-bed corresponding to the hallux, the third region being space apart from each of the first and second regions.

6. The shoe according to claim 5, wherein the first, second, and third regions are separated by the second layer of the foot-bed.

7. The shoe according to claim 4, wherein the first layer of the foot-bed is a bottom layer, a portion of the first layer extends upwardly from part of a peripheral region of the bottom layer in the heel area of the foot-bed.

8. The shoe according to claim 7, wherein the portion of the first layer extending upwardly extends asymmetrically in the heel area as viewed in a heel direction such that a greater portion extends along the lateral edge compared to a back edge of the heel area.

9. The shoe according to claim 7, wherein the bottom layer is formed from at least one of thermoplastic polyurethane and carbon fiber.

10. The shoe according to claim 3, wherein the second layer is formed of a foam material that is less dense than the material forming the bottom layer.

11. The shoe according to claim 6, wherein at least one of the first, second and third regions are formed of a material different from the material of the second layer.

12. The shoe according to claim 11, wherein the material of the at least one of the first, second and third regions is less dense than either of the materials forming the first and second layers.

13. The shoe according to claim 5, wherein at least two of the first, second and third regions extend above a top surface of the second layer a different distance.

14. The shoe according to claim 13, wherein the first region extends a higher distance above the top surface than the second and third regions.

15. The shoe according to claim 7, wherein the first region extends a first distance above a top surface of the second layer, and the portion of the first layer extending upwardly extends a distance above the top surface substantially the same as the first distance.

16. The shoe according to claim 4, wherein the first region includes a substantially planar top surface with beveled edges that are sloped and extend to a top surface of the second layer.

17. The shoe according to claim 5, wherein the first, second and third regions are different from each other in at least one of material, location, dimensions, and thickness.

18. The shoe according to claim 1, wherein the bottom layer is thicker along a medial side than on a lateral side of the foot-bed.

19. The shoe according to claim 18, wherein an angle formed by the bottom layer from a lateral side of the shoe to a medial side of the shoe is approximately fifteen degrees.