US20150366288A1

US20150366288A1 - Adjustable footwear with an integrated unit sole

Info

Publication number: US20150366288A1
Application number: US14/311,126
Authority: US
Inventors: Harry Miller
Original assignee: Harry Miller Manufacturing Co Inc
Current assignee: Harry Miller Manufacturing Co Inc
Priority date: 2014-06-20
Filing date: 2014-06-20
Publication date: 2015-12-24
Also published as: CN105266265A; WO2015196209A1

Abstract

The present disclosure relates to footwear, including at least shoes and boots. The footwear includes a single unit integrated adjustable sole. Additionally, the present disclosure is directed to methods of manufacture of such footwear. The footwear includes a variable sole length. The integrated sole includes a single unit adjustable sub-assembly, a front sole, and a rear sole. The adjustable sub-assembly includes a front portion, a rear portion, and multiple mid sidewall portions that are longitudinally positioned between the front portion and the rear portion. The integrated sole includes a sole sidewall that is formed by at least the mid sidewalls and sidewalls of the front and rear soles. The adjustable sub-assembly is longitudinally positioned between and coupled to each of the front and rear soles. The sole length is varied by varying the adjustable sub-assembly length. A footwear upper is coupled to the integrated sole to form the adjustable footwear.

Description

TECHNICAL FIELD OF THE INVENTION

The invention relates generally to adjustable footwear and more specifically to footwear with an integrated sole where the length of the integrated sole is adjustable to vary the length of the footwear.

BACKGROUND OF THE INVENTION

In today's competitive footwear industry, enhancements to the reliability and usability of footwear, as well as simplifications to a manufacturing process may lead to significant market advantages. In many instances, the manufacturing process for traditional shoes includes gluing a single piece footwear upper to a corresponding sole. In order to increase the usability of a single pair of shoes, innovators in the industry have supplied footwear to allow the lengthening or shortening of the sole to accommodate varying foot sizes. For example, children's shoes that lengthen as a child's feet grow limit the total number of shoes a parent may have to purchase for the child. In addition, parents can shorten the sole length of shoes to pass down the adjustable shoes to smaller children.
However, allowing for the adjustability of the sole length of footwear may limit the reliability of the footwear and increase the difficulty of the manufacturing process. For instance, adjustable shoes may include multiple mechanical components, multiple sole components, and multiple upper components. Multiple upper components may include distinct upper pieces and bellows positioned between the distinct upper pieces. The bellows allow for lengthening the upper when the sole length is increased.
The assembly of these various components into a shoe includes complexities beyond simply gluing a single piece upper to a corresponding sole. Human labor may be involved to interleave and/or align the various components. For example, human labor may be required to position some of the mechanical components between the bellows and other shoe upper pieces. Human labor may also be involved in gluing the multiple shoe upper pieces to the multiple sole pieces. Human labor not only increases the cost of the finished shoe but may also introduce errors in aligning and gluing the components. Such error can reduce the reliability of the finished shoe. It is for these and other concerns that the following disclosure is offered.

SUMMARY OF THE INVENTION

The present disclosure is directed towards articles of footwear, including at least shoes and boots. The articles of footwear include a single unit integrated adjustable ground-engaging assembly, such as an integrated single piece adjustable sole. In addition to engaging the ground, the integrated ground-engaging assembly may engage a foot of the wearer of the footwear. Additionally, the present disclosure is directed to methods of manufacture of such articles of footwear.
At least one embodiment includes an integrated ground-engaging assembly for footwear. The footwear includes a variable sole length. The integrated ground-engaging assembly includes an adjustable sub-assembly. The adjustable sub-assembly may be an integrated single unit adjustable sub-assembly. The integrated ground-engaging assembly further includes a front ground-engaging member and a rear ground-engaging member. The adjustable sub-assembly includes a front portion, a rear portion, and a plurality of mid sidewall portions. At least one of the plurality of mid sidewall portions is longitudinally positioned between the front portion and the rear portion of the adjustable sub-assembly. The front portion may be a portion of front housing of the adjustable sub-assembly. Likewise, the rear portion may be a portion of the rear housing of the adjustable sub-assembly. The length of the adjustable sub-assembly is adjustable and defined by a distance between the front and rear portions.
The front ground-engaging member includes a front sidewall. The rear ground-engaging member includes a rear sidewall. The integrated ground-engaging assembly additionally includes a ground-engaging assembly sidewall that is formed by the front sidewall, at least some of the plurality of mid sidewalls, and the rear sidewall. The ground-engaging assembly sidewall may be an integrated sidewall.
The front ground-engaging member is coupled to the front portion of the adjustable sub-assembly. The rear ground-engaging member is coupled to the rear portion of the adjustable sub-assembly. The adjustable sub-assembly is positioned between the front ground-engaging member and the rear ground-engaging member. The sole length of the integrated ground-engaging assembly is varied by varying the adjustable sub-assembly length.
In at least one embodiment, a portion of an underside of the adjustable sub-assembly is exposed between a rearward portion of a ground-engaging surface of the front ground-engaging member and a forward portion of a ground-engaging surface of the rear ground-engaging member. The exposed portion of the adjustable sub-assembly may be recessed relative to at least one of the ground-engaging surface of the rear ground-engaging member or the ground-engaging surface of the front ground-engaging member.
The sole length may vary between a minimum sole length and a maximum sole length. In some embodiments, when the sole length is the maximum sole length, a gap in the ground-engaging assembly sidewall is formed between the mid sidewall and an adjacent portion of the front sidewall. In at least one embodiment, when the sole length is the maximum sole length, a gap in the ground-engaging assembly sidewall is formed between the mid sidewall and an adjacent portion of the rear sidewall. A difference between the maximum sole length and the minimum sole length is equivalent to at least a whole shoe size.
In a preferred embodiment, the ground-engaging assembly sidewall is configured and arranged to couple to an integrated footwear upper. The integrated footwear upper may include an elastic lateral side region. The elastic lateral side region is coupled to at least one of a rearward portion of the front sidewall or a forward portion of the rear sidewall. The elastic lateral side region accommodates the variable sole length.
The integrated ground-engaging assembly further includes an adjusting module that is configured and arranged to vary the adjustable sub-assembly length. In at least one embodiment, the adjustable sub-assembly in an integrated unit and includes the adjusting module. In a preferred embodiment, the adjusting module is a dial. The adjustable sub-assembly may include a locking mechanism to prevent the adjustment of the sole length.
In at least one embodiment, a method for assembling an article of footwear that includes a variable sole length includes forming an integrated sole that includes a sole sidewall. The method also includes coupling an integrated footwear upper to the integrated sole. This coupling may include coupling at least a portion of an upper sidewall to at least a portion of a sidewall of the integrated sole.
Forming the integrated sole may include further steps, such as coupling a front ground-engaging member to a front portion of an adjustable sub-assembly. The adjustable sub-assembly may include a mid sidewall. The front ground-engaging member includes a front sidewall.
Forming the integrated sole further includes coupling a rear ground-engaging member to a rear portion of the adjustable sub-assembly. The rear ground-engaging member includes a rear sidewall. The adjustable sub-assembly is configured and arranged to vary the sole length. The sole sidewall is formed by the front sidewall, mid sidewall, and the rear sidewall.
In at least one embodiment, coupling the front ground-engaging member to the front portion of the adjustable sub-assembly includes coupling an underside of the front portion of the adjustable sub-assembly to an upper side of the front ground-engaging member. Furthermore, coupling the rear ground-engaging member to the rear portion of the adjustable sub-assembly includes coupling an upper side of the rear portion of the adjustable sub-assembly to an underside of the rear ground-engaging member.
Forming the integrated sole may further include forming a channel in an underside of the rear ground-engaging member to receive the rear portion of the adjustable sub-assembly. In at least one embodiment, forming the integrated sole includes forming a recessed region in an upper side of the front ground-engaging member to receive the front portion of the adjustable sub-assembly.
Forming the integrated sole additionally includes positioning the rear portion of the adjustable sub-assembly between a ground-engaging surface of the rear ground-engaging member and a portion of the rear ground-engaging member that includes the read sidewall. In various embodiments, forming the integrated sole includes at least exposing a portion of an underside of the adjustable sub-assembly. The portion of the underside of the adjustable sub-assembly is positioned between a rearward portion of a ground-engaging surface of the front ground-engaging member and a forward portion of a ground-engaging surface of the rear ground-engaging member. The exposed portion of the underside of the adjustable sub-assembly may be laterally intermediate a pair mid sidewalls
In various embodiments, forming the integrated sole further includes forming a channel in at least one of an underside or an upper side of the rear ground-engaging member. The channel includes a region through a portion of the rear sidewall that is configured and arranged to receive a portion of an adjusting module. The adjusting module is included in the adjustable sub-assembly. The adjusting module is configured and arranged to vary a length of the adjustable sub-assembly. The method may additionally include coupling at least a portion of the integrated footwear upper to the adjustable sub-assembly.
In various embodiments, an adjustable article of footwear includes an integrated sole having an adjustable sole length and a sole sidewall. The article of footwear also includes an integrated footwear upper coupled to the sole sidewall.
In addition to the sole sidewall, the integrated sole includes an integrated adjustable sub-assembly, a front sole that includes a front sidewall, and a rear sole that includes a rear sidewall. In integrated adjustable sub-assembly includes a front portion, a rear portion, and a mid sidewall that is longitudinally positioned between the front and rear portions. The length of the adjustable sub-assembly is an adjustable length. The adjustable length is defined by the distance between the front and rear portions.
The front portion of the integrated adjustable sub-assembly is coupled to the front sole. The rear portion of the integrated adjustable sub-assembly is coupled to the rear sole. In a preferred embodiment, at least a portion of the adjustable sub-assembly is positioned between the front sole and the rear sole. The sole length is varied by varying the adjustable sub-assembly length. The ground-engaging assembly sidewall is formed by the front sidewall, the mid sidewall, and the rear sidewall.
In a preferred embodiment, the integrated footwear upper is a single piece upper. A portion of the integrated adjustable sub-assembly is recessed from and exposed between a ground-engaging surface of the front sole and a ground-engaging surface of the rear sole. The exposed portion of the integrated adjustable sub-assembly is laterally between a pair of mid sidewalls.
When the sole length is lengthened, a gap in the sole sidewall is formed between the mid sidewall and an adjacent portion of the front sidewall. In at least one embodiment, when the sole length is lengthened, a gap in the sole sidewall is formed between the mid sidewall and the rear sidewall.
An underside of the front portion of the integrated adjustable sub-assembly is coupled to an upper side of the front sole. The rear portion of the integrated adjustable sub-assembly is coupled to a channel in the rear sole. The rear portion of the integrated adjustable sub-assembly is received in a trench positioned between a ground-engaging surface and a foot-engaging surface of the rear sole.
The integrated adjustable sub-assembly further includes an adjusting module that is configured and arranged to provide tactile feedback when employed to vary the adjustable sub-assembly length. When the sole length is adjusted to a minimum sole length, a forward portion of the mid sidewall is flush with a rearward portion of the front sidewall. Furthermore, a rearward portion of the mid sidewall is flush with a forward portion of the rear sidewall.
In at least one embodiment, the integrated adjustable sub-assembly includes a locking mechanism that is configured and arranged to secure the adjustable sub-assembly length. A portion of the integrated footwear upper may be coupled to the mid sidewall.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred and alternative examples of the present invention are described in detail below with reference to the following drawings:

FIG. 1 illustrates a side view of an article of footwear that is adjustable and includes an integrated ground-engaging assembly that is consistent with the various embodiments disclosed herein.

FIG. 2 illustrates various components included in an adjustable sub-assembly that is integrated into a ground-engaging assembly. The adjustable ground-engaging assembly is consistent with the various embodiments disclosed herein.

FIG. 3A illustrates an exploded view of an adjustable sub-assembly that may be integrated into a ground-engaging assembly. The adjustable sub-assembly may be employed to vary the length of the ground-engaging assembly. The ground-engaging assembly is consistent with the various embodiments disclosed herein.

FIG. 3B illustrates a top view of an adjustable sub-assembly that may be integrated into a ground-engaging assembly. The adjustable sub-assembly may be employed to vary the length of the ground-engaging assembly. The ground-engaging assembly is consistent with the various embodiments disclosed herein.

FIG. 3C illustrates a bottom view of an adjustable sub-assembly that may be integrated into a ground-engaging assembly. The adjustable sub-assembly may be employed to vary the length of the ground-engaging assembly. The ground-engaging assembly is consistent with the various embodiments disclosed herein.

FIG. 4A illustrates a top view of an adjustable sub-assembly that is adjusted such that the length of the adjustable sub-assembly is a minimum assembly length. The adjustable sub-assembly is consistent with the various embodiments disclosed herein.

FIG. 4B illustrates a top view of an adjustable sub-assembly that is adjusted such that the length of the adjustable sub-assembly is a maximum assembly length. The adjustable sub-assembly is consistent with the various embodiments disclosed herein.

FIG. 4C illustrates a bottom view of an adjustable sub-assembly that is adjusted such that the length of the adjustable sub-assembly is a minimum assembly length. The adjustable sub-assembly is consistent with the various embodiments disclosed herein.

FIG. 4D illustrates a bottom view of an adjustable sub-assembly that is adjusted such that the length of the adjustable sub-assembly is a maximum assembly length. The adjustable sub-assembly is consistent with the various embodiments disclosed herein.

FIG. 5 illustrates a pre-assembled exploded view of an integrated ground-engaging assembly that includes an adjustable length. The integrated ground-engaging assembly is consistent with the various embodiments disclosed herein.

FIG. 6A illustrates a view of sole engaging surfaces of a front and a rear outsole. The outsoles may be integrated into a ground-engaging assembly that is consistent with the various embodiments disclosed herein.

FIG. 6B illustrates a view of ground-engaging surfaces of a front and a rear outsole. The outsoles may be integrated into a ground-engaging assembly that is consistent with the various embodiments disclosed herein.

FIG. 7A illustrates a bottom view of a front and a rear midsole. The midsoles may be integrated into a ground-engaging assembly that is consistent with various embodiments disclosed herein.

FIG. 7B illustrates a bottom view of an adjustable sub-assembly. The adjustable sub-assembly may be integrated into a ground-engaging assembly that is consistent with various embodiments disclosed herein.

FIG. 7C illustrates a bottom view of an adjustable integrated ground-engaging assembly. The integrated ground-engaging assembly includes outsoles, such as the outsoles of FIGS. 6A and 6B, midsoles, such as the midsoles of FIG. 7A, and an adjustable sub-assembly, such as the adjustable sub-assembly of FIG. 7B. The integrated ground-engaging assembly is consistent with various embodiments disclosed herein.

FIG. 8A illustrates a top view of a front and a rear midsole, such as the midsoles of FIG. 7A. The midsoles may be integrated into a ground-engaging assembly that is consistent with various embodiments disclosed herein.

FIG. 8B illustrates a top view of an adjustable sub-assembly, such as the adjustable sub-assembly of FIG. 7B. The adjustable sub-assembly may be integrated into a ground-engaging assembly that is consistent with various embodiments disclosed herein.

FIG. 8C illustrates a top view of an adjustable integrated ground-engaging assembly, such as the integrated ground-engaging assembly of FIG. 7C. The integrated ground-engaging assembly is consistent with various embodiments disclosed herein.

FIG. 9A illustrates a side view of an adjustable integrated ground-engaging assembly, wherein the length of the ground-engaging assembly has been adjusted to a minimum sole length. The ground-engaging assembly being consistent with various embodiments disclosed herein.

FIG. 9B illustrates a side view of an adjustable integrated ground-engaging assembly, wherein the length of the ground-engaging assembly has been adjusted to a maximum sole length. The ground-engaging assembly being consistent with various embodiments disclosed herein.

FIG. 10A illustrates a side view of a footwear upper that may be coupled to an adjustable integrated ground-engaging assembly, such as the ground-engaging assembly of FIGS. 9A and 9B, to form an article of adjustable footwear that is consistent with various embodiments disclosed herein.

FIG. 10B illustrates a top view of a footwear upper that may be coupled to an adjustable integrated ground-engaging assembly, such as the ground-engaging assembly of FIGS. 9A and 9B, to form an article of adjustable footwear that is consistent with various embodiments disclosed herein.

FIG. 10C illustrates an insole that may be included in an adjustable shoe, such as the shoe of FIG. 1. The adjustable shoe being consistent with the various embodiments disclosed herein.

FIG. 11A illustrates a side view of a footwear upper prior to being coupled to an adjustable integrated ground-engaging assembly, such as the adjustable integrated ground-engaging assembly of FIG. 11B. The footwear upper is consistent with various embodiments disclosed herein.

FIG. 11B illustrates a side view of an adjustable integrated ground-engaging assembly prior to being coupled to a footwear upper, such as the footwear upper of FIG. 11A. The adjustable integrated ground-engaging assembly is consistent with various embodiments disclosed herein.

FIG. 12 illustrates a top view of an article of footwear that is adjustable and is consistent with the various embodiments disclosed herein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

To facilitate the understanding of this invention, a number of terms are defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as “a,” “an,” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as outlined in the claims.
Footwear is defined to include any article of manufacture that may be worn on a foot that includes a sole and an upper. Non-limiting examples of such footwear include shoes, boots, sandals, slippers, and the like. Although many of the exemplary embodiments disclosed herein include articles of footwear such as shoes, it is understood that other embodiments are not so constrained. Other embodiments may include any other type of contemplated footwear.
The embodiments disclosed herein include references to the longitudinal length of an article of footwear or the longitudinal length of a footwear ground-engaging assembly, such as an integrated sole. The longitudinal dimension is the linear dimension associated with the longitudinal axis of a wearer's foot, i.e. the dimension substantially defined by the axis between the wearer's heel and toes. In some of the embodiments disclosed herein, the longitudinal length of an article of footwear and/or soles of footwear may be varied, or otherwise adjusted. Likewise, the lateral dimension is the lateral dimension substantially defined by the wearer's foot.
FIG. 1 illustrates a side view of an article of footwear that is adjustable and includes an integrated ground-engaging assembly that is consistent with the various embodiments disclosed herein. In some embodiments, the article of footwear is a shoe 100. In a preferred embodiment, a longitudinal length, such as the length of the sole, may be adjusted to accommodate feet of varying sizes.
The sole length may be increased, as well as decreased, to accommodate variances in the size of a wearer's foot. Such variances may be the result of feet swelling cycles due to various factors, including but not limited to stress and/or trauma induced from excessive running, hiking, traversing extreme terrain, or injury. In a preferred embodiment, the sole length of shoe 100 may be increased to accommodate an increased size of a wearer's foot, such as when the length of the wearer's foot grows over time. In some preferred embodiments, shoe 100 may be a child's shoe. For such embodiments, the need to acquire a new pair of shoes as the child's feet grow may be obviated by increasing or otherwise adjusting the sole length of shoe 100. Additionally, by decreasing the sole length, another child with smaller feet may wear the same shoe. Accordingly, financial resources may be conserved by adjustable footwear, such as shoe 100.
In a preferred embodiment, adjustable shoe 100 includes an integrated ground-engaging assembly. In some embodiments, the integrated ground-engaging assembly may be an integrated sole 130. Integrated sole 130 includes a front ground-engaging member, a rear ground-engaging member, and an adjustable sub-assembly. At least a portion of the adjustable sub-assembly is positioned intermediate the front and rear ground-engaging members. Adjustable sub-assembly may be coupled to each of the front ground-engaging member and the rear ground-engaging member. Integrated sole 130 is an adjustable integrated sole, in that the longitudinal length of integrated sole may be varied between a minimum and a maximum length. In some embodiments, the difference between the minimum and maximum lengths may equivalent to the difference of at least a full shoe size.
An integrated ground-engaging member is a single piece, or single unit sole with an adjustable length. An integrated ground-engaging member may be coupled to a single piece footwear upper to form an adjustable article of footwear, such as shoe 100. As will become clear in the discussion of the various embodiments included herein, integrated sole 130 is a single unit sole. Single unit soles that are consistent with the various embodiments disclosed herein include the mechanical means to vary the length of shoe 100, as well as the structural means to provide structural integrity to shoe 100 or any other article of footwear that includes the single unit sole. The single unit sole also includes the support means to support, cushion, protect, and otherwise comfort the foot of a wearer of shoe 100.
In preferred embodiments, the single unit sole also includes the ground-engaging means to provide the traction required to traverse diverse terrain. In at least one embodiment, the single unit sole includes ruggedized and/or traction enhancing ground-engaging surfaces and/or features. Furthermore, an adjustable single unit sole enables a simplified method of manufacture of a reliable, usable, and adjustable shoe.
The single unit sole includes the integrated mechanical components that enable adjusting the length of the sole. Thus, the integrated single unit sole may be coupled to a single piece footwear upper in a manner similar to traditional shoes. A single piece upper in conjunction with a single unit sole simplifies the manufacturing process, as compared to shoes constructed from uppers that include multiple upper pieces, soles that include multiple sole pieces, and adjusting mechanical components that are interleaved between the multiple upper and multiple sole pieces.
Front ground-engaging member includes front outsole 132. Front ground-engaging member may include front midsole 134. Front ground-engaging member includes front sidewall 162. In some embodiments, the front midsole 134 includes at least a portion of front sidewall 162. In some embodiments, front outsole 132 includes at least a portion of front sidewall 162. In preferred embodiments, outsoles include ruggedized and/or traction enhancing features. Midsoles may be constructed from softer or springier materials than outsoles because the outsoles provide the majority of cushion and comfort to the wearer's feet. The outsole and midsoles may be injection-molded components constructed from any appropriate injection moldable compounds.
Rear ground-engaging portion includes rear outsole 136. Rear ground-engaging member may include rear midsole 138. Rear ground-engaging member includes rear sidewall 166. In some embodiments, rear midsole 138 includes at least a portion of rear sidewall 166. In some embodiments, rear outsole 136 includes at least a portion of rear sidewall 166.
The construction and functionality of an adjustable sub-assembly is disclosed in detail herein, including at least the discussion in regards to FIGS. 2-4D. However, briefly stated, adjustable sub-assembly is configured and arranged to enable the translation along the longitudinal dimension of at least one of the front ground-engaging member or the rear ground-engaging member. By varying the relative positioning of at least one of the ground-engaging members, the sole length of the integrated sole 130 and thus the sole length of shoe 100 is varied.
Adjustable sub-assembly includes mid sidewall 158. Mid sidewall 158 is positioned intermediate front sidewall 162 and rear sidewall 166. Front sidewall 162, rear sidewall 166, and mid sidewall 158 form an integrated sole sidewall. Adjustable sub-assembly includes an adjustment means, such as dial 154. Dial 154 is configured and arranged to adjust the length of the adjustable sub-assembly. Because the adjustable sub-assembly is positioned intermediate and coupled to each of the ground-engaging members, when the length of the adjustable sub-assembly is varied, the sole length of the integrated sole 130 is varied.
Adjustable shoe 100 includes shoe upper 110. Shoe upper 110 is an integrated shoe upper. Shoe upper 110 is coupled to integrated sole 130. In preferred embodiments, coupling the shoe upper 110 to the integrated sole 130 is accomplished by coupling a shoe upper sidewall to a sole sidewall of the integrated sole 130. The sole sidewall is formed by front sidewall 162, mid sidewall 158, and rear sidewall 166.
Shoe upper 110 may be coupled to the sole sidewall using a glue, epoxy, resin, or other adhesive substance. In some embodiments, shoe upper 110 may be coupled to the sole sidewall using stitches, tacks, or other coupling means. An adhesive may be used in conjunction with stitches to enhance the coupling strength. In a preferred embodiment, shoe upper 110 is a shoe upper comprised of a single piece and does not include expandable bellows. A single piece shoe upper may be more easily and/or reliably coupled to the sole sidewall than a multi-piece shoe upper or a shoe upper that includes expandable bellows.
In preferred embodiments, shoe upper 110 is constructed from materials that include at least some stretch to accommodate the varying sole length. The stretch of shoe upper 110 may also accommodate the varying lateral width of a wearer's foot. In at least one embodiment, shoe upper 110 includes an upper lateral side 118. Upper lateral side 118 may be constructed from a material that includes a greater elasticity than other regions of shoe upper 110. As the sole length of adjustable shoe 130 is increased, the elastic material of upper lateral side 118 may be stretched to increase the longitudinal length of the lateral side of shoe upper 110.
Various portions or regions of shoe upper 110 may be constructed from leather, canvas, plastic, or any other man-made or natural material. Multiple pieces of material may be coupled to construct the single piece shoe upper 110 prior to being coupled to the integrated sole 130. Coupling the multiple pieces of material to form the single piece shoe upper 110 may be accomplished with stitches, adhesives, or any other such appropriate coupling means.
In some embodiments, shoe upper 110 may include a fastener, such as shoelace 114, to secure shoe 100 on a wearer's foot. Shoe upper 110 may include a plurality of shoelace eyelets 112 to accommodate shoelace 114. In at least one embodiment, shoelace eyelets 112 are reinforced with grommets to reinforce the integrity of shoelace eyelets 112 and enable the ease of lacing shoe 100. Alternative fasteners, such as buckles, hook and loop material, drawstrings, and the like may be employed in other embodiments. In at least one embodiment, shoe 100 does not include a fastener, but rather shoe 100 is a slip-on shoe.
FIG. 2 illustrates various components included in adjustable sub-assembly 240 that is integrated into a ground-engaging assembly. Integrated ground-engaging assembly 240 is consistent with the various embodiments disclosed herein. The relative configuration of the various components will become clear in the context of the exploded view of adjustable sub-assembly 340 illustrated in FIG. 3A.
Adjustable sub-assembly 240 includes rear housing 246, adjustment shaft 244, and front housing 242. As shown in FIG. 2, front housing 242 includes a plurality of mid sidewalls 258. In alternative embodiments, rear housing 246 includes at least one of the mid sidewalls included in the plurality of mid sidewalls 258. Adjustable sub-assembly 240 includes dial cap 256, dial 254, guide wedge 252, click wedge 250, and key 248.
FIG. 3A illustrates an exploded view of an adjustable sub-assembly 340. Adjustable sub-assembly 340 may be integrated into a ground-engaging assembly, such as integrated sole 130 of FIG. 1. Adjustable sub-assembly 340 may be employed to vary the length of a ground-engaging assembly, such as integrated sole 130 of FIG. 1. The ground-engaging assembly is consistent with the various embodiments disclosed herein.
Similar to the adjustable sub-assembly 240 of FIG. 2, adjustable sub-assembly 340 of FIGS. 3A, 3B, and 3C includes rear housing 346, adjustment shaft 344, and front housing 342. Front housing 342 includes a plurality of mid sidewalls 358. Adjustable sub-assembly 340 includes dial cap 356, dial 354, guide wedge 352, click wedge 350, and key 348.
When assembled into a single piece unit, front housing 342 is coupled to rear housing 346 via adjustment shaft 344. In a preferred embodiment, adjustment shaft 344 is a shaft that includes an outer surface. At least a portion of the outer surface includes continuous threads. Adjustment shaft 344 may be a threaded screw. Threaded adjustment shaft 344 is received by a corresponding threaded channel in front housing 342 through an aperture in a rear portion of front housing 342. In at least one alternative embodiment, adjustment shaft 344 is received by a corresponding threaded channel in rear housing 346 through an aperture in a forward portion of rear housing 346.
Due to the rotating engagement of the threaded adjustment shaft 344 with the corresponding receiving threaded channel of front housing 342, front housing 342 longitudinally translates along a corresponding internal channel in rear housing 346. Thus, a rotation of the adjustment shaft 344 induces a relative longitudinal translation of the front housing 342 and the rear housing 346.
The relative translation results in an adjustment of the distance between the rear housing 346 and the front housing 342. When the distance between the rear housing 346 and the front housing 342 is varied, the length of adjustable sub-assembly 340 is varied. In some embodiments, the length of the adjustable sub-assembly 340 may be varied between a maximum length and a minimum length. When adjusted to the minimum length, a rearward portion of the front housing 342 is flush with a forward portion of the rear housing 346. In a preferred embodiment, the length of the adjustable sub-assembly 340 is varied continuously by the rotational engagement of the threads. In other embodiments, the length of the adjustable sub-assembly 340 is varied in discreet steps.
Dial 354 is coupled to a distal end of adjustment shaft 344 through an aperture in a rearward portion of the rear housing 346. The rearward portion of rear housing 346 and the receiving aperture may be specifically formed to receive dial 354. Dial cap 356 mates with guide wedge 352 and dial 354 to form an adjustment dial to rotate drive shaft 344. Because rotating drive shaft 344 adjusts the length of adjustable sub-assembly 340, a user may adjust the length of the adjustable sub-assembly 340 by rotating the adjustment dial.
Key 348 may secure adjustment shaft's 344 longitudinal position in the internal channel of rear housing 346. Because the longitudinal position of adjustment shaft 344, relative to rear housing 346 is secured, rotation of adjustment shaft 344 longitudinally translates the position of front housing 346, relative to rear housing 242 within the internal channel of rear housing 346.
In a preferred embodiment, dial 354 includes a splined portion. When assembled, the splined portion is positioned within an aperture of click wedge 350. The internal circumference of the aperture within click wedge 350 includes at least one prong. When dial 354 is rotated, the splined portion of dial 354 engages with the at least one prong of click wedge 350. This engagement provides tactile and/or audible feedback when the length of adjustable sub-assembly 340 is varied.
In a preferred embodiment, the adjustment shaft 344 is prevented from rotating by a locking mechanism included in adjustable sub-assembly 340. The locking mechanism secures the length of adjustable sub-assembly 340. When the length of adjustable sub-assembly 240 is secured, the length of an integrated sole of an article of footwear that is constructed from adjustable sub-assembly 340 is locked, or otherwise prevented from varying.
In at least one embodiment, longitudinally translating or pushing the adjustment dial towards rear housing 346 rotationally locks dial 354 by engaging a portion of dial with another portion of adjustable sub-assembly 340 to prevent the rotation of adjustment shaft 344. Longitudinally translating or pulling the adjustment dial away from rear housing 346 rotationally unlocks dial 354. It should be appreciated that many other configurations of adjustable sub-assembly 340, including at least variants on the locking mechanism, are possible to enable and temporarily prevent the adjustability of the length of adjustable sub-assembly 340 without deviating from the spirit of the present disclosure. Accordingly, the other embodiments disclosed herein are not constrained by FIG. 3A.
FIG. 3B illustrates a top view of adjustable sub-assembly 340. Adjustable sub-assembly 340 may be integrated into a ground-engaging assembly, such as integrated sole 130 of FIG. 1. Adjustable sub-assembly 340 may be employed to vary the length of the ground-engaging assembly. The ground-engaging assembly is consistent with the various embodiments disclosed herein.
FIG. 3B shows a top view of the assembled adjustable sub-assembly 340 that FIG. 3A illustrates in a pre-assembled exploded view. Note that the longitudinal length of adjustable sub-assembly 340 has been adjusted to a length that is greater than the minimal length but less than the maximum possible length. The top view of FIG. 3B shows the surface of adjustable sub-assembly 340 that faces a foot of a wearer when the adjustable sub-assembly has been integrated into an adjustable shoe, such as shoe 100 of FIG. 1. When assembled, as shown in FIG. 3B, adjustable sub-assembly 340 is a single piece unit.
FIG. 3C illustrates a bottom view of the adjustable sub-assembly 340. Adjustable sub-assembly 340 may be integrated into a ground-engaging assembly, such as integrated sole 130 of FIG. 1. Adjustable sub-assembly 340 may be employed to vary the length of the ground-engaging assembly. The ground-engaging assembly is consistent with the various embodiments disclosed herein.
The bottom view shows the surface of adjustable sub-assembly 340 that faces the ground when the adjustable sub-assembly has been integrated into an adjustable shoe, such as show 100 of FIG. 1. Note that in at least one preferred embodiment, a portion of the bottom surface of adjustable sub-assembly 340 that is laterally intermediate the pair of mid sidewalls 358 is exposed when integrated in a ground-engaging assembly.
FIG. 4A illustrates a top view of adjustable sub-assembly 440. The length of adjustable sub-assembly 440 has been adjusted to a minimum assembly length. Adjustable sub-assembly 440 is consistent with the various embodiments disclosed herein. When adjusted to the minimum length, a forward portion of rear housing 446 is flush with a rearward portion of front housing 442. Note that the dial cap has been removed to show detail of dial 454.
FIG. 4B illustrates a top view of adjustable sub-assembly 440. The length of adjustable sub-assembly 440 has been adjusted to a maximum assembly length. Adjustable sub-assembly 440 is consistent with the various embodiments disclosed herein. In contrast to the similar view of FIG. 4A, the view in FIG. 4B demonstrates the maximum assembly length. Note that when adjusted to a maximum length, the forward portion of rear housing 446 is spaced apart from the rearward portion of front housing 442.
FIG. 4C illustrates a bottom view of adjustable sub-assembly 440. The length of adjustable sub-assembly 440 has been adjusted to a minimum assembly length, such as the minimum length illustrated in the top view of FIG. 4A. Adjustable sub-assembly 440 is consistent with the various embodiments disclosed herein. When adjusted to the minimum length, a forward portion of rear housing 446 is flush with a rearward portion of front housing 442.
FIG. 4D illustrates a bottom view of adjustable sub-assembly 440. The length of adjustable sub-assembly 440 has been adjusted to the maximum assembly length, such as the maximum length illustrated in top view of FIG. 4B. Adjustable sub-assembly 440 is consistent with the various embodiments disclosed herein. In contrast to the similar view of FIG. 4C, the view in FIG. 4D demonstrates the maximum assembly length. Note that the forward portion of rear housing 446 is spaced apart from the rearward portion of front housing 442.
FIG. 5 illustrates a pre-assembled exploded view of integrated ground-engaging assembly 530 that includes an adjustable length and is consistent with the various embodiments disclosed herein. In a preferred embodiment, ground-engaging assembly 530 is an adjustable integrated sole for footwear. In some embodiments, the adjustable length is an adjustable sole length. The ability to adjust the sole length of ground-engaging assembly 530 is enabled by adjustable sub-assembly 540. In a preferred embodiment, integrated ground-engaging member 530 is similar to integrated adjustable sole 130 of FIG. 1.
FIG. 5 illustrates a pre-assembled exploded view of adjustable sub-assembly 540, which is a similar exploded view of pre-assembled adjustable sub-assembly 340 shown in FIG. 3A. Adjustable sub-assembly 540 includes front housing 542, adjustment shaft 544, and rear housing 546. Front housing includes mid sidewall 558. Adjustable sub-assembly 540 includes dial cap 556, dial cap 556, guide wedge 552, click wedge 550, and key 548.
In a preferred manufacturing method, the various components of adjustable sub-assembly 540 are pre-assembled into an integrated single-unit adjustable sub-assembly 540, prior to being integrated with the other components of the ground-engaging assembly 530. When assembled into a single unit, adjustable sub-assembly 540 may be similar to the adjustable sub-assemblies illustrated in FIGS. 3B-4D.
Integrated ground-engaging assembly 530 includes a front ground-engaging member and a rear ground-engaging member. Front ground-engaging member may be a front sole. Rear ground-engaging member may be a rear sole. In a preferred embodiment, the front sole and rear sole are coupled by the pre-assembled adjustable sub-assembly 540 to form the single unit integrated ground-engaging assembly 530. When the length of adjustable sub-assembly 540 is varied, the distance between the front sole and the rear sole is varied. By varying the distance between the front sole and the rear sole, the sole length of integrated ground-engaging assembly 530 is varied.
In some embodiments, front ground-engaging member includes front outsole 532 and front midsole 534. Likewise, rear ground-engaging member includes rear outsole 536 and rear midsole 538. In some embodiments, at least one of the front ground-engaging member or the rear ground-engaging member is a single piece sole. Front outsole 532 and rear outsole 536 are shown in detail in FIGS. 6A-6B.
The front midsole 534 includes at least a portion of front sidewall 562. In an alternative embodiment, front outsole 532 includes at least a portion of front sidewall 562. Rear midsole 538 includes at least a portion of rear sidewall 566. In at least one alternative embodiment, rear out sole 536 includes at least a portion of rear sidewall 566.
In some embodiments, to enable the coupling of adjustable sub-assembly to the front and rear ground-engaging members, at least one of the front or rear ground-engaging members includes pre-formed structures to snugly receive various regions of adjustable sub-assembly 540. For instance, rear midsole 538 includes a channel or trench 524 to receive at least a portion adjustable sub-assembly 540, such as rear housing 546. Channel and/or trench 524 may be pre-formed in an underside of rear midsole 538. Rear midsole 538 may include recessed area 560 that is pre-formed to snugly receive dial 554 and/or dial cap 556. Although not shown in FIG. 5, front ground-engaging member may include similar features to receive portions of adjustable sub-assembly 540. Because midsoles and outsoles are injection molded soles, various features may be molded features.
In a preferred embodiment, during the manufacturing of ground-engaging assembly 530, at least a portion of the pre-assembled adjustable sub-assembly 540, such as rear housing 546, is positioned intermediate the rear midsole 538 and the rear outsold 536. The rear housing 546 may be positioned in the trench and/or channel 524. When the rear outsole 536 is coupled to the rear midsole 538, the rear housing 546 is sandwiched between the rear outsole 536 and the rear midsole 538. The adjustable sub-assembly 540 may be further coupled to assembled rear ground-engaging member with an adhesive. In an alternative embodiment, the rear housing 546 may be coupled to an upper surface of the rear midsole 538.
Also in a preferred embodiment, a portion of the front housing 542, such as a forward scoop, is coupled to an upper surface of the front midsole 534. In an alternative embodiment, a portion of the front housing 542 may be sandwiched intermediate the front outsole 532 and the front midsole 534 prior to being coupled to the front ground-engaging member.
Once assembled, integrated ground-engaging assembly 530 is a single unit ground-engaging member, or sole, with an adjustable sole length. FIGS. 7C, 8C, 9A, and 9B show various embodiments of assembled single piece ground-engaging soles. Each of these embodiments may be coupled to a single piece footwear upper by the simpler techniques employed in the manufacture of traditional shoes, without sacrificing the reliability, usefulness, or ability to adjust the sole length of the finished footwear.
FIG. 6A illustrates a view of sole engaging surfaces of front outsole 632 and rear outsole 636. Each of these outsoles may be integrated into a ground-engaging assembly, such as integrated ground-engaging assembly 530 of FIG. 5 or ground-engaging assembly 730 of FIG. 7C. The integrated ground-engaging assembly is consistent with the various embodiments disclosed herein.
Collectively, front outsole 632 and rear outsole 636 form an outsole 628 of the integrated ground-engaging assembly. In various embodiments, the outsole includes a majority of the surfaces that engage with the terrain when the integrated ground-engaging assembly that is employed in an article of footwear, such as shoe 100 of FIG. 1. Front outsole 632 may be included in a front ground-engaging member, such as a front sole, in the integrated ground-engaging assembly. For instance, front outsole 632 is coupled to an underside of a front midsole, such as front midsole 734 of FIG. 7A. Likewise, rear outsole 636 is included in a rear ground-engaging member. Rear outsole 636 is coupled to an underside of a rear midsole, such as rear midsole 738 of FIG. 7A.
The surfaces of the front outsole 632 and rear outsole 636 illustrated in FIG. 6A are the surfaces that are face the respective midsoles. The outsoles may be coupled to the midsole by an adhesive, such as a glue, epoxy, or resin. In alternative embodiments, the outsoles and midsoles may be molded as a single piece.
FIG. 6B illustrates a view of the ground-engaging surfaces of front outsole 632 and rear outsole 636. Each of these outsoles may be integrated into a ground-engaging assembly, such as integrated ground-engaging assembly 530 of FIG. 5 or ground-engaging assembly 730 of FIG. 7C. The integrated ground-engaging assembly is consistent with the various embodiments disclosed herein. The surfaces shown in FIG. 6B include the majority of surfaces that engage with the terrain, when the integrated ground-engaging assembly that is employed in an article of footwear, such as shoe 100 of FIG. 1.
FIG. 7A illustrates a bottom view of front midsole 734 and rear midsole 738. The midsoles may be integrated into a ground-engaging assembly, such as integrated ground-engaging assembly 730 of FIG. 7C. The integrated ground-engaging assembly is consistent with various embodiments disclosed herein. The midsoles are shown in FIG. 7A prior to being coupled to outsoles, such as the outsoles illustrated in FIGS. 6A-6B, and an assembled adjustable sub-assembly.
The front midsole 734 and rear midsole 738 may collectively form the midsole 726 of the integrated ground-engaging assembly. Note that the bottom surfaces of each of front midsole 734 and rear midsole 738 include features to receive a front outsole and a rear outsole, such as front outsole 632 and rear outsole 636 of FIGS. 6A-6B, respectively. Also, note that the bottom surface of rear midsole 738 includes a trench or channel 724 to receive an adjustable sub-assembly, such as adjustable sub-assembly 740 of FIG. 7B. Rear midsole 738 also includes a recessed area 760 towards the rear to receive an adjustment mechanism of the adjustable sub-assembly, such as dial 754 of FIGS. 7B-7C.
FIG. 7B illustrates a bottom view of adjustable sub-assembly 740, wherein adjustable sub-assembly 740 may be integrated into a ground-engaging assembly that is consistent with various embodiments disclosed herein.
Adjustable sub-assembly 740 may be similar to other adjustable assemblies disclosed herein, including at least one of adjustable sub-assembly 340 of FIGS. 3A-3C, adjustable sub-assembly 440 of FIGS. 4A-4D, or adjustable sub-assembly 540 of FIG. 5. Adjustable sub-assembly 740 includes front housing 742 and rear housing 746. The distance between front housing 742 and rear housing 746 may be varied by an adjustment mechanism, such as dial 754. Front housing 742 includes a pair of mid sidewalls 758, which form a portion of the integrated ground-engaging assembly's sidewall.
FIG. 7C illustrates a bottom view of adjustable integrated ground-engaging assembly 730. FIG. 7C illustrates the bottom or underside of a fully assembled ground-engaging assembly 730, whereas FIG. 5 illustrates an exploded view of the similar ground-engaging assembly 530 prior to assembly. Ground-engaging assembly 730 includes front outsole 732 and rear outsole 736, which may be similar to front outsole 632 and rear outsole 636 of FIGS. 6A and 6B, respectively. Ground-engaging assembly 730 includes front midsole 734 and rear midsole 738, shown in the bottom view in FIG. 7A. Ground-engaging assembly 730 includes adjustable sub-assembly 740, shown in the bottom view in FIG. 7B. Mid sidewalls 758 form a portion of a sidewall of integrated ground-engaging assembly 730. Note that a portion of the underside of front housing 742 of adjustable sub-assembly 740 is exposed between the bottom surfaces of the front ground-engaging member and the rear ground-engaging member. Other portions of the underside of adjustable sub-assembly 740 are obscured from the bottom view of FIG. 7C. These portions may be obscured because at least some of the portions are embedded in one of the rear or front ground-engaging members. For instance, portions of the rear housing 746 may be sandwiched between the rear midsole 738 and the rear outsole 736. Other obscured portions may be coupled to an upper surface of one of the rear or front ground-engaging members. Also, note that the adjusting dial 754 is exposed through a rearward portion of the sidewall of integrated ground-engaging assembly 730.
FIG. 8A illustrates a top view of front midsole 834 and rear midsole 838. The midsoles may be integrated into a ground-engaging assembly that is consistent with various embodiments disclosed herein, such as integrated ground-engaging assembly 830 of FIG. 8C. The front midsole 834 and rear midsole 838 may collectively form the midsole 826 of integrated ground-engaging assembly 830.
The front midsole 834 includes a front upper surface. Front upper surface may be a front foot-engaging surface 864. The front midsole 834 includes a front sidewall 862. Front sidewall 862 may be positioned along a perimeter of the front midsole 834. In a preferred embodiment, front sidewall 862 is positioned around a perimeter of at least a portion of a forward region of front midsole 834. Front sidewall 862 may be in a substantially vertical orientation. Front sidewall 862 is configured and arranged to couple to a single piece footwear upper, such as shoe upper 110 of FIG. 1.
The upper foot-engaging surface 864 of front midsole 834 may include a recessed portion 822. Recessed portion 822 may be positioned in a rearward region of the foot-engaging surface 864. Recessed portion 822 may be configured and arranged to receive a portion of an adjustable sub-assembly, such as a forward scoop of adjustable sub-assembly 840 of FIG. 8B, as illustrated in FIG. 8C.
Rear midsole 838 includes a rear upper surface. The rear upper surface may be a rear foot-engaging surface 868. Rear sidewall 866 is positioned along a perimeter of the rear midsole 838. In a preferred embodiment, rear sidewall 866 is positioned around a perimeter of at least a portion of a rearward region of rear midsole 838. Like front side 862 and mid sidewall 858, rear sidewall 866 may be in a substantially vertical orientation. Rear sidewall 866 is configured and arranged to couple to a footwear upper. In various embodiments, rear midsole 838 includes a notch in a forward region to receive at least a portion of the adjustable sub-assembly. Front midsole 834 and rear midsole 838 may be similar to front midsole 734 and rear midsole 738 of FIGS. 7A and 7C.
FIG. 8B illustrates a top view of adjustable sub-assembly 840, wherein adjustable sub-assembly 840 may be integrated into ground-engaging assembly that is consistent with various embodiments disclosed herein, such as ground-engaging assembly 830 on FIG. 8C.
Adjustable sub-assembly 840 may be similar to other adjustable assemblies disclosed herein, including at least one of adjustable sub-assembly 340 of FIGS. 3A-3C, adjustable sub-assembly 440 of FIGS. 4A-4D, adjustable sub-assembly 540 of FIG. 5, or adjustable sub-assembly 740 of FIGS. 7B-7C. Adjustable sub-assembly 840 includes front housing 842 and rear housing 846. The distance between front housing 842 and rear housing 846 may be varied by an adjustment mechanism, such as dial 854. Front housing 842 includes a pair of mid sidewalls 858. In a preferred embodiment, front housing 842 includes a forward scoop that configured and arranged to mate with a portion of a surface of the front midsole 834, such as recessed portion 822.
FIG. 8C illustrates a top view of adjustable integrated ground-engaging assembly 830. In some embodiments, integrated ground-engaging assembly 830 may be similar to integrated ground-engaging assembly 730 of FIG. 7C.
Adjustable ground-engaging assembly 830 includes front midsole 834, adjustable sub-assembly 840, and rear midsole 838. Adjustable sub-assembly 840 may be coupled to each of the midsoles with an adhesive, such as a glue, resin, epoxy, or the like. Front sidewall 862, mid sidewall 858, and rear sidewall 866 form an integrated sidewall of ground-engaging assembly 830. The integrated sidewall of ground-engaging assembly 830 is configured and arranged to couple to a single piece footwear upper and form an article of footwear, such as shoe 100 of FIG. 1.
The front foot engaging surface 864, the rear foot engaging surface 868, and an upper surface of a portion of adjustable sub-assembly 840, such as upper surface of front housing 842, form and integrated foot engaging surface. The integrated foot-engaging surface may support, cushion, and otherwise comfort the foot of a wearer when ground-engaging assembly 830 is employed in an article of footwear, such as shoe 100 of FIG. 1. As illustrated in FIG. 8C, the integrated foot-engaging surface may be a contoured and/or form fitting surface.
FIG. 9A illustrates a side view of adjustable integrated ground-engaging assembly 930. The length of ground-engaging assembly 930 has been adjusted to a minimum sole length. Ground-engaging assembly 930 being consistent with various embodiments disclosed herein. In some embodiments, integrated ground-engaging assembly 930 is similar to ground-engaging assembly 730 of FIG. 7C and/or integrated ground-engaging assembly 830 of FIG. 8C. Integrated ground-engaging assembly 930 includes a front ground-engaging member, such as a front sole, adjustable sub-assembly 940, and a rear ground-engaging member, such as a rear sole.
Front sole includes front midsole 934 and front outsole 932. The front midsole 934 includes a front sidewall 962. Rear sole includes rear midsole 938 and rear outsole 936. Rear midsole 938 includes a rear sidewall 966. Adjustable sub-assembly 940 includes at least a mid sidewall 958 and an adjusting mechanism, such as dial 958.
When integrated into a single unit, front sidewall 934, mid sidewall 958, and rear sidewall 966 form an integrated sole sidewall. The longitudinal length of integrated ground-engaging assembly 940 may be adjusted by engaging or rotating dial 958. When the longitudinal length is a minimum, such as that illustrated in FIG. 9A, mid sidewall 958 is flush with both rear sidewall 966 and front sidewall 962.
FIG. 9B illustrates a side view of an adjustable integrated ground-engaging assembly 930. The length of round engaging 930 assembly has been adjusted to a maximum sole length. Ground-engaging assembly 930 being consistent with various embodiments disclosed herein. When the sole length of ground-engaging assembly 930 has been adjusted to a greater length than the minimum length, a gap between mid sidewall 958 and rear sidewall 966 accommodates the increased sole length. In alternative embodiments, the gap may be between mid sidewall 958 and front sidewall 962. In at least one embodiment, when the sole length is adjusted to a maximum sole length, a gap may exist between the rear sidewall 966 and the mid sidewall 958. Another gap may exist between the front sidewall 962 and the mid sidewall 958.
In a preferred embodiment, the difference between the maximum sole length and the minimum sole length is equivalent to at least a full shoe size. Other embodiments are not so constrained, and footwear, such as shoe 100 of FIG. 1 may be adjusted to be equivalent to several shoe sizes.
FIG. 10A illustrates a side view of a footwear upper 1010. Footwear upper 1010 may be coupled to an adjustable integrated ground-engaging assembly, such as ground-engaging assembly 930 of FIGS. 9A and 9B, to form an article of adjustable footwear, such as shoe 100 of FIG. 1. In a preferred embodiment, footwear upper 1010 is a single piece upper. In alternative embodiments, footwear upper 1010 is a shoe upper. In at least one alternative embodiment, footwear upper 1010 is a boot upper.
Footwear upper 1010 includes a plurality of shoelace eyelets 1014 and a tongue 1016. Footwear upper 1010 includes an upper sidewall 1020. As illustrated in FIGS. 11A and 11B, upper sidewall 1020 may be coupled to a sidewall included in an integrated ground-engaging assembly, such the ground-engaging assembly to form a shoe.
Footwear upper 1010 may include upper lateral side 1018. In a preferred embodiment, upper lateral side 1018 is constructed from a material that has some elasticity to accommodate the variable sole length of the coupled ground-engaging assembly. As the sole length of adjustable ground-engaging assembly is increased, the elastic material of upper lateral side 1018 is stretched to increase the longitudinal length of the lateral side of footwear upper 1010.
FIG. 10B illustrates a top view of footwear upper 1010 that may be coupled to the adjustable integrated ground-engaging assembly to form an article of adjustable footwear that is consistent with various embodiments disclosed herein.
FIG. 10C illustrates insole 1070 that may be included in an adjustable article of footwear, such as shoe 100 of FIG. 1. The adjustable article of footwear being consistent with the various embodiments disclosed herein.
Insole 1070 includes a front insole 1076, mid insole 1074, and rear insole 1072. Front insole 1076 is coupled to mid insole 1074 by stitches or other coupling means. Mid insole 1074 is coupled to rear insole 1072 by stitches or other coupling means to form the integrated insole 1070. Integrated insole 1070 may be coupled to a footwear upper, such as shoe upper 1010 of FIGS. 10A and 10B. Coupling insole 1070 to a footwear upper may be accomplished via stitches or other equivalent means.
Integrated insole 1070 may be positioned atop a foot-engaging surface, such as the foot-engaging surface of the integrated ground-engaging assembly formed by front foot engaging surface 864, upper surface of front housing 842, and rear engaging foot 868 of FIG. 8C. Integrated insole 1070 may be coupled to the foot-engaging surface of the integrated ground-engaging assembly with a glue or any other such adhesive.
In a preferred embodiment, at least mid insole 1074 is constructed from a material with at least some elasticity to accommodate the increase in sole length of the adjustable article of footwear. Mid insole 1074 may be position over and above an exposed portion of an adjustable sub-assemble. The exposed portion may be upper surface of the adjustable sub-assembly that increases in length when the sole length is adjusted, such as the exposed region of the upper surface of front housing 842 of FIG. 8C.
FIG. 11A illustrates a side view of a footwear upper 1110 prior to being coupled to an adjustable integrated ground-engaging assembly, such as the adjustable integrated ground-engaging assembly 1130 of FIG. 11B. Footwear upper 1110 is consistent with various embodiments disclosed herein. Footwear upper 1110 includes an upper sidewall 1120 that is configured and arranged to couple with an integrated sole sidewall of the integrated ground-engaging assembly. When coupled to the integrated ground-engaging assembly, an article of footwear, such as shoe 100 of FIG. 1, is formed. In some embodiments, footwear upper 1110 includes an upper lateral side 1118 that will stretch to accommodate an increase in the sole length of the integrated ground-engaging assembly.
FIG. 11B illustrates a side view of adjustable integrated ground-engaging assembly 1130 prior to being coupled to a footwear upper, such as the footwear upper 1110 of FIG. 11A. Adjustable integrated ground-engaging assembly 1130 is consistent with various embodiments disclosed herein.
Adjustable integrated ground-engaging assembly 1130 includes an integrated sidewall that is formed by front sidewall 1162, mid sidewall 1158, and rear sidewall 1164. The integrated sidewall may be coupled to a corresponding sidewall of a footwear upper, such as upper sidewall 1120 of FIG. 11A. In a preferred embodiment, at least a portion of an inner surface of the sidewall of the integrated ground-engaging assembly is coupled to at least a portion of an outer surface of upper sidewall 1120. In at least one embodiment, the integrated sidewall of the ground-engaging assembly surrounds the upper sidewall 1120. In some embodiments, at least a portion of an outer surface of the sidewall of the integrated ground-engaging assembly is coupled to at least a portion of an inner surface of upper sidewall 1120.
Integrated ground-engaging assembly 1130 includes an adjusting mechanism, such as dial 1154. Engaging dial 1154 adjusts the sole length of integrated ground-engaging assembly 1130. FIGS. 11A and 11B illustrates of footwear upper 1110 and integrated ground-engaging member 1130 prior to (but in alignment) being coupled to form shoe 100 of FIG. 1.
FIG. 12 illustrates a top view of an article of footwear that is adjustable and is consistent with the various embodiments disclosed herein. The article of footwear may be a shoe 1200. In a preferred embodiment, the length of the sole of the shoe 1200 is adjustable. Shoe 1200 includes a shoe upper 1210. Shoe upper 1210 includes a plurality of shoelace eyelets 1212 and a tongue 1216. Shoe upper 1210 is coupled to an integrated unit sole, such as one of the various embodiments of an integrated ground-engaging member disclosed herein.
Shoe 1200 includes an insole 1270, which may be similar to insole 10170 of FIG. 10C. Insole 1270 includes a front insole 1276, a mid insole 1274, and a rear insole 1272. Stitches are shown to couple front insole 1276 to the elastic mid insole 1274. Stitches couple elastic mid insole 1274 to rear insole 1272. Stitches are also shown to couple insole 1270 to shoe upper 1210. In a preferred embodiment, an arch-supporting and/or cushioning footbed is positioned between insole 1270 and the foot of a wearer.
While the preferred embodiments of the invention have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiments. Instead, the invention should be determined entirely by reference to the claims that follow.

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. An integrated ground-engaging assembly for footwear having a variable sole length, the integrated ground-engaging assembly comprising:

an adjustable sub-assembly comprising:

a front portion;

a rear portion;

a mid sidewall disposed intermediate the front portion and the rear portion; and

an adjustable sub-assembly length defined by a distance between the front portion and the rear portion;

a front ground-engaging member that includes a front sidewall, wherein the front ground-engaging member is coupled to the front portion of the adjustable sub-assembly;

a rear ground-engaging member that includes a rear sidewall, wherein the rear ground-engaging member is coupled to the rear portion of the adjustable sub-assembly such that the sole length is varied by varying the adjustable sub-assembly length, and

a ground-engaging assembly sidewall is formed by the front sidewall, the mid sidewall, and the rear sidewall.

2. The integrated ground-engaging assembly of claim 1, wherein a portion of an underside of the adjustable sub-assembly is exposed between a rearward portion of a ground-engaging surface of the front ground-engaging member and a forward portion of a ground-engaging surface of the rear ground-engaging member.

3. The integrated ground-engaging assembly of claim 2, wherein the exposed portion of the adjustable sub-assembly is recessed relative to at least one of the ground-engaging surface of the rear ground-engaging member or the ground-engaging surface of the front ground-engaging member.

4. The integrated ground-engaging assembly of claim 1, wherein the sole length varies between a minimum sole length and a maximum sole length.

5. The integrated ground-engaging assembly of claim 4, wherein when the sole length is the maximum sole length, a gap in the ground-engaging assembly sidewall is formed between the mid sidewall and an adjacent portion of at least one of the front sidewall or the rear sidewall.

6. The integrated ground-engaging assembly of claim 4, wherein a difference between the maximum sole length and the minimum sole length is equivalent to at least a whole shoe size.

7. The integrated ground-engaging assembly of claim 1, wherein the ground-engaging assembly sidewall is configured and arranged to couple to an integrated footwear upper.

8. The integrated ground-engaging assembly of claim 7, wherein the integrated footwear upper includes an elastic lateral side region that is coupled to at least one of a rearward portion of the front sidewall or a forward portion of the rear sidewall and the elastic lateral side region accommodates the variable sole length.

9. The integrated ground-engaging assembly of claim 1 further comprising:

an adjusting module that is configured and arranged to vary the adjustable sub-assembly length.

10. The integrated ground-engaging assembly of claim 9, wherein the adjustable module is integrated into the adjustable sub-assembly.

11. A method for assembling an article of footwear that includes a variable sole length, the method comprising:

forming an integrated sole that includes a sole sidewall, wherein forming the integrated sole includes the following steps:

coupling a front ground-engaging member to a front portion of an adjustable sub-assembly, wherein the adjustable sub-assembly includes a mid sidewall and the front ground-engaging member includes a front sidewall;

coupling a rear ground-engaging member to a rear portion of the adjustable sub-assembly, wherein the rear ground-engaging member includes a rear sidewall, the adjustable sub-assembly is configured and arranged to vary the sole length, and the sole sidewall is formed by the front sidewall, mid sidewall, and the rear sidewall; and

coupling an integrated footwear upper to the integrated sole by coupling at least a portion of an upper sidewall to at least a portion of a sidewall of the integrated sole.

12. The method of claim 11, wherein coupling the front ground-engaging member to the front portion of the adjustable sub-assembly includes coupling an underside of the front portion of the adjustable sub-assembly to an upperside of the front ground-engaging member.

13. The method of claim 11, wherein coupling the rear ground-engaging member to the rear portion of the adjustable sub-assembly includes coupling an upperside of the rear portion of the adjustable sub-assembly to an underside of the rear ground-engaging member.

14. The method of claim 11, wherein forming the integrated sole further includes:

forming a channel in an underside of the rear ground-engaging member to receive the rear portion of the adjustable sub-assembly.

15. The method of claim 11, wherein forming the integrated sole further includes:

forming a recessed region in an upperside of the front ground-engaging member to receive the front portion of the adjustable sub-assembly.

16. The method of claim 11, wherein forming the integrated sole further includes:

positioning the rear portion of the adjustable sub-assembly intermediate a ground-engaging surface of the rear ground-engaging member and a portion of the rear ground-engaging member that includes the read sidewall.

17. The method of claim 11, wherein forming the integrated sole further includes:

exposing a portion of an underside of the adjustable sub-assembly, wherein the portion of the underside of the adjustable sub-assembly is disposed intermediate a rearward portion of a ground-engaging surface of the front ground-engaging member and a forward portion of a ground-engaging surface of the rear ground-engaging member.

18. The method of claim 17, wherein the exposed portion of the underside of the adjustable sub-assembly is laterally intermediate a pair mid sidewalls.

19. The method of claim 11, wherein forming the integrated sole further includes:

forming a channel in at least one of an underside or an upperside of the rear ground-engaging member, wherein the channel includes a region through a portion of the rear sidewall that is configured and arranged to receive a portion of an adjusting module included in the adjustable sub-assembly, wherein the adjusting module is configured and arranged to vary a length of the adjustable sub-assembly.

20. The method of claim 11, the method further comprising:

coupling at least a portion of the integrated footwear upper to the adjustable sub-assembly.

21. An adjustable article of footwear comprising:

an integrated sole having an adjustable sole length, the integrated sole comprising:

a sole sidewall;

an integrated adjustable sub-assembly comprising:

a front portion;

a rear portion;

a mid sidewall longitudinally disposed intermediate the front portion and the rear portion; and

an adjustable sub-assembly length defined by a distance between the front portion and the rear portion; and

a front sole that includes a front sidewall, wherein the front portion of the integrated adjustable sub-assembly is coupled to the front sole; and

a rear sole that includes a rear sidewall, wherein the rear portion of the integrated adjustable sub-assembly is coupled to the rear sole such that the sole length is varied by varying the adjustable sub-assembly length, and wherein the ground-engaging assembly sidewall is formed by the front sidewall, the mid sidewall, and the rear sidewall; and

an integrated footwear upper coupled to the sole sidewall.

22. The article of footwear of claim 21, wherein the integrated footwear upper is a single piece upper.

23. The article of footwear of claim 21, wherein a portion of the integrated adjustable sub-assembly is recessed from and exposed between a ground-engaging surface of the front sole and a ground-engaging surface of the rear sole.

24. The article of footwear of claim 23, wherein the exposed portion of the integrated adjustable sub-assembly is laterally intermediate a pair of mid sidewalls.

25. The article of footwear of claim 21, wherein when the sole length is lengthened, a gap in the sole sidewall is formed between the mid sidewall and an adjacent portion of at least one of the front sidewall or the rear sidewall.

26. The article of footwear of claim 21, wherein an underside of the front portion of the integrated adjustable sub-assembly is coupled to an upperside of the front sole.

27. The article of footwear of claim 21, wherein the rear portion of the integrated adjustable sub-assembly is coupled to a channel in the rear sole.

28. The article of footwear of claim 21, wherein the rear portion of the integrated adjustable sub-assembly is received in a trench positioned intermediate a ground-engaging surface and a foot engaging surface of the rear sole.

29. The article of footwear of claim 21, wherein the integrated adjustable sub-assembly further comprises:

an adjusting module that is configured and arranged to provide tactile feedback when employed to vary the adjustable sub-assembly length.

30. The article of footwear of claim 21, wherein when the sole length is adjusted to a minimum sole length, a forward portion of the mid sidewall is flush with a rearward portion of the front sidewall and a rearward portion of the mid sidewall is flush with a forward portion of the rear sidewall.

31. The article of footwear of claim 21, wherein the integrated adjustable sub-assembly further comprises:

a locking mechanism that is configured and arranged to secure the adjustable sub-assembly length.

32. The article of footwear of claim 21, wherein a portion of the integrated footwear upper is coupled to the mid sidewall.