Note: Descriptions are shown in the official language in which they were submitted.
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13~3755
CUSTOM MIDSOLE
TECHNICAL FIELD OF THE INVENTION
This invention relates in general to athletic or
other activewear shoes, and more particularly relates to
shoes having custom midsoles.
1323755
BACKGROUND OF THE INVENTION
Athletic or other activewear shoes of a
conventional construction generally have three or four
separate parts. First, such shoes are provided with an
outsole that is made of a durable material and that
extends across the lower surface of the shoe. A midsole
is joined to the outsole to provide a cushioning layer to
the wearer's foot. Usually, an upper formed of leather,
synthetics or other materials is joined to the midsole.
In many conventional structures, an insole is further
provided for disposal between the midsole and the wearer's
foot for additional cushioning.
The midsoles of these conventional constructions
have two undesirable characteristics. First, they have
the property of deforming over a large area of surface
when a downward force is impressed on them. Second, the
midsoles are affixed to the shoes and therefore customers
can make no choice in the midsole's cushionability without
selecting another shoe. Thus, conventional midsoles do not
offer anything in the way of independent suspension or
deformation of various areas thereof, and further are
suited to only a particular weiqht class or cushionability
preference of wearers.
Thus, a need exists in the industry for a
midsole that has a plurality of cushioning elements, each
demonstratin~ an individual suspension and deforming
independently from the remaininq elements. Further, a
need exists in the industry for midsoles that can be
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selected according to the weight or cushionability
preference of the wearer.
4 13237~5
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention there is
provided a shoe, comprising: a durable outsole having an
outsole upper surface; a cushionable midsole. comprising at
least one cushionable peripheral portion and a separate
removable insert, a lower surface of said peripheral portion
being joined to said outsole upper surface, said at least one
peripheral portion forming an orifice for receiving and
laterally enclosing said insert; said insert having a
preselected cushionability in that it is selected from a
plurality of like inserts having differing degrees of
cushionability and it is selected according to the weight of
the wearer; and an upper joined to said peripheral portion.
In accordance with another aspect of the invention there
is provided a midsole for disposal on an upper surface of an
outsole, comprising: a removable insert of said midsole, and a
peripheral member of said midsole disposed laterally outwardly
of said removable insert; said peripheral member forming an
orifice, said removable insert insertable through said orifice
to be substantially adjacent to said upper surface of said
outsole, said peripheral member permanently affixed to said
upper surface of said outsole; said removable insert having a
lower surface for disposal substantially adjacent to said
upper surface of said ou~sole, a plurality of cushioning
elements formed to fill at least a major portion of said lower
surface, said elements each operable to cushionably deform and
flatten responsive to a force having a component perpendicular
to said lower sllrface at said element, each element operable
to deform independently of the remaining elements.
In accordance with yet another aspect of the invention
there is provided a sole construction for a shoe, comprising:
an outsole having an upper surface; a cushionable midsole
comprising at least one cushionable peripheral portion and a
separate removable insert, a lower surface of said peripheral
portion being joined to said outsole upper surface, said at
least one peripheral portion forming an orifice for receiving
and laterally enclosing said insert; said insert having a
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5 13237~
preselected cushionability and being selected according to the
weight or cushionability preference of the wearer from among a
plurality of like inserts having differing degrees of
cushionability.
In accordance with yet another aspect of the invention
there is provided a method for fabricating a shoe, comprising:
joining an outsole to a cushionable peripheral member of a
midsole to form an orifice for receiving and peripherally
enclosing a removable insert of the midsole; joining an upper
to the peripheral portion; selecting the insert from a
plurality of like inserts having different cushionabilities,
the selection being made according to the weight or
cushionability preference of the wearer; and inserting the
selected insert into the orifice.
6 13237~
BXIEF DESCRIPTION OF THE DRAWINGS
Various aspects of the invention and their
advantages will be more completely understood by reference
to the following Detailed Description in conjunction with
the appended drawings in which:
EIGURE 1 is an isometric view of a shoe
construction according to the invention as fitted with a
custom midsole therefor, with parts broken away to show
interior structure;
FIGURE 2 is a bottom isometric view of a
preferred embodiment of a custom midsole insert of the
invention;
FIGURE 3 i8 a longitudinal section taken
substantially along line 3-3 of EIGURE l;
FIGURE 4 is a top isometric view of an alternate
embodiment of a custom midsole insert according to the
invention; and
FIGURE 5 is a longitudinal section taken
substantially along line 5-5 of FIGURE 4.
7 1323~55
DETAILED DESC~IPTION
Referring first to FIGURE 1, an isometric view
of a preferred embodiment of a shoe construction according
to the invention is shown. A custom midsole insert is
indicated generally at lO. Insert lO is shown as fitted
into an active wear shoe indicated generally at 12. While
the illustrated shoe 12 is one designed for walking, the
invention can also be employed in other types of athletic
shoes, such as running, aerobics, or court shoes. The
invention also has application in any circumstance where
varying midsole cushionability is desired.
Shoe 12 is comprised of an outsole 14 that forms
the wearing surface of the shoe. Outsole 14 is preferably
constructed of a relatively durable, resilient material
such as natural rubber. Outsole 14 has an exterior
surface that is provid0d with a suitable tread surface 16.
Outsole 14 further has an interior or upper surface 18.
Upper surface 18 may be smooth and featureless throughout,
or may have a central area 20 that is reticulated or
webbed in order to save weight. A peripheral area (not
shown) of upper surface 18 presents a smooth surface or
gluing or other means of attachment.
A peripheral midsole member 22 is formed to be
glued or otherwise attached to the peripheral area of
outsole upper surface 18. Peripheral member 22 is more
cushionable and yieldable than outsole 14, and can be
conveniently molded of polyurethane foam or ethylene vinyl
acet~ee copolymer (EVA). Per~pheral member ~ ls in the
8 13237~5
illustrated embodiment endless and extends completely
around the periphery of outsole 14. Peripheral member has
an interior sidewall 24 and an upper surface 26. Member
22 defines a central receptacle 28 that is dimensioned for
5 receiving insert lO.
While in the illustrated embodiment peripheral
member 22 is endless, this need not necessarily be the
case. Member 22 can, for example, take the form of two
longitudinal strips, one for each side of the shoe, or
could take the form of several sections spaced around the
periphery of the shoe. The form taken by peripheral
member 22 should in any event perform its dual function of
retaining insert lO and provide stru-.ural support for the
peripheral area of the shoe.
Shoe 12 further comprises an upper 30 that can
be fashioned of leather, cloth, synthetic materials or a
combination of these, and is attached to upper surface 26
of peripheral member 22 by a method later described.
Insert 10 comprises an upper base member 32 and
a plurality Gf supporting elements 34 that are preferably
formed integrally with base member 32 to depend therefrom.
As shown, elements 34 occupy receptacle 28 when central
member or element lO is inserted into shoe 12. Elements
34 are dimensioned such that their depth matches the depth
of sidewall 24, and are formed so as to occupy
substantially all of receptacle 28 from one sidewall 24 to
the other. Base member 32 has an upper surface 36. A
flocking material 38, which is preferably formed of a
9 13237~5
polyester/nylon material but can be formed of any suitable
fabric, is joined as by gluing to upper surface 36. As
finished out by flocking material 38, insert 10 would not
require any insole or liner on top of it to be suitable
5 for wearing.
As shown, base member 32 has a control member
42, and a lip member 40 ~hat extends beyond a central area
42. Cushioning elements 34 depend from central member 42.
Lip member 40 i5 formed to be coextensive with top surface
26 of peripheral member 22. A uniform cushionable upper
surface 36 is therefore presented to the wearer's foot
throughout the interior of the shoe_.
Referring now to FIGURE ~;- a bottom isometric
view of insert 10 is shown. In the illustrated
embodiment, insert 10 is integrally formed with an insole
portion 44. In the embodiment shown in FIGURE 2, upper
surface 36 comprises the upper surface of insole portion
44, and the flocking material 38 (FIGURE 1) is joined to
this surface.
In the illustrated embodiment, elements 34 each
ta~e the form of a pillar with a rounded free end.
Elements 34 are formed in central area 42 in a closest
pac~ing arrangement in Grder to provide cushionable
support throughout central area 42. Elements 34 are
formed independently of each other, and are only joined to
base 32. In this manner, elements 34 provide in effect a
multiple-point independent suspension. This is because
elements 34 will be compressed and will yield
lo 13237~
independently of each other. This is an advantage over
midsoles or insoles of solid construction, which have a
tendency to yield and compress continuously and uniformly
over large areas. The discrete elements 34 on the other
hand give an independent, discontinuous support to
different portions of the foot that is not obtainable by a
midsole or insole of uniform construction.
Elements 34 are graduated in size in order to
conform to the depth of sidewall 24 (FIGURE 1). In a
front area 46 of area 42, a plurality of relatively small
elements 48 and formed. Elements 48 will conform to the
relatively thin depth of peripheral member 22 in the front
region. In heel region 50, a relatively smaI' number of
large heel cushioning elements 52 are formed. The larger
size of elements 52 adapts them to the larger depth of
peripheral member 22 in heel region 50. Further, since
there is a larger cushioning depth of material, the larger
size of elements 52 will make sure there is no undue
bending or nonradial deformation, as might otherwise occur
if a plurality of long, thin elements were used.
Referring now to FIGURE 3, an elevational
section taken substantiaily along line 3-3 of FI~URE 1 is
shown. FIGURE 3 particularly illustrates the graduated
size of elements 34 from front region 46 to rear region
50- Some o the elements 34 are not shown in section
because section line 3-3 did not pass throuqh them, or are
shown only partially in section because line 3-3 did not
pass through them along their major diameter. Insole
11 13237~
portion 44 is shown to have a concave surface 54 in heel
region 50 for the support of the heel of the wearer's
foot.
Upper 30 has a bottom lip member 56 for mating
5 with upper surace 26 of peripheral member 22. Lip member
56 is attached as by gluing to upper surface 26. Then, an
element 58 is placed on top of lip member 56. Element 58
is elongate and extends around the periphery of shoe 12,
corresponding to upper surface 26. Element 58 can
10 conveniently be formed of a leatherized paper material or
other relatively strong material. Stitching 60 is used to
join element 58, lip member 56 and peripheral member 22,
y and optionally outsole 14, together.
In operation, shoes 12 and inserts 10 are
15 distributed to retailers as separate items. Each insert
10 has a specific durometer reading that measures its
relative yieldability or resiliency. The cushionability
of inserts 10 can also be varied by changing the shape
and/or spacing of elements 34. A plurality of different
2~ inserts 10 having a range of durometer readings are
provided for each shoe size, such that any pair of
numerous pairs of inserts 10 can be inserted into a
respective pair of shoes 12. A particular pair of inserts
10 are selected for a particular customer according to the
25 customer's weight and cushioning preference. Thus, a
lightweight person will in general require an insert 10
that is more cushionable and less resilient than a heavier
person. Further, the customer may have a particular
12 13237~5
preference concerning how "soft" or "hard" the shoe feels,
and may select a pair of inserts 10 that match his or her
preferences in this respect. Finally, there may be medical
reasons for selecting a right insert 10 that has a
different resiliency and cushionability that a left insert
1n, and the invention will permit this selection.
Referring now to FIGURES 4 and 5, a~ alternate
embodiment of a custom insert according to the invention
is illustrated. Referring first to FIGURE 4, an alternate
insert is indicated generally at 62. Like the other
illustrated embodiments, insert 52 has a base member 64 to
which a layer 66 of flocking material is attached as by
gluing. Insert 62 comprises a central region 68 and a
peripheral lip member 70 that is preferably formed
lS integrally with region 68. The embodiments shown in
FIGURES 4 and 5 differ from the inserts shown in FIGURES
1-3 in that the insole portion 44 formed integrally with
the first embodiment has been omitted. In its place, a
plurality of convex surface elements 72 has been formed in
central region 68. Convex elements 72 are provided to
have a massaging effect on the lower surface of the foot
of the wearer.
Referring particularly to FIGURE 5, a plurality
of cushioning elements 74 depend downwardly from central
region 6~. Like the first embodiment, elements 74 are
preferably made of large size in the heel region, and are
preferably made of smaller size in the toe region in order
to conform t~ the lift of peripheral member 2Z. Elements
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74 are joined at a middle depth 76 thereof in order to
form base member 64. It is preferred that convex surfaces
72 be formed in registry with respective depending
elements 74 for convenience in fabrication.
In summary, a novel midsole with a custom insert
has been provided in order to vary the resiliency and
cushionability of the midsole according to the wearer's
needs. Two embodiments of the midsole have been provided,
one with an integral insole portion and the other with a
plurality of convex elements for a massaging action of the
foot. Either embodiment of the midsole has a plurality of
depending elements that provide an independent cushioning
suspension. _
While preferred embodiments of the invention and
their advantages have been described above, the invention
is not limited thereto but only by the spirit and scope of
the claims which follow.
13237~5
13a
SUPPLEMENTARY DISCLOSURE
The present invention preferably has a footbed
reinforcing layer joined to the bottom of the receptacle prior
to placing the insert therein. The footbed reinforcing layer
is preferably much thinner than the depth of the receptacle
and provides torsional strength for lateral support of the
wearer's foot.
In accordance with one aspect of the invention there is
provided a shoe, comprising a durable outsole having an
outsole upper surface; a cushionable midsole comprising at
least one cushionable peripheral portion and a separate
removable insert, a lower surface of said peripheral portion
being joined to said outsole upper surface, said at least one
peripheral portion forming an orifice for receiving and
laterally enclosing said insert; a reinforcing layer joined to
said outsole upper surface within said receptacle, said
reinforcing layer being substantially thinner than the depth
of said receptacle and providing torsional strength; said
insert having a lower surface for contacting said reinforcing
layer and a preselected cushionability in that it is selected
from a plurality of li~e inserts having differing degrees of
cushionability and it is selected according to the weight of
the wearer; and an upper joined to said peripheral portion.
DESCRIPTION OF D~AWINGS SUPPORTED BY THE SUPPLEMENTARY
DISCLOSURE
FIGURE 6 is an isometric view of a shoe construction
according to the invention as fitted with a custom midsole
therefor and a reinforcing layer, with parts broken away to
show interior structure.
DETAILED DESCRIpTIoN OF THE SUPP~EMENTARY DISCLOSURE
Referring to FIG~RE 6, an isometric view of a preferred
embodiment of a shoe construction according to the invention
is shown. A custom midsole insert is indicated generally at
10. Insert 10 is shown as fitted into an active wear shoe
indicated generally at 12. While the illustrated shoe 12 is
one designed for walking, the invention can also be employed
in other types of athletic shoes, such as running, aerobic or
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13237~5
court shoes. The invention also has application in any
circumstance where varying midsole cushionability is desired.
Shoe 12 is comprised of an outsole 14 that forms the
wearing surface of the shoe. Outsole 14 is preferably
5 constructed of a relatively durable, resilient material such
as natural rubber. Outsole 14 has an exterior surface that
is provided with a suitable tread surface 16. Outsole 14
further has an interior or upper surface 18. Upper surface
18 may be smooth and featureless throughout, or may have a
10 central area 20 that is reticulated or webbed in order to
save weight. A peripheral area (not shown) of upper surface
18 represents a smooth surface for gluing or other means of
attachment.
A peripheral midsole member 22 is formed to be glued or
15 otherwise attached to the peripheral area of outsole upper
surface 18. Peripheral member 22 is more cushionable and
yieldable than outsole 14, and can be conveniently molded of
polyurethane foam or ethylene vinyl acetate copolymer (EVA).
Peripheral member 22 is as shown in the illustrated
20 embodiment, endless and extends completely around the
periphery of outsole 14. Peripheral member 22 has an
interior sidewall 24 and an upper surface 26. Member 22
defines a central receptacle 28 that is dimensioned for
receiving insert 10.
While in the illustrated embodiment peripheral member 22
is endless, thi~ need not necessarily be the case. Member 22
can, for example, take the form of two longitudinal strips,
one for each side of the shoe, or could ta~e the form of
several sections spaced around the periphery of the shoe.
30 The form taken by the peripheral member 22 should in any
event perform its dual function of retaining insert 10 and
providing structural support for the peripheral area of the
; shoe.
A footbed reinforcing layer 31 is affixed as by gluing
35 to outsole upper surface 18 within receptacle 28. Layer 31
is preferably much thinner than the depth of central
receptacle 28 so as to allow room for insert 10. Reinforcing
A layer 31 is sized to substantially coincide with the bottom
area of receptacle 28.
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~3~5~
Layer 31 is fabricated of a relatively resilient firmand less flexible material in relation to the EVA forming
peripheral member 22. For example, layer 31 can be
constructed of a leatherized paper or cardboard. The purpose
5 of layer 31 is to replace torsional strength lost by the
creation of receptacle 28 in midsole member 22. Thus, a
midsole/outsole configuration having satisfactory torsional
strength is formed for proper lateral support of the wearer's
foot while at the same time providing for a central insert 10
10 having selectable cushionability.
Shoe 12 further comprises an upper 30 that can be
fashioned of leather, cloth, synthetic materials or a
combination of these, and is attached to upper surface 26 of
peripheral member 22.
Insert 10 comprises an upper base member 32 and a
plurality of supporting elements 34 that are preferably
formed integrally with base member 32 to depend therefrom.
As shown, elements 34 occupy receptacle 28 when central
member or element 10 is inserted into shoe 12. Elements 34
20 are dimensioned such that their depth matches the depth of
sidewall 24 minus the thickness of layer 31, and are formed
so as to occupy substantially all of receptacle 28 from one
sidewall 24 to the other. Peripheral member 22 and removable
insert 10 are apportioned such that most of the weight of the
25 wearer will be borne by insert 10.
Base member 32 has an upper surface 36. A flocking
material 38, which is preferably formed of a polyester/nylon
material but can be formed of any suitable fabric, is joined
as by gluing to upper surface 36. As finished out by
30 flocking material 38, insert 10 would not require any insole
or liner on top of it to be suitable for wearing.
As shown, base member 32 has a central member 42, and a
lip 40 that extends beyond central area 42. Cushioning
elements 34 depend from central member 42. Lip member 40 is
35 formed to be coextensive with top surface 26 of peripheral
member 22. A uniform cushionable upper surface 36 is
therefore presented to the wearer's foot throughout the
interior of the shoe.
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