1
FOOTWEAR SYSTEM
Field of the Invention
This invention relates to footwear and, more
particularly, to a footwear system having a sock and a
shoe for interfacing with the sock.
Hackaround of the Invention
Various shoes have been developed over the
years which have attempted to emulate the sole of the
foot of the wearer to thereby provide a degree of
comfort when walking, running, or the like. These
shoes typically anticipated the wearer to use a
conventional thin knit sock with the shoe so that the
innersole of the shoe substantially corresponds to the
sole of the foot. Examples of such shoes may be seen
in the French Published Application (FR-A-2661805) by
Roger titled "Podologic Orthosis"; U.S. Patent
3,470,880 by Pagliano titled "Foot Shank Pad"; the
Swiss Patent (CFi-A-256494) titled "Hygienic Footwear
With Supportive Insole"; U.S. Patent 4,831,750 by
Miiller titled "Shoe- Construction, Shoe-Construction
Product, and Method Of Fabricating The Products"; and
U.S. Patent 4,305,212 by Coomer titled "Orthotically
Dynamic Footwear."
The common assignee of the present invention,
however, recognized that when wearing shoes, the major
wear and tear on the foot occurs in the ball and heel
regions of the foot because a major portion of the
person's weight is distributed in these regions when
standing, walking, or running. Therefore, the common
AMENDED SHEET
~.~ ~7D47
assignee developed a knit sock having an increased
density of knit fabric in the ball and heel portions of
the sock to provide added comfort to the wearer and
reduce the damage to these regions of the foot. An
AMENDED SHEET
CA 02167047 2003-08-07
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described herein by the provision of more comfortable
footwear for a wearer's foot having thicker fabric ball
and heel portions of a sock when positioned on the foot
of a wearer matingly interfacing with the sole of a
shoe so that wear and tear to the ball and heel
portions of the foot of the wearer are reduced during
use. The thicker fabric portions of a knit sock when
positioned on the foot of a wearer, preferably the ball
and heel portions thereof, matingly interface in
male/female interlocking fashion with the contours of
the sole of the shoe so as to provide internal multi-
directional movement in the thicker fabric portions
interfacing with the foot of the wearer thereby
reducing friction shearing forces and without requiring
a larger shoe size. The sole of the shoe has a ball
portion, a heel portion, and a raised arch portion for
contacting and interfacing with the respective
overlying portions of the sock. The raised arch
portion of the sole of the shoe preferably corresponds
substantially to the lengthwise extent of the thinner
fabric arch portion of the sock and also matingly
interfaces therewith so that the male/female
cooperation between the sock and the sole of the shoe
is further enhanced.
More particularly, the footwear system has a
knit sock and a shoe. The knit sock overlies and
contacts the shoe and includes a ball portion, a heel
portion, and an arch portion disposed between the ball
and heel portions. Each of the ball and heel portions
of the sock is formed of thicker knit fabric than the
arch portion of the sock. The thicker knit fabric
preferably is formed of a predetermined density of
raised terry loops thereby providing a greater amount
of protection and cushioning to the ball and heel of
the foot of the wearer. The shoe has a sole including
a ball portion, a heel portion, and a raised arch
portion for contacting and interfacing with the
..
-4-
respective overlying portions of the sock. The sole of
the shoe, according to the invention, preferably
includes an innersole and an outersole. The raised
arch portion of the innersole preferably corresponds
substantially to the lengthwise extent of the thinner
fabric arch portion of the sock when positioned on the
foot of the wearer so as to provide a substantially
mating interfacing relationship for added protection
and comfort to the wearer. According to another
embodiment of the invention, the arch portions of the
knit sock and the innersole of the shoe each have a
shorter lengthwise extent than either the ball or heel
portion sof the sock or innersole and also matingly
interface so that a male/female mating relationship is
provided. The matingly interface relationship of the
sock with the innersole of the shoe according to the
embodiments of the invention thereby provides a
male/female cooperation type of approach to foot
protection which protects against the shearing and
impact forces normally received by the foot during
activity thereof.
Also, the innersole of the shoe is preferably
a multiple layer innersole having a ball portion, a
heel portion, and a raised arch portion therebetween.
The-raised arch portion preferably has a hump, a
substantially flat plateau portion adjacent peripheries
of the hump, and oppositely inclined fore and aft
portions for providing a smooth transition with the
ball portion and major areas of the heel portion. The
hump extends widthwise from the instep of the innersole
to medial portions of the raised arch portion, has a
greater thickness along the instep, decreasing
thickness toward the medial portions, and substantially
the same contour as major portions of the arch of a
foot of a wearer. The innersole may be secured to the
outersole, or an intermediate layer therebetween, or
may also be advantageously used as an insert and
CA 02167047 2003-08-07
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view of a shoe of a footwear system according to the
present invention with the foot of a wearer in phantom
lines;
Figure 10 is a vertical cross-sectional view
of a shoe of a footwear system according to the present
invention taken along line 10-10 of Figure 7;
Figure 11 is a fragmentary cross-sectional
view of a shoe of a footwear system according to the
present invention illustrating the raised arch portion
of the innersole of the shoe;
Figure 12 is a perspective view of an
innersole of a shoe of a footwear system according to a
first embodiment of the present invention;
Figure 13 is a perspective view of an
innersole of a shoe of a footwear system according to a
second embodiment of the present invention with phantom
lines illustrating the innersole in a position of
partial removal from the shoe;
Figure 14 is a vertical cross-sectional view
of an innersole of a shoe of a footwear system
according to the present invention taken along line 14-
14 of Figure 12;
Figure 15 is a fragmentary vertical cross-
sectional view of an innersole of a shoe of a footwear
system according to the present invention taken along
line 15-15 of Figure 12;
Figure 16 is an exploded perspective view of
an innersole of a shoe according to a first embodiment
of a footwear system of the present invention;
Figure 17 is an exploded perspective view of
an innersole of a shoe according to a second embodiment
of a footwear system of the present invention;
Figure 18 is a vertical cross-sectional view
of another embodiment of a footwear system according to
the present invention;
Figure 19 is a horizontal cross-sectional
view of another embodiment of a footwear system
~~6'~~4~
according to the present invention taken along line 19-
19 of Figure 18;
Figure 20 is a horizontal cross-sectional
view of another embodiment of a footwear system
according to the present invention taken along line 20-
20 of Figure 18;
Figure 21 is a horizontal cross-sectional
view of another embodiment of a footwear system
according to the present invention taken along line 21-
21 of Figure 18;
Figure 22 is a top plan view of an innersole
of another embodiment of a footwear system illustrated
in Figure 18; and
Figure 23 is a side elevational view of an
innersole of another embodiment of a footwear system
illustrated in Figures 18 and 22.
Detailed Description Of A Preferred Embodiment
The present invention now will be described
more fully hereinafter with reference to the
accompanying drawings in which illustrated embodiments
of the invention are shown. This invention may,
however, be embodied in many different forms and should
not be construed as limited to the embodiments set
forth herein; rather, these embodiments are provided so
that this disclosure will be thorough and complete and
will fully convey the scope of the invention to those
skilled in the art. Like numbers refer to like
elements throughout.
The footwear system, according to the present
invention, broadly designated at 20, has a knit sock 30
overlying and contacting a shoe 50 as best shown in
Figures 7 and 9. Figures 1-3 show the knit sock 30 of
the footwear system 20 including a view of the knit
sock on the foot of a wearer with phantom lines
illustrating the bones of the foot for clarity. The
sock 30 is illustrated as an athletic sock. The sock
30, however, can be knit for use as a dress sock or
CA 02167047 2003-08-07
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ball or heel portions 33, 34 of the sock 30 such as in
its relaxed position as illustrated in Figures 1 and 2
or may have a lengthwise extent shorter than the ball
portion 33 and approximately equal to the lengthwise
extent of the ball portion 34 such as in its stretched
position on the foot of a wearer as illustrated in
Figure 3.
Also, as illustrated in Figures 1 and 2, the
instep portion 32 of the sock 30 preferably has
opposite side edges or peripheries forming lengthwise
extending, opposing side panels 37, 38 which are knit
without raised terry loops. The other opposing side
panel 38 is not shown but is preferably a mirror image
of the opposing side panel 37 shown in Figures 1 and 2.
The side panels 37, 38 preferably extend lengthwise
from the toe portion 36 to the upper cuff 31 and extend
widthwise from a lower sole, formed by the ball, heel,
and arch portions 33, 34, 35, several Wales (i.e.,
preferably 4 to 14 Wales) into the instep portion 32.
The shoe 50, as best shown in Figure 4-6, 8,
10-11, and 18, has a shoe upper 51 and a sole shown as
an innersole 60 and an outersole 80. The shoe 50
illustrated is a casual walking shoe, but other various
shoes, including athletic shoes, dress shoes, and
sandal-type shoes, may also be used as will be apparent
to those skilled in the art. The innersole 60 of the
shoe 50 overlies the outersole 80 and has a ball
portion 62, a heel portion 61, and a raised arch
portion 63, as best shown by the bracketed portion in
Figures 6 and 8, for contacting and interfacing with
the respective overlying portions of the knit sock 30.
The ball portion 62 extends lengthwise fore of the
raised arch portion 63 and preferably includes the
portion underlying the toe portion of an overlying sock
or toes of the foot of the wearer thereof. The heel
portion 61 extends lengthwise aft of the raised arch
portion 63 as illustrated and preferably extends to
21 fi704 7
-10-
include the heel portion of an overlying sock or the
heel of the foot of a wearer thereof. As illustrated
in the embodiment of Figures 1-17 of the present patent
application, the raised arch portion 63 of the
innersole 60 may have a lengthwise extent that is
substantially shorter than the ball portion 61 and
approximately equal to or slightly greater than the
lengthwise extent of the heel portion 61, as best shown
in Figures 7-9, so that the lengthwise extent of the
raised arch portion 63 of the innersole 60 corresponds
substantially to the lengthwise extent of the thinner
fabric arch portion 35 of the knit sock 30 when worn on
the foot of a wearer so as to provide a substantially
mating interfacing relationship for added protection
and comfort to the wearer. According to another
embodiment of a footwear system according to the
present invention, the raised arch portion 63" of the
innersole 60" may also have a substantially shorter
lengthwise extent than either the ball portion 62" or
the heel portion 61", as best illustrated in Figures
18-23 with double prime (") notation corresponding to
like elements of the first embodiment of the invention
as described herein. The shorter lengthwise extent of
the raised arch portion 63" preferably has a range from
about 20% to 28% of the overall lengthwise extent of
the innersole 60" for all sizes of a shoe 50". The
raised arch portion 63 according to the embodiments of
the invention also generally extends across the entire
width of the innersole 60.
The matingly interface relationship of the
sock 30 with the sole of the shoe 50, as best shown in
Figures 7, 9, and 18, thereby provides internal multi-
directional movement in the thicker fabric portions of
the sock 30 interfacing with the foot of the wearer so
as to reduce impact and friction shearing forces
received by the foot of the wearer. The matingly
interface relationship is preferably a male/female
216704 7
-11-
cooperation type of approach that protects the foot
during activity thereof such as walking, jogging, and
participating in various sports. The footwear system
according to the invention also provides a shoe 50 that
comfortably receives a sock, such as the knit sock 30,
having thicker fabric in the ball and heel portions
thereof than in the arch without requiring a larger
shoe size for the wearer of the sock.
The innersole 60 of the shoe 50, as best
shown in Figures 6, 12-17, and 22-23, is preferably
formed of multiple layers including a backing layer 57
and an integrally molded foam layer 70 overlying the
backing layer 57. The backing layer 57 (as shown in a
first embodiment in Figures 12 and 16) preferably has a
substantially uniform thickness throughout and may be
integrally formed of a relatively stiff and flexible
material, such as compressed paperboard, so as to
impart relatively stiff support to the integrally
molded foam layer 70. The backing layer 57' (as shown
in a second embodiment in Figures 13 and 17) may also
be bifurcated into first and second portions 57a', 57b'
and secured along common and overlapping edges 57c',
57d'. The first portion 57a' of the backing layer 57'
extends substantially the length of the ball portion
62', and the second portion 57b' extends substantially
the length of the arch portion 63' and substantially
the length of the heel portion 61'. The second portion
57b' is formed of a stiffer material than the first
portion 57a' so that the stiffer second portion 57b'
reduces lateral and bending movement of the heel and
the arch of the wearer of the shoe 50, and yet the
first portion 57a' still provides flexible bending in
and around the ball and toes of the foot of the wearer.
The material forming the first portion 57a' is
preferably formed of compressed paperboard and the
material forming the second portion 57b' is preferably
formed of a more densely compressed paperboard.
-12-
Also in the second embodiment of the
innersole 60, the first portion 57a is relatively
thinner than the second portion 57b', and the two
portions 57a', 57b' have adjoining inclined edges 57c',
57d' which are secured together in the arch portion 63'
of the innersole 60' or in an area forming a transition
between the ball portion 62' and the arch portion 63'.
The backing layer 57 is illustrated in Figures 16 and
17 as a single layer, but may also comprise composite
or multiple layers. As shown, the molded foam layer 70
and the backing layer 57 have substantially the same
overall configuration.
An intermediate lower layer 59, preferably
formed of a material such as PORON (a polyurethane
material) manufactured by Rogers Corporation of
Connecticut, having substantially the same overall
configuration as the backing layer 57 and the molded
foam layer 70 is preferably positioned between the
backing layer 57 and the molded foam layer 70 as best
illustrated in Figures 16 and 17. The intermediate
lower layer 59 provides additional backing as described
above in reference to the backing layer 57 and provides
additional overall thickness to the molded foam layer
70 of the innersole 60. The intermediate lower layer
59 may be cut and laminated to the compressed
paperboard, and the overlying molded foam layer 70 then
secured thereon. It will be apparent to those skilled
in the art that the molded foam layer 70 may be molded
so as to provide a thicker lower portion and a
similarly dimensioned upper portion and still generally
have the ball portion 72, heel portion 71, and raised
arch portion 73 as described above and thereby
eliminate the intermediate lower layer 59. Since the
intermediate lower layer 59 of the innersole 60 is
preferably included in the construction of the
innersole 60, an innersole 60" not having the
intermediate lower layer 59, i.e., only having the
CA 02167047 2003-08-07
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14
30. The raised arch portion 73 of the molded foam
layer preferably includes a hump 77 extending widthwise
from the instep of the innersole 60 to medial portions
of the raised arch portion 73. The hump 77 preferably
has a greater thickness along the instep, decreasing
thickness toward medial portions of the raised arch
portion 73 as illustrated, and substantially the same
contour as major portions of the arch of the foot of
the wearer. The raised arch portion 73 also preferably
includes a relatively flat plateau 78 adjacent
peripheries of the hump 77. The plateau 78 is raised
with respect to the ball portion 72 and major areas of
the heel portion 71 of the molded foam layer 70 of the
innersole 60 so that corresponding areas of the arch
portion 35 of the knit sock on the foot of a wearer
matingly interface therewith.
The ball portion 61 and major areas of the
heel portion 71 of the molded foam layer 70 of the
innersole 60 are relatively thin and of substantially
the same thickness. The plateau 78 of the raised arch
portion 73 of the molded foam layer 70 is preferably
about 0.32 cm (1/8th inch) thicker than either the ball
portion 72 or the major areas of the heel portion 71.
Preferably, the ball portion 72 and the major areas of
the heel portion 71 of the molded foam layer 70 each
have a thickness of about 0.16 cm (1/l6th inch), and
the plateau 78 of the arch portion 73 of the molded
foam layer 70 has a thickness of at least twice that of
either the ball portion 72 or the heel portion 71, such
as 0.48 cm (3/16 inch).
Additionally, the molded foam layer 70 of the
innersole 60 further preferably has a thickened outer
peripheral edge surrounding the major areas of the heel
portion 71 and defining a raised heel ridge 76 so as to
provide additional support for side heel areas of the
wearer thereby providing added comfort to the wearer.
The raised heel ridge 76 of the molded foam layer 70
AMENDED SHEET
-15-
preferably terminates at a lower height than the raised
arch portion 73 of the molded foam layer 70.
The raised arch portion 73 of the molded foam
layer 70 further preferably has a peripheral instep
edge defining an upstanding arch ridge 79, as best
illustrated in Figure 14, which uninterruptedly joins
the raised heel ridge 76. The upstanding arch ridge 79
extends higher than the raised heel ridge 76 for
enhancing support of the instep arch portion of the
wearer. The raised arch portion 73 of the molded foam
layer 70, as best shown in Figures 12-15, preferably
extends across the entire width of the innersole 60
from the arch ridge 79 toward the outstep of the
innersole 60. It will also be apparent that the raised
arch portion 73 of the molded foam layer 70 has a
general decreasing thickness in cross-section so as to
more closely conform to the incline of the arch portion
of the foot having the thinner fabric arch portion 35
of the knit sock 30 positioned thereon.
The raised arch portion 73 of the molded foam
layer 70 also has oppositely inclined fore and aft
portions 74, 75, of decreasing thickness for providing
a smooth transition with the thinner ball portion 72
and the major areas of the heel portion 71. The fore
and aft portions 74, 75 of the raised arch portion 73
are preferably substantially parallel in a transverse
direction for a more effective mating interfacing
relationship with the thinner fabric arch portion 35
and the respective thicker fabric ball and heel
portions 33, 34 of the knit sock 30. It will be
understood by those skilled in the art that angled
variations of the fore and aft portions 74, 75 in a
transverse direction may also be used.
Also, the innersole 60 of the present
invention may be secured to the outersole 80, or an
intermediate layer sole therebetween, or may be used as
an insert such as for an orthotic insert for other
16
shoes not having the innersole to provide the mating
interfacing relationship with the sock 30. If the
innersole 60 is used as an insert, it would preferably
have the backing layer configuration as shown in
Figures 12 and 16.
In an embodiment of the footwear system
wherein the innersole 60 is used as an insert, the shoe
50 preferably would be an extra-depth shoe adaptable
for receiving the innersole 60 as well as other types
of orthotic inserts when the innersole 60 is removed
therefrom. The extra-depth shoe has a sole and a shoe
upper 51. The sole as illustrated preferably includes
a multilayer innersole 60 and an outersole 80. The
extra-depth shoe preferably has an added depth of about
0.64 cm (1/4th inch) more than conventional shoes, and
the combined thickness of the multilayer innersole 60
has a thickness of about 0.64 cm (1/4th inch) in the
ball portion 72 and major areas of the heel portion 71.
For example, the conventional shoe may have a depth
adapted to receive the foot of a wearer of about 5.4 cm
(2-1/8th inches) from the upper surface of major areas
of the heel portion to slightly below the ankle in the
shoe upper, i.e., low-top shoe. An extra-depth shoe,
on the other hand, has a depth in this position of
about 6.04 cm (2-3/8ths inches) from the upper surface
of major areas of the heel portion to slightly below
the ankle in the shoe upper. It will be understood by
those skilled in the art that the dimensions of this
depth of the shoe, according to the present invention,
may vary depending on the style of shoe and the
thickness of the insert desired. The extra-depth shoe
embodiment of the footwear system preferably also
substantially conforms to the illustrated drawings, but
having the innersole 60 as illustrated being adaptable
for ease of insertion and removal from the shoe.
As set forth above, the innersole 60 as an
insert would preferably have the backing layer
M,~~NDED SHEET
-17-
configuration as shown in Figures 12 and 16. The shoe
50 would then preferably have a bifurcated intermediate
backing layer 57', as best shown in Figure 17,
overlying the outersole 80 on the inside of the shoe
50. The first portion 57a' of the intermediate backing
layer 57' extends substantially the length of the ball
portion 62', and the second portion 57b' extends
substantially the length of the arch portion 63' and
substantially the length of the heel portion 61'. The
second portion 57b' is formed of a stiffer material
than the first portion 57a' so that the stiffer second
portion 57b' reduces lateral and bending movement of
the heel and the arch of the wearer of the shoe 50, and
yet the first portion 57a' still provides flexible
bending in and around the ball and toes of the foot of
the wearer. The material forming the first portion
57a' is preferably formed of compressed paperboard and
the material forming the second portion 57b' is
preferably formed of a more densely compressed
paperboard. A lining layer 90 substantially the same
as the lining layer 90 as described with the innersole
60 overlies the intermediate backing layer 57' to
provide ease of removal and insertion of the innersole
60 insert as shown in Figures 12 and 16. It will be
understood by those skilled in the art that other types
of extra-depth shoes or other shoes as needed can also
be adaptable to receive the innersole 60 insert
according to the present invention.
The outersole 80 of the shoe 50 according to
the embodiments of the present invention, as best shown
in Figures 5 and 8, is formed of an integrally molded
foam material such as a Vibram° outersole manufactured
by Quabaug Corporation of North Brookfield,
Massachusetts. The outersole 80 preferably has a
roughened outer surface shown in the form of a
plurality of ribs 81 for providing increased frictional
contact with the ground or surface upon which the
~ .~ 6 '~ ~ 4 '~
wearer walks. The plurality of ribs 81 preferably
extend across the entire widthwise extent of the
outersole 80 and generally are parallel to each other
in a transverse direction. It also will be apparent to
those skilled in the art that the outersole 80,
although illustrated as a single molded foam layer in
Figures 8-9, may comprise various other types or
styles, including two composite layers 82" and 83" as
illustrated in Figure 18, more than two composite
layers, or a fabricated unit outersole which is
fabricated and not molded.
In the drawings and specification, there has
been disclosed typical preferred embodiments of the
invention and, although specific terms are employed,
they are used in a generic and descriptive sense only
and not for the purposes of limitation. The invention
has been described in considerable detail with specific
reference to various preferred embodiments. It will be
apparent, however, that various modifications and
changes can be made within the spirit and scope of the
invention as described in the foregoing specification
and defined in the appended claims.
