Note: Descriptions are shown in the official language in which they were submitted.
CA 02746876 2013-06-05
TECHNICAL FIELD
[0001] This disclosure relates to articles of footwear that provide
complementary
movement and/or proprioceptive feedback.
BACKGROUND
[0002] Generally, infant shoes include an upper portion and a sole. When
the
upper portion is secured to the sole, the upper portion along with the sole
define a void
that is configured to securely and comfortably receive and hold an infant's
foot. Often,
the upper portion and/or sole are/is formed from multiple layers that can be
stitched or
adhesively bonded together. For example, the upper portion can be made of a
combination of leather and fabric, or foam and fabric, and the sole can be
formed from at
least one layer of rubber. Often materials are chosen for functional reasons,
e.g., water-
resistance, durability, abrasion-resistance, and breathability, while shape,
texture, and
color are used to promote the aesthetic qualities of the infant shoe.
SUMMARY
[0003] The present disclosure provides an article of footwear that promotes
complimentary movement and/or proprioceptive feedback of an user's foot for a
range of
activities that may include walking, crawling, standing, turning, cruising
(e.g., walking
while holding onto a support object), climbing, etc. An infant relies on the
sensations felt
by his/her feet to learn to walk and an article of footwear that promotes,
rather than
masks, translation of the ground contours and contact forces helps the infant
learn to walk
while still providing a protective covering over the infant's foot. Therefore,
the article of
footwear needs to be flexible for bending with the foot and a forefoot portion
of the sole
needs to be thin enough to allow translation of ground contact forces. Besides
providing
a protective covering, the article of footwear may also provide a certain
degree of
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stability and agility to the infant's foot, such as ground contact
conformability, bending,
complimentary movement, and torsion control, so that the infant's foot is not
completely
free to twist.
[0004] Pre-school children (e.g., 2-6 years old) children generally need
shoes that
provide natural or complimentary movement of the feet, thus allowing them to
sense
(e.g., via proprioceptive feedback) the ground, ladders, bike pedals, etc.
under their feet,
and provide them with a high level of stability and agility for performing a
wide range of
activities.
[0005] Post pre-school children (e.g., over 6 years of age) and adults
can also
benefit from shoes that provide complimentary movement and allow
proprioceptive
feedback therethrough. Such shoes can aid post pre-school children in
activities that
include (but not limited to) playground activities, wall/rock climbing,
balancing, etc.
[0006] In one aspect, an article of footwear includes an outsole having a
forefoot
region, a heel region, and a mid region substantially in between the forefoot
and heel
regions. The forefoot region of the outsole includes a base portion
interconnecting
ground contact pads configured to move relative to one another. Each ground
contact pad
moves substantially independently of the other relative to the base portion.
[0007] Implementations of this aspect of the disclosure may include one
or more
of the following features. In some implementations, the article of footwear
includes a
flex portion at least partially circumscribing each ground contact pad and
attaching each
ground contact pad to the base portion. The flex portion may comprise an
elastic material,
such that the flex portion elastically deforms to allow movement of the
associated ground
contact pad. In some examples, the flex portion includes at least one groove
defined by
the base portion interconnecting the ground contact pads. The flex portion may
define
substantially corrugated or undulated shape, which is amenable to bending and
flexing
for allowing movement of the associated ground contact pad. In some
implementations,
the flex portion has a thickness less than a thickness of the ground contact
pad. Also, the
base portion may have a thickness less than at least one of the mid region and
the heel
region.
[0008] In some implementations, the mid region has a torsional stiffness
of
between about 15 degreesN*m and about 75 degrees/N*m. In some examples, the
mid
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region of the outsole includes a torsion control portion defining a
substantially cruciform
shape from a bottom view of the outsole. The torsion control portion may
comprise a
composite material or a combination of attached materials to provide a desired
torsional
resistance for the mid region of the outsole.
[0009] In another aspect, an article of footwear includes an outsole
having a
forefoot region, a heel region, and a mid region substantially in between the
forefoot and
heel regions. The outsole defines a sagittal axis, a front axis, and a
transverse axis. The
outsole is configured to allow bending of the forefoot region about at least
one of the
sagittal axis and the front axis, and substantially inhibit bending about the
transverse axis.
The mid region includes a torsion control portion defining a substantially
cruciform shape
from a bottom view of the outsole and having a torsional stiffness greater
than the
forefoot and heel regions.
[0010] Implementations of this aspect of the disclosure may include one
or more
of the following features. In some implementations, the mid region has a
torsional
stiffness of between about 15 degreesN*m and about 75 degrees/N*m. In some
examples, the forefoot region is allowed to bend about the sagittal axis to a
45 degree
angle when a force of between about 0.5 kg to about 3.5 kg is applied to an
intersection
of the forefoot region and the mid region (e.g., when the heel region is held
stationary).
The forefoot region is allowed to deflect less than about 5 mm about the
transverse axis
away from the front axis when a force of about 5 kg is applied to an
intersection of the
forefoot region and the mid region (e.g., when the heel region is held
stationary).
[0011] In some implementations, the forefoot region of the outsole
includes a
base portion interconnecting ground contact pads configured to move relative
to one
another, each ground contact pad moving substantially independently of the
other. The
article of footwear may include a flex portion at least partially
circumscribing each
ground contact pad and attaching each ground contact pad to the base portion.
The flex
portion may comprise an elastic material, such that the flex portion
elastically deforms to
allow movement of the associated ground contact pad. In some examples, the
flex
portion includes at least one groove defined by the base portion
interconnecting the
ground contact pads. An exemplary flex portion defines a substantially
corrugated shape.
The flex portion has a thickness less than a thickness of the ground contact
pad for
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providing a region of relatively greater flexibility and bend-ability so that
the ground
contact pads can move relative to one another. Also, the base portion has a
thickness less
than at least one of the mid region and the heel region
[0012] Implementations of the disclosure may include one or more of the
following features. In some implementations, the heel region of the outsole
includes an
outer heel member having an inner heel region, and an inner heel member
located in the
inner heel region. The inner heel member has a ground contacting surface and a
relatively lower durometer than the outer heel member. The inner heel member
is
positioned and dimensioned to fit under a user's heel during use of the
article of footwear.
The outer heel member has a durometer of between about 40 Shore A and about 70
Shore
A. The inner member has a durometer of between about 30 Shore A and about 60
Shore
A. In some examples, the heel region includes a heel cushion portion disposed
on the
inner heel member and having a durometer of between about 25 Asker C and about
55
Asker C.
[0013] In some implementations, the article of footwear includes an
insole
disposed on the outsole, for example, in the forefoot, mid, and heel regions.
The insole is
attached to the ground contact pads in the forefoot region while remaining
substantially
unattached to a base portion interconnecting the contact pads in the forefoot
region. By
attaching the insole to the ground contact pads and not the base portion
interconnecting
the ground contact pads, the ground contact pads are allowed to move relative
the base
portion to translate contours and forces to the user's foot.
[0014] In some implementations, a footbed includes a base and a plurality
of
pads. The base has a first side opposite a second side, the first and second
side each
extending from a forefoot region to a heel region. Each pad has a first
portion
substantially opposite a second portion, the first portion extending away from
the first
side of the base and the second portion extending away from the second side of
the base.
The second side of the base is positionable adjacent to an outsole of an
article of footwear
such that the first side of the base is adjacent a user's foot during use of
the article of
footwear. Each pad is movable substantially independently of the each of the
other pads,
relative to the base, in response to a force applied to the respective pad
during use of the
article of footwear. The plurality of pads can be interconnected by the base.
At least
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some the plurality of pads can be arranged on a triangular spherized grid or
hexagonal
spherized grid. The base can have a forefoot region with a sagittal dimension
greater
than the sagittal dimension of the heel region of the base.
[0015] In some aspects, the base defines a plurality of orifices
extending from the
first side of the base to the second side of the base, each of the plurality
of pads disposed
in a corresponding orifice and free to move within the orifice.
[0016] In certain aspects, the base has a substantially uniform thickness
of
between about 0.5 mm to about 6 mm from the forefoot region to the heel
region.
[0017] In some aspects, at least some of the plurality of pads are
disposed along
the forefoot region and at least some of the plurality of pads are disposed
along the heel
region, the pads at the heel region having a thickness greater than the pads
at the forefoot
region. In some examples, the first portion of each of the plurality of pads
extends away
from the first side of the base by a substantially uniform distance. In
certain examples,
the second portion of at least one of the pads extends away from the second
side of the
base by a distance greater than at least one of the other pads (e.g., between
about 0.5 mm
to about 2 mm greater than at least one of the other pads). The at least one
pad extending
away from the second side by a distance greater than at least one of the other
pads can be
disposed along the forefoot region, the heel region, and/or the midsole
region.
[0018] In certain aspects, the second portion of each pad at the forefoot
region
extends away from the second side of the base by a first distance and the
second portion
of each pad at the heel region extends away from the second side of the base
by a second
distance greater than the first distance. In some examples, the first distance
is between
about 0.5 mm and about 4 mm and the second distance is between about 5 mm and
about
15 mm.
[0019] In some aspects, at least some of the plurality of pads have a
substantially
elliptical shape and at least some of the plurality of pads are arranged in a
spherized grid
pattern.
[0020] In certain aspects, at least some of the plurality of pads are
disposed along
the base such that at least one of the pads contacts the ball of a user's foot
during use of
the article of footwear.
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[0021] In some aspects, the base and the plurality of pads are made of:
polyurethane foam and/or ethylene vinyl acetate. The base can have a durometer
of
between about 30 Asker C and about 70 Asker C.
[0022] In some implementations, an article of footwear includes an outsole
and a
footbed. The outsole has a forefoot region, a heel region, and a midsole
region
substantially between the forefoot region and the heel region. The footbed
includes a
plurality of pads and a base, the base having a first side opposite a second
side and a
plurality of pads. Each pad has a first portion substantially opposite a
second portion, the
first portion extending away from the first side of the base and the second
portion
extending away from the second side of the base. The second side of the base
is adjacent
the outsole such that the first side of the base is adjacent a user's foot
during use of the
article of footwear. Each pad is movable substantially independently of the
each of the
other pads, relative to the base, in response to a force applied to a portion
of the outsole
adjacent to the respective pad during use of the article of footwear. In some
examples, at
least a portion of the footbed can be fastened to the outsole such that the
footbed is
substantially fixed relative to the outsole. In certain examples, the footbed
is moveable
relative to the outsole such that the footbed is removable from the article of
footwear.
[0023] In some aspects, the forefoot region of the outsole includes a base
portion
interconnecting ground contact pads movable substantially independently of one
another
relative to the base portion. The ground contact pads are substantially
aligned with at
least some of the plurality of pads.
[0024] The details of one or more implementations of the disclosure are
set forth
in the accompanying drawings and the description below. Other aspects,
features, and
advantages will be apparent from the description and drawings, and from the
claims.
DESCRIPTION OF DRAWINGS
[0025] FIG 1 is a front perspective view of an article of footwear.
[0026] FIG 2 is a rear perspective view of an article of footwear.
[0027] FIG 3 is a top, front perspective view of an outsole for an article
of
footwear.
[0028] FIG 4 is a rear, bottom perspective view of the outsole shown in
FIG 3.
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[0029] FIG 5 is a front view of the outsole shown in FIG. 3.
[0030] FIG. 6 is a rear view of the outsole shown in FIG 3.
[0031] FIG 7 is a right (inner) side view of the outsole shown in FIG. 3.
[0032] FIG. 8 is a left (outer) side view of the outsole shown in FIG 3.
[0033] FIG 9 is a top view of the outsole shown in FIG 3.
[0034] FIG 10 is a bottom view of the outsole shown in FIG. 3.
[0035] FIG 11 is a side section view of the outsole shown in FIG 10 along
line
11-11.
[0036] FIG 12 is an end section view of the outsole shown in FIG 10 along
line
12-12.
[0037] FIG 13 is an end section view of the outsole shown in FIG 10 along
line
13-13.
[0038] FIG 14 is an end section view of the outsole shown in FIG 10 along
line
14-14.
[0039] FIG 15 is an end section view of the outsole shown in FIG. 10
along line
15-15.
[0040] FIG 16 is a top, front perspective view of an outsole for an
article of
footwear.
[0041] FIG 17 is a bottom, rear perspective view of the outsole shown in
FIG 16.
[0042] FIG 18 is a front view of the outsole shown in FIG 16.
[0043] FIG 19 is a rear view of the outsole shown in FIG. 16.
[0044] FIG 20 is a right (inner) side view of the outsole shown in FIG
16.
[0045] FIG 21 is a left (outer) side view of the outsole shown in FIG.
16.
[0046] FIG 22 is a top view of the outsole shown in FIG 16.
[0047] FIG 23 is a bottom view of the outsole shown in FIG. 16.
[0048] FIG 24 is a side section view of the outsole shown in FIG 23 along
line
24-24.
[0049] FIG. 25 is a side section view of the outsole shown in FIG 23
along line
25-25.
[0050] FIG. 26 is an end section view of the outsole shown in FIG 23
along line
26-26.
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[0051] FIG 27 is an end section view of the outsole shown in FIG 23 along
line
27-27.
[0052] FIG. 28 is an end section view of the outsole shown in FIG. 23
along line
28-28.
[0053] FIG 29 is a top view of a footbed for an article of footwear.
[0054] FIG 30 is a side section view of the footbed shown in FIG 29 along
line
30-30.
[0055] FIG 31 is an end section view of the footbed shown in FIG. 29
along line
31-31.
[0056] FIG 32 is an end section view of the footbed shown in FIG 29 along
line
32-32.
[0057] FIG 33 is an end section view of the footbed shown in FIG. 29
along line
33-33.
[0058] FIG. 34 is a top view of a footbed for an article of footwear.
[0059] FIG. 35 is a partially exploded side section view of the footbed
shown in
FIG. 34 along line 34-34.
[0060] Like reference symbols in the various drawings indicate like
elements. By
way of example only, all of the drawings are directed to a shoe suitable to be
worn on a
user's left foot. The invention includes also the mirror images of the
drawings, i.e. a shoe
suitable to be worn on the user's right foot.
DETAILED DESCRIPTION
[0061] Infants (e.g., babies) have substantially rounded feet, unlike
adolescents
and adults whom have relatively elongated feet with pronounced arch
development.
Infants generally experience relatively quick muscle growth and coordination
development. An infant learns to walk and develops a gait through coordination
development and receiving proprioceptive feedback from nerve endings in its
feet. The
most influential time for gait development is between about 9 and 24 months of
age. As
a result, an infant shoe configured to allow or promote complimentary movement
and
proprioceptive feedback while donned on an infant's foot will likely aid the
infant in
learning to walk, development of a natural gait, and reduce stubbles and
falls.
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Furthermore, an infant shoe configured to cradle an infant's foot and mimic
the infant
foot shape is advantageous, for movement, comfort, and fit.
[0062] Pre-school children (e.g., 2-6 years old) undergo significant foot
development ¨ bone formation, muscle and tendon development, etc - as well as
a
relatively large amount of activity development ¨ walking proficiency, as well
as
running, jumping, climbing, rolling, twisting, bike riding, etc. The feet of
pre-school
children generally need shoes that provide natural or complimentary movement
of the
feet, thus allowing them to sense (e.g., via proprioceptive feedback) the
ground, ladders,
bike pedals, etc. under their feet, and provide them with a high level of
stability and
agility for performing a wide range of activities.
[0063] Post pre-school children (e.g., over 6 years of age) and adults
can also
benefit from shoes that provide complimentary movement and allow
proprioceptive
feedback therethrough. Such shoes can aid post pre-school children in
activities that
include (but not limited to) playground activities, wall/rock climbing, etc.
Such shoes
can aid adults in activities that include (but not limited to) fishing on rock
jetties, walking
or fishing in lakes, rivers, ocean with rocky surfaces, etc.
[0064] The present disclosure describes articles of footwear that provide
a user
with proprioceptive feedback of the ground (via ground contract pads), multi-
directional
flexibility, enhanced matched foot ground contact, a complimentary foot bed
that allows
sensing of the ground contract pads and pressure distribution due to
conforming/molding
to the foot bed, and shaping of the articles of footwear to substantially
match the user's
feet.
[0065] FIGS. 1 and 2 illustrate an exemplary article of footwear 10. The
article
of footwear 10 can be configured to aid an infant in learning to walk (e.g.,
gait
development), crawl, turn, cruise, and other activities by allowing and/or
enhancing
complimentary movement and proprioceptive feedback of the infant's feet. The
article of
footwear 10 can also be configured for use by pre-school children (e.g., 2-6
years old),
post pre-school children (e.g., over 6 years of age) and adults, so as to
provide
complimentary movement and proprioceptive feedback which may benefit each age
group in different ways. The article of footwear 10 (e.g., shoe, sandal, boot,
etc.)
includes an outsole 100 attached to an upper 200. The outsole 100 and upper
200 can
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both be dimensioned for use by an infant (e.g., 0-4 years old), pre-school
children (e.g.,
2-6 years old), post pre-school children (e.g., over 6 years of age) and
adults. The upper
200 defines a void 205 configured to receive a user's foot. The upper 200 is
stitched to
the shoe outsole 100, in some implementations, providing a substantially
smooth
transition between the upper 200 and the outsole 100. Using stitches to secure
the upper
200 to the outsole 100, rather than cement, creates a smooth (e.g. non-bulky)
and supple
transition between the upper 200 and the outsole 100. In other
implementations, the
upper 200 is bonded (e.g., adhered) to the outsole 100. Soft, premium leathers
may be
used in the construction of the upper 200 to provide a flexible, soft,
comfortable fitting
infant article of footwear 10. Other materials may be used for the upper 200
as well
including textiles, non-woven materials, and any other suitable material. In
preferred
examples, the upper 200 includes moisture-wicking materials. The outsole 100
provides
stability and comfort while allowing for or promoting complimentary movement
and
proprioception. The rounded edges of the outsole 100 allow a user to roll the
shoe 10
over right and left lateral edge portions 102, 104, as well as toe and heel
edge portions
106, 108 without catching a sharp edge that may cause the user to trip and
fall.
[0066] FIGS. 3-15 illustrate one implementation of the outsole 100, 100A
and
FIGS. 16-28 illustrate another implementation of the outsole 100, 100B. The
outsole
100, 100A, 100B includes a forefoot region 110, 110A, 110B a mid region 120,
120A,
120B and a heel region 130, 130A, 130B as shown in FIGS. 3-8 and 16-21. The
forefoot
region 110, 110A, 110B of the outsole 100, 100A, 100B is very flexible,
pliable, and
compliant, allowing complimentary movement and tactile sensation of a
supporting
surface through the article of footwear 10. The ability to feel the supporting
surface
through the article of footwear 10 allows the user to receive proprioceptive
feedback of
the supporting surface through the outsole 100. The proprioceptive feedback
can be very
beneficial for infants and toddlers learning to use while learning to walk,
developing a
proper gait in walking, as well as in other activities such as crawling,
cruising, turning,
climbing, etc.
[0067] The outsole 100, 100A, 100B defines a sagittal axis 101, a front
axis 103,
and a transverse axis 105. The outsole 100 is configured to provide motion
control along
three axes of rotation. In particular, the outsole 100 allows bending about
the sagittal
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axis 101, substantially inhibits bending about the transverse axis 105, and
provides
torsional resistance about the front axis 103 (e.g., to prevent an inward
twisting motion of
a developing foot).
[0068] Torsion stiffness (also referred to as torsion flexibility) of the
article of
footwear 10 can be measured using a tensile tester connected via braided cable
to a
pulley/forefoot plate assembly rotating at 13.32 deg/s. Force and displacement
data is
collected as raw data by software at 20 Hz and converted to moment and angle
in
spreadsheet software. The heel region 130 is secured in place by rotating a
vertically
translating screw. For torsional stiffness testing, the cable rotates the
pulley applying a
frontal plane twisting moment to the article of footwear 10 through the
forefoot plate.
The forefoot region 110 of the article of footwear 10 is grounded to the
forefoot plate via
a horizontal clamping bar. The forefoot plate is angled in the sagittal plane
to
accommodate dorsiflexion in the toe rocker. For mounting shoes for testing, a
piece of
3/8 inch closed cell foam is inserted in the toe box past the toe break line
and another
piece of 3/8 inch closed cell foam is placed under the plunger of the of the
rear foot-
grounding device. The shoes are pre-marked on the lateral side to indicate the
forward
edge of the heel and lateral location of the toe break line at 25% and 75% of
the shoe
length, respectively. Each shoe is centered relative to the axis of rotation
of the forefoot
plate, as suggested in the standard developed by ASTM for running shoes (ASTM,
1994).
The heel region 130 and forefoot region 110 of the shoe 10 are grounded such
that the
posterior mark aligned with the front edge of the rear foot-grounding device
and the
forward mark is aligned with a fulcrum of applied force (e.g., the rear edge
of a forefoot
torsion plate in the torsional flexibility configuration or the lateral side
of the angled
clamping bar in the toe break flexibility configuration.) When measuring
torsional
flexibility, the gauge length of the tensile tester is set at zero at the
position where the
torsional testing platform is horizontal. The shoe is mounted in the heel
region 130 first
and the forefoot platform is angled in the sagittal plane to accommodate the
toe break
angle of the last. For each trial, the tensile tester is positioned at -5 mm
and the shoe is
pre-torqued in inversion manually with five pulses of 2.0 Nm, so as to pre-
positioned the
sample in an inverted position. The forefoot region 110 is rotated on the heel
region 130
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to approximately 50 degrees (e.g., an angle selected to represent the extreme
of forefoot
inversion in a toddler foot).
[0069] In some
implementations, the outsole 100 provides a torsional resistance
of at least 15 degrees/ N*m, and preferably a torsional resistance of between
about 15
degrees/ N*m and about 75 degrees/ N*m (e.g., about the front axis 103).
Tables 1 and 2
below provide exemplary torsion angles, minimum torsional resistance and
ranges of
torsional resistance for different user groups.
Torsion Flexibility For First-Walker
(Age: about 12-18 months, (e.g., Size 5 children's shoes))
Torsion angle Preferred Torsion level Range of
Torsion Level
(Degrees) ( /Nm) ( /Nm)
About 10 to about 15 About 55 About 30 to about 75
About 15 to about 20 About 50 About 28 to about 65
Table 1
Torsion Flexibility For Pre-School
(Age: about 4-6 years, (e.g., Size 12 children's shoes))
Torsion Angle Preferred Torsion level Range of
Torsion level
(Degrees) ( /Nm) ( /Nm)
About 10 to about 15 About 40 About 25 to about 60
About 15 to about 20 About 35 About 20 to about 55
Table 2
[0070] Toe-
break flexibility experiments can be performed using a tensile tester
connected by a cable to the mobile end of a hinged plate. Force readings are
taken
continuously over a range of 0 to 50 degrees of flexing with the tensile
tester operating at
a speed of 500 mm/minute. The rear of the flex location on the lateral side of
the shoe is
defined as the point (L) which is 60% of the entire shoe length from the rear
of the heel.
The rear of the flex location for the medial side corresponds to the point (M)
which
connects to the line drawn from the point L at an angle of 20 degrees from the
longitudinal axis of the shoe. The line LM defines the rear of the toe-break
flex zone.
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The shoe is position on the testing fixture such that line LM is positioned
over the
stationary end of the fixture ¨ rear of the shoe sits on the stationary
portion of the fixture,
while forefoot of the shoe sits on the hinged plate. The shoe is clamped onto
the
stationary portion of fixture 10 mm behind line LM.
[0071] Relatively greater flexibility of the article of footwear 10,
particularly the
outsole 100, about the sagittal axis 101 increases ground contact of the
outsole 100 for
increased stimulation (e.g., proprioceptive learning) as the user proceeds
forward over the
shoe 10. In some examples, the forefoot region 110, 110A, 110B includes one or
more
portions (e.g., a base portion 114 and a flex portion 116, as will be
described later) having
a thickness thinner than thicknesses of the mid and heel regions 120, 130 to
facilitate
flexibility and bending of the outsole 100, 100A, 100B and shoe 10 about the
sagittal axis
101. In some examples, when the outsole 100 is held stationary in the heel
region 130,
the forefoot region 110 is allowed to bend or deflect about the sagittal axis
101 to a 45
degree angle when a force of between about 0.5 kg to about 3.5 kg is applied
to an
intersection of the forefoot region 110 and the mid region 120. Table 3 and
table 4
provide exemplary flexibility values for different user groups.
Toe Break Flexibility For First-Walker
(Age 12-18 months, Size 5 children's shoes)
Flex Angle Preferred Flexibility Range Maximum Flexibility Limit
(Degrees) (kg) (kg)
450 About 1.0 to about 2.0 About 2.5
Table 3
Toe Break Flexibility For Pre-School
(Age 4-6 years, Size 12 children's shoes)
Flex Angle Preferred Flexibility Range Maximum Flexibility Limit
(Degrees) (kg) (kg)
450 About 1.0 to about 2.5 About 3.0
Table 4
[0072] The article of footwear 10 has a transverse stiffness that allows
the user to
bend the article of footwear 10 while moving, so as to provide proprioceptive
feedback.
When the shoe 10 is clamped at the intersection of the heel region 130 and the
mid region
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120, and a force of about 5 kg is applied to the intersection of the forefoot
region 110 and
the mid region 120, the level of deflection at the mid-forefoot intersection
is less than
about 5 mm ¨ in both lateral and medial directions. In other words, the
forefoot region
110 can deflect less than about 5 mm about the transverse axis 105 away from
the front
axis 103 when a force of about 5 kg is applied to an intersection of the
forefoot region
110 and the mid region 120.
[0073] Typical shoes include a relatively thick outsole and foot bed that
mask,
minimize, and/or unify ground contact forces and surface contours experienced
by the
user's foot. The outsole 100 is configured to allow the user to experience the
contours of
the supporting surface and localized forces across the outsole 100,
particularly in the
forefoot region 110 (e.g., to aid development of a proper gait and/or to feel
the ground
surface for balancing while performing some activity). Referring to FIGS. 10
and 23, the
forefoot region 110, 110A, 110B of the outsole 100, 100A, 100B includes one or
more
ground contact pads 112 configured to move with respect to one another or a
common
base portion to conform to the contours of a supporting surface. The ground
contact pads
112 translate forces incurred by the ground contact pads 112 to the user's
foot, thereby
allowing the user to experience relatively greater proprioceptive feedback
from his/her
foot. For example, the ground contact pads 112 allow the user to feel the
distributed and
localized forces across the foot, particularly in the forefoot region 110,
110A, 110B of the
outsole 100, 100A, 100B. The ground contact pads 112 are shown as generally
elliptical
in shape, but may be of any shape (e.g., circular, rectangular, polygonal,
star, etc.), and of
various sizes and thicknesses. Relatively larger ground contact pads 112 may
be
positioned under locations of a received foot that generally experience larger
impact
forces or contact frequency (e.g., under the ball of the foot), while
relatively smaller
ground contact pads 112 may be positioned under areas of the foot that
experience
relatively smaller impact forces or less contract frequency, therefore
providing localized
load points for sensory feedback of the foot.
[0074] Referring to FIGS. 9-11 and 22-24, the forefoot region 110, 110A,
110B of
the outsole 100, 100A, 100B includes a base portion 114 for the ground contact
pads 112.
The ground contact pads 112 are connected to the base portion 114 in a manner
that
allows each ground contact pad 112 to move relative to one another
substantially
14
CA 02746876 2011-07-20
independently, and in some examples, relative to the base portion 114. In
preferred
examples, the ground contact pads 112 can move in any direction (e.g., as the
forefoot
region 110 bends, twists, etc.) to translate localized forces and sensations
to the user's
foot. In some implementations, a flex portion 116 connects each ground contact
pad 112
to the base portion 114 and is configured to allow the ground contact pad 112
to move
relative to the base portion 114.
[0075] In some implementations, the proprioceptive feedback of the ground
surface to the user's foot is generally provided through the ground contact
pad pads 112,
the multi-directional flexibility of the outsole 100, enhanced matched foot
ground
contact, a complimentary foot bed 300 to allow sensing of the ground contact
pad pads
112, and shaping of the shoe 10 to better match the user's foot. The ground
contact pad
pads 112 function to provide proprioceptive feedback through the bottom
portion as well
as the top portion of the outsole 100. The shape of the ground contact pad
pads 112 can
vary in top and bottom, and do not have to be the same on top and bottom.
Furthermore,
the ground contact pad pads 112 do not necessarily have to fully align on the
top and
bottom of the outsole 100. The ground contact pad pads 112 can be made of
different
materials and different durometers. The ground contact pad pads 112 can also
be
integrated into a foot bed 300 of the shoe 10.
[0076] In some implementations, the forefoot region 110, 110A, 110B
comprises
multiple materials of different Young's modulii of elasticity and/or
durometers. In some
examples, the flex portion 116 comprises an elastic material having a Young's
modulus of
elasticity and/or durometer less than the other portions of the forefoot
region 110, 110A,
110B. As a result, the flex portion 116 elastically deforms relatively more
easily (e.g.,
under lower forces) than both the ground contact pad 112 and the base portion
114, thus
allowing the ground contact pad 112 to move relative to the base portion 114.
Similarly,
the ground contact pad 112 may have a Young's modulus of elasticity and/or
durometer
greater than the base portion 114 so that the ground contact pad 112 maintains
a
substantially uniform shape to transfer ground contact forces.
[0077] In the examples shown in FIGS. 9-14 and 22-27, the base portion
114 has
a thickness T1 less than a thickness T2 of the ground contact pads 112 and a
thickness T3
of the mid region 120 to provide greater flexibility in the forefoot region
110 as compared
CA 02746876 2011-07-20
to the mid region 120 and optionally the heel region 130. The flex portion 116
at least
partially circumscribes each ground contact pad 112 in the base portion 114.
In some
examples, the flex portion 116 has a thickness T4 less than the base portion
thickness Ti
and the ground contact pad thickness T2, allowing the flex portion 116 to bend
more
easily than the other portions of the forefoot region 110. In examples where
the flex
portion 116 comprises an elastic material, such as rubber, the relatively
thinner flex
portion 116 elastically deforms more easily than the other portions of the
forefoot region
110 for allowing ground contact pad movement.
[0078] Referring to FIGS. 11 and 24, in some implementations, the flex
portion
116 defines a substantially corrugated shape (e.g., having one or more
undulations) to
facilitate bending and flexing thereof and movement of the associated ground
contact pad
112. The undulation(s) of the flex portion 116 aid vertical movement of the
ground
contact pad 112 with respect to the base portion 114. In some examples, the
flex portion
comprises a groove or recess defined by the base portion 114.
[0079] In some examples, the heel region 130, 130A, 130B of the outsole
100
defines a heel cavity 133 for receiving a heel insert 160 to provide
additional cushioning
under the heel of the infant's foot. The heel insert 160 may comprise a
polyolefin, such
as an ethylene-vinyl-acetate copolymer (EVA) and have a durometer softer than
the heel
region 130, 130A, 130B of the outsole 100. In some implementations, the heel
insert 160
has a durometer of between about 25Asker C and about 55 Asker C.
[0080] The outsole 100 may include multiple materials of different
durometers.
In some examples, the forefoot region 110 has a durometer of between about 40
Shore A
and about 70 Shore A (preferably between about 47 Shore A and about 60 Shore
A), the
mid region 120 has a durometer of between about 40 Shore A and about 80 Shore
A
(preferably between about 45 Shore A and about 75 Shore A), and the heel
region 130 has
a durometer of between about 40 Shore A and about 70 Shore A (preferably
between
about 47 Shore A and about 60 Shore A).
[0081] Referring to the examples shown in FIGS. 10 and 23, the heel
region 130,
130A, 130B of the shoe outsole 100, 100A, 100B includes an outer heel member
132
having an inner heel region 134, and an inner heel member 136 located in the
inner heel
region 134. The inner member 136 has a ground contacting surface 137 and a
relatively
16
CA 02746876 2011-07-20
lower durometer than the outer heel member 132. The outer heel member 132 may
have
a durometer of between about 40 Shore A and about 70 Shore A (preferably
between
about 47 Shore A and about 60 Shore A). The inner member 136 may have a
durometer
of between about 30 Shore A and about 60 Shore A (preferably between about 40
Shore
A and about 55 Shore A). The inner heel member 136 is positioned and
dimensioned to
fit under a user's heel during use of the article of footwear 10. In the
examples shown,
the inner heel member 136 substantially defines a key shape. The relatively
softer
durometer of the inner heel member 136 (relative to the rest of the outsole
100) in
combination with the heel insert 160 provides cushioning for the infant's heel
while
walking.
[0082] Referring again to FIGS. 9, 11, 22, and 24, in some
implementations, the
outsole 100 includes a shank 150 disposed substantially in the mid region 120.
The
shank 150 may include a material, such as plastic, that provides torsional
resistance about
the front axis 103 and/or the transverse axis 105. In some examples, the shank
150 is a
sheet of thermoplastic polyurethane (TPU), glass filled nylon, rubber sheet,
foam sheet,
or combination thereof, and has a thickness of between about 0.5 mm and about
2 mm.
The torsional resistance provided by the shank 150 decreases twisting of a
user's foot
while learning to walk.
[0083] Referring again to FIGS. 10 and 23, the mid region 120, 120A, 120B
of
the shoe outsole 100, 100A, 100B may be configured to provide resistance to
torsion
about the front axis 103 and the transverse axis 105. In some implementations,
the mid
region 120 has a torsional stiffness of between about 15 degrees/N*m and about
75
degrees/N*m. The mid region 120, 120A, 120B may have a torsional stiffness
greater
than the forefoot region 110 and the heel region 130. The mid region 120 may
include
the outsole 110 and a torsion control portion 122 (e.g., reinforcing
material), which
together provide the desired torsional stiffness of the mid region 120. The
torsion control
portion 122 may comprise a material having a durometer of between about 45
Shore A
and about 75 Shore A. In some examples, the torsion control portion 122
defines a
substantially cruciform shape from a bottom view of the outsole 100, which
impedes
flexing of the outsole 100 about the sagittal axis 101 and the front axis 103,
while
substantially inhibiting flexing of the outsole 100 about the transverse axis
105. The
17
CA 02746876 2011-07-20
torsion control portion 122 may be configured to provide a torsion resistance
about the
front axis 103 of between about 15 degrees/N*m and about 75 degrees/N*m and/or
a
bending stiffness about the transverse axis 105 of about 5 in*lbs per 5 mm of
displacement. Different amounts of torsional resistance and bending stiffness
can be
achieved for the torsion control portion 122 by a combination (e.g., adhered
layers) or
composite of different materials.
[0084] In some examples, the article of footwear 10 has a transverse
stiffness
such that when the article of footwear 10 is clamped at the intersection of
the heel region
130 and the mid region 120 and a force of 5 kg is applied to the intersection
of the
forefoot region 110 and the mid region 120, the deflection at the intersection
of the
forefoot region 110 and the mid region 120 is less than about 5 mm ¨ in both
lateral and
medial directions.
[0085] The article of footwear 10 includes an optional insole 170
disposed on the
outsole 100, for example as shown in FIGS. 11 and 24. In some examples, the
insole 170
comprises a relatively thin (e.g., between about 0.5 mm and about 1.2 mm) non-
woven
material for allowing substantially direct transmission of forces between the
outsole 100
and the user's foot. The insole 170 may be adhered to the outsole 100. In the
base
portion 114 of the forefoot region 110, the insole 170 is attached only to the
ground
contact pads 112 (e.g., and not the base portion 114 interconnecting the
ground contact
pads 112), thereby allowing decoupled movement of the ground contact pads 112
from
the base portion 114. For example, if an adhesive is applied to the ground
contact pads
112 and also to the base portion 114 and to the flex portions 116, these
components of the
forefoot region 110 will move as a monolithic sheet, rather than with respect
to each
other. By attaching (e.g., via adhesive) only the ground contact pads 112 to
the insole
170 in the base portion 114, while attaching the insole 170 to the mid region
120, heel
region 130, and the remaining peripheral portion 111 of forefoot region 110
(e.g., such as
the portions surrounding the base portion 114), the flex portions 116 are
allowed to flex
(e.g., elastically deform) to allow movement of the ground contact pads 112.
[0086] The article of footwear 10 may include a footbed 300 disposed on
the shoe
outsole 100 (e.g., secured or freely stacked) and/or insole 170 in the void
205 defined by
the upper 200 and the outsole 100. The footbed 300 is compliant to conform to
and
18
CA 02746876 2011-07-20
exhibit the shape of the infant's foot bottom and portions of outsole 100. The
footbed
300 may be a foam sheet having thickness of between about 1 mm and about 8 mm
(preferably between about 2 mm and about 4 mm in the forefoot region 110 and
between
about 2 mm and about 6 mm in the heel region 130) with a woven or non-woven
fabric,
or leather covering the foam sheet. At least portions of the footbed 300 can
be relatively
thin (e.g., between about 2 mm and about 4 mm thick) and conformably to allow
transmission of motion of the ground contact pads 112 to a user's foot.
[0087] While certain embodiments have been described, other embodiments
are
possible.
[0088] As an example, while the footbed 300 has been described as a foam
sheet
other embodiments are possible. In some embodiments, referring to FIGS. 29-33,
a
footbed 302 includes pads 310a,b disposed along at least a portion of a base
304 having a
forefoot region 306, a heel region 308, and a midsole region 307 substantially
between
the forefoot region 306 and the heel region 308. The base 304 includes
interconnecting
portions 316 disposed between adjacent pads 310a,b. The interconnecting
portions 316
are flexible such that each pad 310a,b moves relative to the base 304,
substantially
independently of the other pads, in response to a force applied to the
respective pad
310a,b. For example, the pad 310a,b to which force is directly applied can
move in a
direction substantially normal to the base 304 by a distance greater than
about 20 percent
(e.g., greater than about 50 percent) of the distance moved by adjacent pads
that do not
receive the directly applied force.
[0089] During use, the footbed 302 is disposed on the shoe outsole 100
and/or
insole 170 in the void 205 defined by the upper 200 and the outsole 100 in a
manner
analogous to footbed 300 (see, e.g., FIGS. 11 and 24). At least some of the
pads 310a,b
align with the ground contact pads 112 on the outsole 100 such that force
(e.g., in a
direction substantially normal to the outsole 100) exerted on one or more
ground contact
pads 112 is transmitted to respective pads 310a,b aligned with the ground
contact pads
112 receiving the exerted force such that the pads 310a,b move substantially
independently of each other and of the base 304 to transmit force to a user's
foot. Such
transmission of force can improve the proprioceptive feedback to the user to
facilitate, for
example, effective traversal of uneven and/or slippery terrain (e.g., rocky
shorelines).
19
CA 02746876 2011-07-20
[0090] The base 304 has a first side 312 substantially opposite a second
side 314
such that, during use of the article of footwear, the first side 312 is
disposed toward a
user's foot and the second side 314 is disposed toward the shoe outsole 100.
The base
304 defines a sagittal axis 401 extending in a direction parallel to a width
dimension of
the base 304 and a front axis 403 extending in a direction parallel to a
length dimension
of the base 304, substantially perpendicular to the sagittal axis 401.
[0091] The forefoot region 306 and the heel region 308 each have
respective
maximum width dimensions parallel to the sagittal axis 401, with the maximum
width
dimension of the forefoot region 306 being greater than the maximum width
dimension
of the heel region 308. In some implementations, the larger maximum width
dimension
of the forefoot region 306 can create an interference fit and/or frictional
forces with one
or more surfaces of the outsole 100 and/or the upper 200 to facilitate holding
the base 304
in place relative to the outsole 100 and/or insole 170 while allowing, for
example, the
base 304 to be removable from the article of footwear 10 (e.g., for
replacement, repair,
drying, and/or cleaning). In some implementations, the base 304 is fastened to
the article
of footwear 10 such that the base 304 remains in substantially fixed relation
to the shoe
outsole 100 and/or insole 170. For example, adhesive can be applied between
the outsole
100 and/or insole 170 and at least a portion of the second side 314 of the
base 304.
Additionally or alternatively, at least a portion of the base 304 can be
fastened stitched to
the outsole 100, insole 170, and or upper 200.
[0092] The base 304 has a maximum thickness of between about 0.5 mm to
about
6 mm and is flexible about an axis parallel to the sagittal axis 401 during
use of the article
of footwear 10. In this thickness range, the base 304 has a durometer of
between about
30 Asker C and about 70 Asker C which can, for example, balance the tradeoff
between
durability of the article of footwear 10 and comfort for the user. Examples of
materials
that can be used to form a base having characteristics falling within these
thickness and
durometer ranges are polyurethane foam and ethylene vinyl acetate (EVA). In
some
implementations, the thickness of the base 304 is substantially uniform (e.g.,
varying by
less than about two percent) which can, for example, improve proprioceptive
feedback of
the footbed 302 by facilitating substantially uniform flexibility of the pads
310 disposed
along the base 304.
CA 02746876 2011-07-20
[0093] Each pad 310a,b is integrally formed with the base 304 such that,
as
described above, the interconnecting portions 316 of the base 304 extend
between the
pads 310. The interconnecting portions 316 flex to allow each pad 310a,b to
move
substantially independently of each of the other pads in response to a force
applied to the
pad 310a,b. The integral formation of the pads 310a,b and the base can allow
the footbed
302 to be formed through cost effective manufacturing processes including, for
example,
extrusion and/or molding.
[0094] Each pad 310a,b has a first portion 318 that extends away from the
first
side 312 of the base 304 and a second portion 320 that extends away from the
second side
314 of the base 304. Thus, during use, the first portion 318 of each pad
310a,b is oriented
toward a user's foot while the second portion 320 of each pad 310a,b is
oriented toward
the outsole 100 and/or insole 170. Force from the outsole 100 and/or insole
170 is
transmitted to the second portion 320 of the respective pad 310a,b
substantially aligned
with the portion (e.g., the ground contact pad 112) of the outsole 100 and/or
insole 170
receiving the force from the ground and transmitted to the user's foot via the
first portion
318 of the pad 310a,b. The surface area of the first portion 318 that comes
into contact
with the user's foot is approximately equal to the surface area of the second
portion 320
that comes into contact with the outsole 100 and/or insole 170 to allow the
pressure
transmitted by the outsole 100 and/or insole 170 to be approximately equal to
the
pressure exerted on the user's foot during use.
[0095] The respective first portions 318 of at least some of the pads
310a,b extend
away from the first side 312 of the base 304 by a substantially uniform
distance (e.g.,
about 1 mm) to facilitate contact with the user's foot for proprioceptive
feedback. As
discussed below, the first portions 318 of certain pads 310a,b extend away
from the first
side of the base 304 by a distance of about 0.5 mm to about 2 mm greater than
the first
portions 318 of other pads 310a,b. Such extension of the first portion 318 of
the pads in
certain areas of the footbed 302 can emphasize proprioceptive feedback to
portions of the
user's foot in contact with those extended first portions 318 during use of
the article of
footwear 10.
[0096] The respective second portions 320 of the pads 310a,b disposed
along the
forefoot region 306 extend away from the second side 314 of the base 304 by
between
21
CA 02746876 2011-07-20
about 0.5 mm and about 4 mm and the second portions 320 of the pads 310a,b
disposed
along the heel region 308 extend away from the second side 314 of the base 304
by
between about 0.5 mm and about 15 mm such that the overall thickness of the
footbed
302 in the heel region 308 is greater than the overall thickness of the
footbed 302 in the
forefoot region 306. Such varying thickness can, for example, facilitate
cushioning in
the heel region 308 while maintaining finer proprioceptive feedback in the
forefoot
region 306. The overall thickness of the pads 310a,b disposed along the
midsole region
307 can be between the thickness of the pads 310a,b disposed along the
forefoot region
306 and the heel region 308 such that the overall thickness of the footbed 302
is
substantially tapered from the heel region 308 to the forefoot region 306.
[0097] The pads 310a are arranged with centers substantially aligned on a
grid
(e.g., a hexagonal grid, a triangular grid, or other substantially regularly
repeating
pattern). The pads 310a can provide support to the user's foot while also
providing some
proprioceptive feedback to the user. The pads 310b are arranged along the base
304 to
contact specific portions of the user's foot (e.g., the medial ball of the
user's foot, the
lateral ball of the user's foot, and/or the heel of the user's foot) to
emphasize
proprioceptive feedback to those areas.
[0098] The pads 310a can be arranged on a "spherized" grid such that at
least
some of the pads 310a are wrapped around a three-dimensional sphere and mapped
onto
the two-dimensional grid. Arranging the pads 310a along a spherized grid can,
for
example, improve the proprioceptive feedback of the footbed 302 by improving
contact
between the pads 310a on the grid and the user's foot (e.g., the forefoot) as
the user's foot
flexes during use of the article of footwear 10. The pads 310a have a
substantially
elliptical (e.g., pill-like) shape as viewed from the top or bottom of the
footbed 304. The
substantially rounded edges of this shape reduces the likelihood of pressure
focal points
that could cause discomfort to the user's foot as force is transmitted through
the pad
310a. Additionally or alternatively, the pill-like shape of the pads 310a can
allow a large
number of pads 310 to be arranged within the area defined by the base 304.
Such a high
concentration of the pads 310a can improve the life of the footbed 302 by, for
example,
distributing the weight of the user more uniformly across the footbed 302.
This can
reduce packing out (e.g., permanent deformation) of the footbed 302.
22
CA 02746876 2011-07-20
[0099] The pads 310a can provide direct or indirect proprioceptive
feedback to
the user's foot. For example, at least some of the pads 310a can align with
corresponding
contact pads 112 on the outsole 100 to provide substantially direct
transmission of a
ground contact force to the user's foot. Additionally or alternatively, at
least some of the
pads 310a can align with portions of the outsole 100 that do not correspond to
the contact
pads 112 to provide substantially indirect transmission of a ground contact
force to the
user's foot.
[0100] At least some of the pads 310b have first portions 318 extending
away
from the first side 312 of the base 304 between about 0.25 mm and about 1.5 mm
proud
of the first portions 318 of the pads 310a. Pads 310b that extend proud of the
pads 310a
along the first side 312 of the base 304 can make first contact with the
user's foot in
response to a force, emphasizing proprioceptive feedback along that portion of
the user's
foot. The second portions 320 of at least some of the pads 310b extend away
from the
second side 314 of the base 304 between about 0.5 mm and about 2 mm proud of
the
second portions 310 of the pads 310a. The pads 310b that extend proud of the
pads 310a
along the second side 314 of the base 304 begin independent movement toward
the user's
foot before less-extensive pads 310a,b begin movement. This can also emphasize
proprioceptive feedback to the respective portion of the user's foot.
[0101] While the footbed 302 has been described as including the pads 310
integrally formed with the base 304, other embodiments are possible. In some
embodiments, referring to FIGS. 34-35, a footbed 340 includes pads 336
disposed along a
base 332. The base 332 has a forefoot region 338, a heel region 342, and a
midsole
region 340 substantially between the forefoot region 338 and the heel region
342 and
defines orifices 334 extending from a first side 344 to a second side 346 of
the base 332.
Each pad 336 is disposed in a corresponding orifice 334 and is substantially
free to move
within the orifice 334.
[0102] During use, the footbed 340 is disposed in an article of footwear
10 with
the first side 344 of the base 332 disposed toward a user's foot during use of
the article of
footwear 10 and the second side 346 of the base disposed toward the outsole
100 and/or
insole 170 (e.g., in a manner analogous to footbeds 300 and 302 described
above). Each
pad 336 moves substantially independently of each of the other pads 336 in
response to a
23
CA 02746876 2013-06-05
force applied to the pad 336 to provide proprioceptive feedback to the user of
the article
of footwear 10.
[0103] The base 332 has a substantially uniform thickness (e.g., about 2.0
mm),
and the pads 336 can have a thickness of between about 4 mm and about 16 mm.
The
pads 336 can be arranged such that the thickest pads 336 are disposed along
the heel
region 342 to provide cushioning. The thickness of the pads can decrease from
the heel
region 342 of the base 332 to the forefoot region 338 of the base 332 such
that the overall
thickness of the footbed 340 tapers down from the heel region 342 to the
forefoot region
338.
[0104] To reduce the likelihood of the pads 336 becoming dislodged from
the
orifices 334 during use of the article of footwear 10, sheets 348 and 350 can
be fastened
to either side of the base 332 and/or pads 336 to cover the respective sides
of the pads
336 and the base 332. For example, the sheets 348 and 350 can be fastened to
the pads
336 by cement can be applied to faces 352 and 354 of the pads 336.
Additionally or
alternatively, the sheets 348 and 350 stitch bound around the perimeter of the
base 332.
[0105] The sheets 348 and 350 can be formed of a stretchable material such
as a
polyurethane-polyurea copolymer (e.g., Lycra , available from INVISTA S.a r.l.
of
Wichita, KS). Such stretchable material can allow a degree of travel of the
pads 336
within the respective orifices 334 while retaining at least a portion of the
pads 336 within
the respective orifices 334.
[0106] The scope of the claims should not be limited by the preferred
embodiments
set forth in the examples, but should be given the broadest interpretation
consistent with
the description as a whole.
24
