US20150040436A1

US20150040436A1 - Article of footwear

Info

Publication number: US20150040436A1
Application number: US14/449,562
Authority: US
Inventors: Matthew R. Clerc; Kevin J. Crowley; James H. Cheney; Matthew D. Beck
Original assignee: Wolverine World Wide Inc
Current assignee: Wolverine Outdoors Inc
Priority date: 2013-08-09
Filing date: 2014-08-01
Publication date: 2015-02-12

Abstract

Footwear having an outsole including treads spaced about 3.0 mm to about 6.0 mm from one another so that a rocky terrain feature can fit between adjacent treads thereby providing traction through the outsole on the rocky terrain feature, each tread of a height of about 1.5 mm to about 2.5 mm so the tread engages the rocky terrain feature without substantially bending upon such engagement. The treads can include a tread edge defining a right angle to form a substantially non-radiused corner. The outsole can include preselected regions having different durometers, e.g., a harder durometer to assist the treads in holding firm against terrain features, and a softer durometer to add flexibility to the outsole. A footbed with zone pods and secondary pods can be secured to the upper in a Strobel construction, the zone pods and secondary pods interacting with the outsole to provide enhanced feedback to the wearer.

Description

BACKGROUND OF THE INVENTION

The present invention relates to footwear, and more particularly to footwear for use on rocky terrain or other surfaces in or near water bodies.
There is a variety of footwear designed for outdoor activities, particularly activities on or near bodies of water. Many such activities involve navigation over wet, slippery or slimy rocks or other surfaces, such as those present in streams, ponds, rivers, lakes, oceans and the like. This navigation can present difficulties, and in some cases, can result in inconvenience or injury where sufficient traction is not established by the footwear. Slips, falls, and resultant injuries typically are caused by a lack of good footing. Even if a person does not actually slip or fall, the need to carefully traverse a slippery surface can be inconvenient, can slow movement, and can be a distraction that interferes with a person's ability to be aware of their surroundings and to otherwise enjoy the activity.
The technical performance of footwear for such activities is largely dependent on the sole of the footwear. Some footwear manufacturers attempt to improve traction by simply adding cleats to the sole to provide the footwear with more bite. Many times, however, this causes the sole to become more rigid and less flexible, and in turn reduces or eliminates sensory feedback provided through the sole to the wearer's foot. This can present issues of perception, and while enhancing bite, can actually reduce the confidence of the wearer traversing the slippery surface.
Other footwear manufacturers have attempted to improve traction around water by creating a siping pattern in the sole. While this can enhance traction on flat, wet surfaces, such as a boat deck or a dock, it usually does not significantly enhance traction on slimy or uneven surfaces, such as rocks, reefs, or other surfaces covered with slimes, algae, mosses or other slippery materials. The siping can plug with the slippery materials, negating its traction enhancing effect. Further, siped soles are many times rather thin, and offer limited protection to jagged surface features.
Although there are many existing footwear for activities on or near bodies of water, most are designed for particular uses, and fall short of offering superior characteristics for traversing wet, slimy, slippery rocky terrain or other surfaces near or in those bodies of water.

SUMMARY OF THE INVENTION

An article of footwear and related sole assembly are provided that balance underfoot sensory feedback, foot agility, traction on wet, slippery and/or slimy surfaces and protection for the foot. The footwear includes multiple treads having novel configurations and structure. The sole assembly can include a multi-durometer monolithic molded, one-piece outsole with a harder durometer compound to assist treads in holding firmly against underfoot terrain, and a softer durometer compound to enhance the agility and flexibility of the sole assembly.
In one embodiment, the sole assembly can include an outsole having multiple treads spaced about 3.0 mm to about 6.0 mm from one another along a reference line parallel to a longitudinal axis of the outsole and/or direction of travel, so that a rocky terrain feature can fit between adjacent treads, thereby providing traction through the outsole on the terrain feature. This can provide stability to the wearer's foot on the rocky terrain feature, particularly where the rocky terrain feature is wet, slippery and/or slimy.
In another embodiment, the outsole treads can be of a height of about 1.5 mm to about 2.5 mm from an outsole base so that the tread sufficiently engages the rocky terrain feature without substantially bending or deforming upon such engagement.
In still another embodiment, the outsole treads can include a tread edge defining a right angle, which can form a substantially non-radiused corner. The tread edge and/or the configuration and spacing of the treads can assist in enhancing traction and helping a wearer in traversing rocky terrain, particularly when it is wet, slimy and/or slippery.
In even another embodiment, the outsole can include preselected regions having different durometers, for example, a harder durometer for the treads to assist the treads in holding firm against rocky terrain features, and a softer durometer to add flexibility to the outsole, allowing the footwear to conform to the rocky terrain feature. The first durometer can be about 70 Asker C to about 80 Asker C, and the second durometer can be about 55 Asker C to about 65 Asker C.
In yet another embodiment, the outsole can include different preselected regions having different durometers. The metatarsals region, phalanges region and part of the heel region of the outsole can be constructed from material with a harder durometer, while the arch region and a center of the heel region can be constructed from material with a softer durometer to provide flexibility and agility to the outsole and the footwear in those regions. Optionally, in the heel region, the harder durometer material can surround the softer durometer material to provide enhanced cushioning in the heel.
In yet another embodiment, the footwear can include a footbed with zone pods and secondary pods. The footbed can be secured to the upper to form a Strobel construction. The zone pods and secondary pods can interact with the outsole to provide enhanced sensory feedback to the wearer's foot.
The present invention provides footwear and a sole assembly having a balance of terrain sensory or proprioceptive feedback, foot agility and traction on wet, slippery and/or slimy rocky terrain features, while also providing a good level of protection to the foot. The footwear is well suited for activities involving navigation in and near bodies of water, as well as other activities. The outsole/treads can enable the outsole to bite into and generally grab the rocky terrain features so that it is less susceptible to slippage relative to the rocky terrain features, particularly where the rocky terrain features are wet, slippery and/or slimy. The footwear and sole assembly also can assist in cutting through rock debris, rocky terrain, and other ground surfaces similar to rocky terrain, as well as holding against various cracks, crevices and other features of rocky terrain. Further, the footwear can assist in providing the wearer with an understanding of the rocky terrain, for example, the size, shape and stability of rocks or other features.
These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.
Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a bottom view of the footwear including a sole assembly in accordance with a current embodiment;

FIG. 2 is a section view of the footwear taken along line 2-2 of FIG. 1;

FIG. 3 is a side view of the sole assembly of the footwear;

FIG. 4 is a front view of the sole assembly of the footwear;

FIG. 5 is a section view of the footwear taken along line 5-5 of FIG. 1;

FIG. 6 is a section view of the footwear taken along line 6-6 of FIG. 1;

FIG. 7 is a section view of the footwear taken along line 7-7 of FIG. 2;

FIG. 8 is a perspective, close-up view of treads on the sole assembly;

FIG. 9 is a side close-up view of the treads engaging a rocky terrain feature;

FIG. 9A is a close-up view of a tread edge;

FIG. 10 is a top view of a footbed included in the footwear;

FIG. 11 is a section view of the footbed taken along line 11-11 of FIG. 10;

FIG. 12 is a section view of the footbed taken along line 12-12 of FIG. 10;

FIG. 13 is a bottom view of a first alternative embodiment of the footwear;

FIG. 14 is a section view of the footwear taken along line 14-14 of FIG. 13;

FIG. 15 is a side view of the sole assembly of the footwear; and

FIG. 16 is a close-up perspective view of treads of the sole assembly of the first alternative embodiment.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

An article of footwear in accordance with a current embodiment is shown in FIGS. 1-12 and generally designated 10. The footwear 10 includes a sole assembly 20 having an outsole 40. The footwear includes an upper assembly 12 that is optionally of a Strobel construction in which a foot-receiving upper 14 is closed on its bottom or lowermost portion by a footbed 60 or other similar component. Although not shown, the footwear 10 can include other upper components with the footbed fitted into the upper 14.
As illustrated in FIGS. 1, 2, and 5-10, the footwear 10, and in particular the outsole 40, can include treads 50 spaced about 3.0 mm to about 6.0 mm from one another so that a rocky terrain feature RF can fit between adjacent treads 50A, 50B thereby providing traction through the outsole on the rocky terrain feature RF. Each tread can be of a height H of about 1.5 mm to about 2.5 mm so the tread engages the rocky terrain feature RF without substantially bending, deforming or otherwise giving way so the tread disengages the tread feature upon such engagement. The treads 50 can include a tread edge 50E defining an angle α, which can be a right angle to form a substantially non-radiused corner. The outsole 40 can include preselected regions having different durometers. For example, first regions 70A-70I can have a harder durometer to assist the treads in holding firm against rocky terrain features. Second regions 80A-80B, optionally located around or between the first regions, and/or within the arch region, can have a softer durometer to provide flexibility and agility to the outsole 40. The footwear 10 also can include a footbed 60 having zone pods 60A-60H, optionally aligned with the preselected regions on the outsole, and secondary pods 66 that are independently moveable. The zone pods and secondary pods can interact with the outsole to provide enhanced feedback to the wearer's foot WF. The footbed 60 can be secured to the upper 14 to form a Strobel construction.
Although the current embodiments are illustrated in the context of a water or outdoor shoe, they may be incorporated into any type or style of footwear, including performance shoes, running shoes, athletic shoes, hiking shoes, trail shoes and boots, hiking boots, all-terrain shoes, barefoot running shoes, sneakers, conventional tennis shoes, walking shoes, multisport footwear, casual shoes, dress shoes or any other type of footwear or footwear components. Generally, the shoe is well suited for traversing rocky terrain features or other surfaces in or around bodies of water. For example, the shoe can be used in to navigate wet, slippery and/or slimy rock surfaces, for example, those in rocky streams, ponds, lakes, oceans or other water bodies. As used herein, rocky terrain feature(s) includes, but is not limited to, features of rocks or other hard surfaces that are generally rough, jagged, pointy, uneven, irregular, creviced, cracked, loose and/or unstable, and in some cases can include man-made surfaces, such as those constructed from concrete, wood or other materials. In many cases, rocky terrain features can include jagged points, sharp edges or crevices, for which the shoe is well suited to grip and firmly hold to provide traction, as well as protect the wearer's foot from such features. The shoe also is well suited to provide such properties where the rocky terrain feature is wet, slimy or slippery, due to the feature being wet, covered with algae, slime, moss, mud, or other slippery substance.
It also should be noted that directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. Further, the terms “medial,” “lateral” and “longitudinal” are used in the manner commonly used in connection with footwear. For example, when used in referring to a side of the shoe, the term “medial” refers to the inward side (that is, the side facing the other shoe) and “lateral” refers to the outward side. When used in referring to a direction, the term “longitudinal direction” refers to a direction generally extending along the length of the shoe between toe and heel, and the term “lateral direction” refers to a direction generally extending across the width of the shoe between the medial and lateral sides of the shoe. The use of directional terms should not be interpreted to limit the invention to any specific orientation.
Further, as used herein, the term “arch region” (or arch or midfoot) refers generally to the portion of the footwear or sole assembly corresponding to the arch or midfoot of the wearer's foot; the term “metatarsals region” (or part) refers generally to the portion of the footwear partly within and/or forward of the arch region corresponding to the metatarsals (for example, including the ball and metatarsal head) of a wearer's foot; the term “phalanges region” (or part) refers generally to the portion of the footwear forward of the metatarsals region corresponding to the phalanges (for example, including the toes) of a wearer's foot; and the term “heel region” (or heel) refers generally to that portion of the footwear rearward of the arch region corresponding to the heel of the wearer's foot. The phalanges region 91, metatarsals region 92, arch or midfoot 93 and heel 94 are generally identified in FIG. 3, however, it is to be understood that delineation of these regions may vary depending upon the configuration of the sole assembly and footwear.
The upper assembly 12 of the illustrated embodiment includes an upper 14 formed from one or more layers of material that are shaped to form an enclosure or void 13 of roughly the size and shape of a wearer's foot WF. The upper 14 may include quarters that form the sides and a vamp that closes the top. Foxing and other trim or extra material may be added to the upper 14 as desired for functional or aesthetic reasons. Optionally, the upper 14 can include a tongue and a closure system (not shown) to facilitate fitting and removal of the shoe 10 on a wearer's foot. The upper 14 can include a heel counter (not shown) configured to provide control and stability to the wearer's heel. For example, the upper 14 may include a rigid or semi-rigid insert (not shown) that forms a sidewall in the heel region to seat the wearer's heel. In some embodiments, the heel counter may be eliminated from the upper.
The embodiments herein are described in connection with footwear 10 in the form of a shoe 10 having an upper assembly 12, which as mentioned above, can include a Strobel construction. For example, the upper 14 can include a lower peripheral allowance or edge 16. That lower peripheral allowance 16 can be stitched with stitching 18, cemented or otherwise fastened to the footbed 60 around the perimeter of the footbed. In such a Strobel construction, the footbed 60 closes the upper so that the void 13 within the upper is bounded by a closed bottom formed by the footbed 60. Of course, the sole assembly 20 herein can be combined with any other type or style of upper construction capable of being suitably joined with the outsole 40. The joining of the sole assembly/outsole and the upper can be accomplished using adhesives, cement, injection molding, pour molding or any other technique used to join an upper and sole.
As noted above, the sole assembly 20 of shoe 10 generally can include the footbed 60 and outsole 40. Optionally, the sole assembly 20 can include a midsole 95, shown in FIG. 3, which can be located generally starting in the arch region 93, extending under the heel region 94. The midsole can be disposed between the footbed 60 and the outsole 40, and more particularly between the lower surface 62 of the footbed 60 and the upper surface 41 of the outsole 40. The midsole can be constructed from ethyl vinyl acetate (EVA), polyurethane (PU), latex, foam, a gel or other materials. Generally the density of the midsole is such that it compresses relatively easily to provide cushion to the wearer's foot, for example, the heel. The midsole can be of a low profile or depth D″ under the heel, for example, optionally about 0 mm to about 12 mm, further optionally about 4 mm to about 8 mm, and even further optionally about 6 mm. Of course, if desired, the midsole can be eliminated from the footwear if desired.
The sole assembly 20 can be constructed so that the footbed 60 interacts with the outsole 40 to provide proprioceptive or sensory feedback to the wearer of underfoot surfaces, such as rocky terrain features. The sole assembly also can allow the wearer to experience the contours of the supporting surface and localized forces across the outsole; to aid in understanding the size, shape, and stability of the rocky terrain features. As shown in FIGS. 2 and 10-12, the footbed 60 can include a footbed base 63 having a first or upper surface 61 adapted to face the wearer's foot and a second or lower surface 62 opposite the first surface facing toward the outsole 20. The footbed can be compliant to confirm to the shape and contours of the wearer's foot. The footbed also can be bounded by perimeter 69, generally of a shape corresponding to a wearer's foot. Optionally, the size, shape, features and configurations of the footbed 60 can vary from application to application.
The footbed 60 can be constructed from a sheet of material, such as foam, EVA, PU, latex, gel or other materials, and can have a thickness of optionally about 1 mm to about 8 mm, further optionally about 2 mm to about 4 mm, and even further optionally about 2 mm and about 6 mm. These thicknesses can vary by region as well. Depending on the application, the thickness can be about 2 mm to about 4 mm in the phalanges and metatarsals region, and about 2 mm to about 6 mm in the heel region. The footbed can be covered with a woven or non-woven fabric, leather, or other material. The footbed and any optional covering can be treated with an antimicrobial or other compound to reduce odor and/or deterioration of the footbed. Optionally, the footbed can include the features of and be of a similar construction to that disclosed in U.S. Pat. No. 8,333,022 to Crowley, which is hereby incorporated by reference in its entirety.
With further reference to FIGS. 10, 11 and 12, the footbed 60 can include one or more zone pods 60A-60H and/or secondary pods 65 extending from a base 64. The zone pods and/or secondary pods can extend from one or both of the upper surface 61 and lower surface 62 of the footbed 60. The secondary pods 65 can extend upward from the base 64 a distance to form an upwardly projecting pod part 65A. The secondary pods 65 can extend downward from the base 64 a distance to form a downwardly projecting pod part 65B. These secondary pods can project any predetermined distances, but optionally can extend upwardly about 0 mm to about 4 mm, and downwardly about 0 mm to about 15 mm. As shown, the secondary pods upwardly extending part 65A can extend a lesser distance than the downwardly extending lower pod part 65B from the base 64. This of course can be reversed in certain circumstances, or the degree of extension can be equal from the base. The thickness of the individual secondary pods 65 also can vary depending on the region within which they are located to enhance sensory feedback, for example, proprioceptive feedback in the phalanges region and/or the metatarsals region, or any other region.
Optionally, the secondary pods 65 in the heel region 94 can be thicker as shown in FIG. 11 than the secondary pods in the phalanges 91 and metatarsals regions 92. The secondary pods in the arch region can be of a thickness between that of the heel region 94 and the metatarsals 92 and/or phalanges 91 regions if desired. Further optionally, the overall thickness of the footbed 60 can be tapered, decreasing in overall thickness from the heel region 94 to the phalanges region 91.
Generally, the variance in thickness of the secondary pods and the variance in the overall thickness of the footbed, can assist in the proprioceptive feedback to the bottom of the wearer's foot. The secondary pods also can interact with the anatomical design and the contours of the upper surfaces 41, 96 of the outsole and/or midsole to move more like a bare foot of the wearer, providing more barefoot-like contact with the ground or underlying rocky terrain features.
Optionally, the secondary pods 65 can have a substantially elliptical shape when viewed from the top or bottom of the footbed 60. This shape can be replaced with other shapes, for example polygonal, circular, rounded, irregular or other shapes as desired for a particular application.
Generally, the base 64, zone pods and individual secondary pods can be formed as a one-piece monolithic structure with the material from which the structure is constructed being generally homogenous throughout the footbed 60, except for optional differences in density and/or durometers as explained herein. Further, the base 64 can have a substantially uniform thickness, for example optionally about 1 mm, 2 mm, 3 mm, 4 mm; and the secondary pods 65 can have a thickness as noted above or optionally about 4 mm to about 16 mm. The individual pods 65 can move independently and separately from adjacent secondary pods 65. This can be due to the thinner or more flexible base 64 connecting the adjacent secondary pods, flexing or moving, allowing the individual pods 65 to move independently of one another. This relationship between the base and secondary pods, and/or zone pods in general, can provide sensory feedback where forces are transmitted through the outsole to one or more individual secondary pods or zone pods, which in turn can provide the wearer with an understanding of the underfoot surfaces, for example. With this feedback, the wearer can understand the size, shape and stability of the rocky terrain feature being traversed.
Optionally, the thickness of the sole assembly 20 under the wearer's foot, and generally the footwear, under the wearer's foot, can be minimized to enhance the quality of the proprioceptive feedback. For example, the total thickness of material under the wearer's foot in the footwear 10 can range optionally from about 4 mm to about 18 mm, optionally about 6 mm to about 16 mm, even further optionally about 9 mm to about 15 mm.
As shown in FIGS. 10-12, one or more of the secondary pods 65 can include a lower pod surface 67. These surfaces can generally lie within one or more continuous planes or other contours. Generally, these planes or contour can match that of the upper surface 41 of the outsole and/or the upper surface 96 of the midsole 95 if one is included. The upper surface 41 of the outsole and the upper surface 96 of the midsole can be substantially continuous, without voids, recesses, gaps or other apertures therein into which the secondary pods interfit. Of course if desired, such features can be included in these surfaces.
As shown in FIG. 10, the footbed also can include one or more zone pods 60A-60H. These zone pods can extend from the base 64 and can more independently of one another, similar to the secondary pods. Optionally, in the outlined regions surrounding the individual pods for example pods 60D, 60C, 60E-H, the base can be relatively thin in those areas. Each of the zone pods 60A-60H can be outlined as illustrated in FIG. 10. The zone pods 60A-60H can be configured to be positioned in different regions 91-94 of the footbed, optionally overlapping certain regions. For example, the zone pod 60A can be located in both the heel region 94 and the arch region 93. Optionally, zone pods 60A can extend substantially only within the lateral portion of the footwear, without extending in or through the medial portion.
As shown in FIG. 10, the footwear includes a longitudinal axis LA. The medial portion M of the footwear 10 is located on one side of the longitudinal axis LA and the lateral portion L is located on the opposite side of the longitudinal axis LA. The zone pod 60A can extend substantially only in the lateral portion L of the footwear but not in the medial portion M of the footwear. The zone pod 60A also can extend into the metatarsals region in the medial portion M. Another zone pod 60B can extend under the medial portion M generally in the metatarsals region. Zone pod 60C can be located in the medial portion M generally in the phalanges region 91 Likewise, the zone pod 60D can also extend in the phalanges region 91, but in the lateral portion L. The additional zone pods 60E-60H can be located in the phalanges region 91 in one or both lateral L and medial M portions as well, if desired. Optionally, the different zone pods can be separated into different regions or locations other than those illustrated in FIG. 10.
As shown in FIG. 10, the zone pods 60A-60H can align generally vertically (one above the other) with the underlying preselected regions 70A-70H of the outsole 40. This alignment of the zone pods and the specific regions of the outsole can be one-on-one so that forces from an underlying surface, for example a rocky terrain feature, can be transferred through the regions to the respective aligned zone pods (as well as the secondary pods if present). In this manner, a wearer can be provided with proprioceptive feedback regarding the rocky terrain feature through the wearer's foot, from the outsole or generally the sole assembly. In turn, the wearer can better understand the rocky terrain feature. As part of the feedback, the individual secondary pods, zone pods and/or preselected regions can move independently, and yet further enhance the wearer's sense of the rocky terrain feature.
As mentioned above, the sole assembly 20 can include the footbed 60 and the outsole 40. The outsole 40 is generally disposed below the upper 14, the midsole (if included) and the footbed 60. The outsole can include a toe cap 44 that extends upwardly over the upper 14 in the phalanges region 91 of the footwear to provide enhanced protection to the toes. This can be helpful where traversing rocky terrain features.
The outsole 20 can be constructed from one or more materials, for example, natural or synthetic rubber, thermoplastic polyurethane elastomers (TPU), nylon, polymer blends, wear resistant polymers, elastomers and/or other materials. Other materials, such as fiber-reinforced polymers can be used, which can include epoxy, polyethylene or thermosetting plastic reinforced with carbon, glass and/or aramid fibers for enhanced protection.
As shown in FIG. 1, the outsole can include multiple treads 50 as described further below. The outsole also can include one or more flex contours 49A and 49B. These flex contours can be disposed under the ball of the foot, optionally overlapping the metatarsals region 92 and/or the phalanges region 91. Although only two flex contours 49A and 49B are shown, additional ones can be included. The flex regions can be in the form of a recess or groove that extends across the width of the footwear generally across the medial portion M and the lateral portion L, traversing the longitudinal axis LA. Although the flex contours 49A and 49B are shown as recesses or grooves to enhance the flexibility between the respective parts of the outsole 40, these grooves can be removed. Alternatively, the flexibility between these outsole parts can be enhanced via a softer durometer material in the second preselected region 80A being located between the sets of pods 70C, 70D and 70E-70I. Each of the flex contours 49A and 49B can be rearwardly concave or curved as shown, with the apex of the curve at or near the longitudinal axis LA being closer to the toe than the respective ends of the contours adjacent the lateral and medial sides of the footwear. Although shown as a curve, the contours can also be linear and generally angled.
As illustrated in FIGS. 1 and 5-7, the outsole can include multiple first regions 70A-70I, and second regions 80A and 80B. These regions can have different durometers. The particular shape of the first preselected region 70A-70I can vary from those illustrated. Generally, the outsole can be constructed from a monolithic molded, one-piece structure of the same or different materials. In one example, the material can be a rubber compound, having a first durometer in a first preselected region and a second durometer a second preselected region. The first durometer can be greater than the second durometer. Optionally, however, the one-piece structure can be constructed from multiple different materials such as rubber and polymers, that are co-molded so that they integrally bond with one another to form that monolithic construction. The method of manufacture can be any type of molding, for example injection molding, pour molding, two-shot molding, gas injection molding or the like.
With reference to FIG. 1, a first preselected region can be region 70A located in the heel region 94 and extending into the arch region 93 and/or metatarsals region 92. This outlined preselected first region 70A, can be of a first durometer. The first durometer can be greater than the durometer of the material in the second region 80B and/or 80A. This is further illustrated in FIG. 5, where the material in the first preselected region 70A is of a first durometer and the material in the second preselected region 80A is of a second durometer.
It has been discovered that with a mixture of different durometer materials in the first preselected regions and the second preselected regions, the sole assembly provides exceptional flexibility and agility, while still providing excellent traction on rocky terrain features, particularly those that are wet, slippery and/or slimy. Particular durometers work surprisingly well. For example, the first durometer in the first preselected regions can be about 70 Asker C to about 80 Asker C. The second durometer in the second preselected regions can be about 55 Asker C to about 65 Asker C. Again, the first preselected regions can be those regions 70A-70I, and the second preselected regions can be 80A and 80B. Other regions with these or other durometers are contemplated
Generally, the region 80A is a majority of the remaining portion of the footwear outsole 40 “outside” the regions 70A-70I. The softer, lesser durometer material in the region 80A can extend underfoot, through regions 91-94, and optionally can extend upwardly, forming the sides of the outsole. This second, lower durometer material can form the part of the outsole that extends upwardly along one or more portions of the upper, for example, up and over a portion of the toes, forming the toe bumper 44, and/or along the medial and lateral and heelward sides of the upper as shown in FIGS. 2 and 5-7. With the softer durometer material in these locations, the footwear can exhibit surprising flexibility and agility, thereby allowing the sole assembly 20 to flex and contort, further following the contours of an underlying rocky terrain feature. Generally, the sole assembly provides a better proprioceptive feedback to the wearer, allowing the wearer to better understand and navigate the rocky terrain feature.
FIGS. 6 and 7 show further examples of different durometers in different regions of the outsole 20. There, the first preselected region 70A occupies only a portion of the width of the sole 40. Optionally, this higher durometer material and region 70A can be located substantially only in the lateral portion L of the outsole 40, with the medial portion M across that cross section being substantially only the lower durometer material in the second region 80A. The second region 80A also can laterally flank the first preselected region 70A on the outermost part of the lateral portion L of the outsole 40. Optionally, the second preselected region 80A with the lower durometer material can be located across a majority of the width of the sole 40 through the arch region and all or a portion of the metatarsals region. This can provide enhanced agility and flexibility of the forefoot relative to the heel of the sole assembly 20, thereby in some cases, enhancing the ability of the footwear to conform to the contours of an underlying rocky terrain feature.
As shown in FIGS. 5 and 6, it is also noted that the different durometer material can overlap parts of individual treads 50. For example, each individual tread can be constructed of either the first durometer material or the second durometer material. Alternatively, portions of the treads can be overlapped by and include both the first durometer material and the second durometer material. Optionally, the treads 50 located in the first preselected regions 70A-70I can be constructed substantially entirely from the first durometer material. With the first durometer material being harder than the second durometer material, that tread can hold firmly against a rocky terrain feature. Generally, the tread can be resistant to bending or undue flexing, which can lose traction between the tread and/or the outsole and the respective underlying rocky terrain feature.
The first preselected regions 70A-70I can correspond to the portions of the wearer's foot that transmit a substantial portion of forces to the underlying surface upon which the sole assembly is located during a normal gait. For example, significant forces are transmitted through the ball of the foot and the toes in certain parts of the gait cycle. Therefore, the harder durometer material can be located in the preselected regions 70B, 70C and 70D, as well as the regions 70E-70I upon toe-off. Typically, because significant forces are not transmitted through the arch region, the amount of harder durometer material through the arch region can be limited to that of the preselected region 70A on only the lateral portion L of the outsole 40. The inside, medial portion in the arch region can be void of the higher durometer material and thus provide greater flexibility via the softer durometer material in the second preselected region 80A there.
With reference to FIG. 7, the preselected regions 70A and 70B can include the greater durometer material, while the surrounding preselected regions 80A can include the softer durometer material. With the higher durometer material separated by a softer durometer material 80A across the longitudinal axis and/or along the longitudinal axis LA, the respective preselected regions 70A and 70B on the respective lateral portion L and medial portion M can flex relative to one another on opposite sides of the longitudinal axis. Therefore, the footwear can exhibit flexibility across this axis, enabling the lateral portion L to flex independently of the medial portion M, and vice versa. Optionally, this division of the respective portions and preselected regions can be primarily in the forefoot, that is, in the metatarsals and phalanges regions, where there are multiple metatarsals in the wearer's foot that can move independently.
In the heel region, however, the different durometer materials might not be separated and isolated independently on the lateral portion L and in the medial portion M. The heel region can include a particular combination of different durometer materials. For example, the first preselected region 70A of the harder durometer material can completely surround the second preselected region 80B of the softer durometer material in the heel. If the first region 70A hypothetically defined an aperture under the wearer's heel, the second preselected region 80B would fill that aperture. But because the outsole 40 is constructed from a one-piece monolithic molded structure, there technically is not an aperture through the first preselected region 70A. Of course, there can be such a hole or a recess if desired. The region 70 A simply circumferentiates or surrounds the second preselected region 80B. In a different construction, the first preselected region, with the greater durometer 70A, does not completely circumferentiate the second preselected region 80B in the heel. Instead, there can be an opening so that second regions 80A and 80B are connected and contiguous. If desired the entire second preselected region 80B can be absent from the construction, with the first preselected region 70A spanning throughout the heel region under the wearer's heel. Generally, the softer durometer material in the second preselected regions 80A, 80B and the harder durometer material in the respective regions 70C, 70D and 70E-70I, those regions 70C, 70D and 70E-70I can flex relative to one another through the softer durometer material. This can provide a more natural feel and articulation of the wearer's foot. The first preselected regions 70A-70I can correspond to the portion of the outsole that contacts an underlying structure, such as the ground or an underlying rocky terrain feature. The higher durometer material can offer that greater level of protection, and in some cases prevent penetration of the outsole in those regions by the rocky terrain feature. As noted above, with the second preselected region 80A of the softer durometer surrounding the respective harder durometer first preselected regions 70A-70I, those first preselected regions, which can be more stiff than the second preselected regions 80A, 80B, can flex and bend relative to one another allowing greater contact and maintaining contact between the outsole and an underlying rocky terrain feature. Further, this bending and flexing relative to one another can provide better proprioceptive feedback to the wearer of the underlying rocky terrain features, as well as the stability, shape and/or size of the underlying rocky terrain features. In some cases, each of the respective preselected regions can flex and bend across multiple axes relative to one another, allowing the footwear to conform to the underlying rocky terrain feature and/or grip or bite it to provide enhanced traction. In some cases, this can allow the shoe to move, flex and conform to underlying surfaces in a barefoot-like manner with enhanced conformance to irregular surfaces such as rocky terrain features under the wearer's foot.
As shown in FIGS. 1 and 3, the outsole 20 includes multiple treads 50. These treads 50 can be oriented in a first direction forward of the arch region 93 and in a second direction rearward of the arch region 93. With the treads 50 oriented in a “forward pointing” orientation as shown in FIG. 3, generally in the metatarsals region 92 and the phalanges region 91, the individual treads can provide enhanced traction to propel the wearer forward. The treads 50 in the heel region 96, however, generally are “rearward pointing” and can provide enhanced braking action in the heel to enable a user to slow themselves down when traversing a particular surface, or to act as a brake when traversing down an inclined surface. Thus, the treads can be bi-directionally oriented, with some of the treads generally pointing or facing forward, to enhance forward propulsion, and other treads rearwardly oriented, generally the opposite direction, to provide braking.
As shown in FIGS. 2 and 6-9, the treads 50 can be integrally formed with an outsole base 45. The outsole base 45 can include an upper surface 41 of the outsole. The outsole base can be of a preselected thickness, for example 1 mm to about 4 mm, further optionally about 2 mm. This thickness can be selected to provide the desired flexibility between individual treads, regions and/or portions of the outsole 40. The outsole base 45 can include an outer surface 46 from which the individual treads 50 extend. The treads 50 can extend upwardly and outwardly from the base, in particular the outer surface 46 of the base.
The treads can be of a preselected height H, about 1.5 mm to about 2.5 mm. It has been discovered that this height provides surprising and unexpected results in that the individual treads can engage rocky terrain features, particularly wet, slippery and/or slimy rocky terrain features, and yet hold firm against them without substantially bending and thereby losing traction. The treads can be spaced along the base 45, and in particular the outer base surface 46 a particular distance from one another. Specifically, it has been discovered that when the treads are spaced a distance D1 of about 3.0 mm to about 6.0 mm, the treads enable a rocky terrain feature to fit or project generally between adjacent treads. For example as shown in FIG. 9, the rocky terrain feature RF includes a jagged tip or point that extends upwardly between the adjacent treads 50A and 50B. This distance D1 is surprisingly sufficient to accommodate most rocky terrain features and yet enable those features, to enter between the treads, allowing at least one surface of the treads and optionally the base, to engage the rocky terrain feature RF and provide traction and/or bite relative to it.
The individual treads 50 can be spaced a distance D1 from one another along reference lines RL1 and RL2 which are generally parallel to the longitudinal axis LA and generally parallel to forward movement of a wearer. The spacing of distance D1 can be about 3.0 mm to about 6.0 mm from one another along those respective reference lines RL1 and RL2. Optionally, the spacing between adjacent, laterally spaced treads along a reference line RL3 can be a distance D2. This distance D2 also can be about 3.0 mm to about 6.0 mm. Of course, this distance D2 can be varied to other distances for example about 0.5 mm to about 6.0 mm. Alternatively, the adjacent treads along the reference line RL3, which can be transverse to the longitudinal axis LA, can actually overlap one another so that there is no distance that separates the respective treads. This is illustrated in FIG. 1, within the second preselected region 80B, where parts of adjacent treads 50C and 50D overlap one another laterally. Of course, in some circumstances the spacing between treads that lay along different reference lines, for example RL1 and RL2 can overlap as well, and can have different spacing than the distances D1 and/or D2 mentioned above.
With reference to FIGS. 8 and 9, the individual treads 50 each include a ground contacting surface 54 and one or more tread sidewalls 55. The tread sidewalls generally extend upwardly and optionally perpendicularly to the outer surface 46 of the base 45. The sidewalls 55 transition at a tread edge 50E to the ground contacting surface 54. Although referred to as a ground contacting surface, this generally refers to the fact that when on a completely flat surface, that surface 54 of many of the treads contact the underlying flat surface. Many times however, when traversing rocky terrain features, the ground contacting surface 54 does not even contact the features of the rocky terrain feature. Instead, the rocky terrain feature RF as shown in FIG. 9 extends upwardly between individual tread 50A and 50B.
As shown in FIG. 9A, the tread side surface 55 transitions to the ground contacting surface 54 at the tread edge 50E. The tread edge 50E defines a right angled corner between the side surface 55 and the ground contacting surface 54. This right angle can form a non-radiused, non-chamfered corner, or a minimally-radiused or minimally-chamfered corner to enhance release from a mold. For purposes of this disclosure, a substantially non-radiused corner can include a minute radius used for enhancing mold release of the treads from a mold. Other edge configurations are possible as well.
More particularly, as shown in FIG. 9A, the tread edge 50E forms the substantially right angle α between those surfaces. This angle α can have slight tolerances depending on the particular mold with which the outsole is formed. The right angle edge 50E can provide enhanced traction and bite into the rocky terrain feature RF, particularly when it is wet, slippery and/or slimy to enhance slip resistance and traction. This sharp corner edge 50E also can provide relatively better traction compared to a substantially rounded corner, since the sharp edge can catch on the surfaces of the rocky terrain feature RF. Further, where the outsole base 45 flexes, the respective tread edges 50E can grab the rocky terrain feature RF for enhanced traction. Further, due to the reduced bending of the individual treads, this can further enhance traction.
As shown in FIG. 8, the respective treads 50 are in the form of an open delta shape projecting outwardly from the base 45. By open delta shape, it is meant that the bottom, portion opens up to form a generally triangular or otherwise open void opposite the point of the delta. The lateral and medial sides of each of the individual treads as shown also can be truncated to form a generally squared off ends 56, which can inhibit unwanted flexing or bending of those ends and the tread in general. This too can provide enhanced traction and hold of the individual treads relative to the rocky terrain feature RF. Of course, if desired, other shapes can be selected for the treads such as rectangular, triangular, trapezoidal, polygonal, hexagonal or other shapes.
As shown in FIG. 9, when the outsole 40 engages a rocky terrain feature RF, that rocky terrain feature RF can fit between, on, across and/or adjacent treads 50A, 50B. At least one of the tread edge 50E and the tread side surface 55, and in some cases adjacent the ground contacting surface 54 can engage the rocky terrain features RF. By way of this engagement, one or more of the treads thereby provides traction between the outsole and the rocky terrain feature. This enhanced traction between the tread and in particular the edge and/or side surface can reduce the incidence of slippage between the outsole and that rocky terrain feature, particularly where the terrain feature is wet, slippery and/or slimy.
In some cases, the rocky terrain feature RF also can engage the ground contacting surface 54, which further enhances traction. Generally, the forces applied to the treads 50A, 50B and generally the outsole 40 are transferred through the base 50 into the midsole and/or footbed. In this transfer, the forces are transferred to the zone pods 60A-60H and/or the individual secondary pods 65, which can independently move relative to one another as described above. This in turn provides enhanced proprioceptive feedback to the wearer's foot regarding the rocky terrain feature RF. Accordingly, the wearer can sense and better understand that rocky terrain feature, for example, it's size, shape and stability.
A first alternative embodiment of the footwear is shown in FIGS. 13-16 and generally designated 110. This footwear 110 is identical to the embodiment described above in connection with FIGS. 1-12 with several exceptions. For example, the footwear 110 includes a sole assembly 120, and in particular an outsole 140. To the sole assembly 120 an upper 114 is attached. The upper 114 forms a void 113 within which the wearer's foot can be positioned. The footwear 110 also includes a footbed 160 of the type described above, which can be incorporated via a Strobel construction and joined with the upper 114. If desired, a midsole 195 can also be incorporated into the footwear 110. The outsole 120, however, can differ in that it can also include one or more flex contours 149A-149C disposed in the metatarsal and phalanges regions of the footwear. The footwear 110 can also define a longitudinal axis LA as with the embodiment above.
If desired, the outsole 120 also can be constructed from a monolithic molded, one-piece structure. It can include one or more materials having different durometers, for example first and second durometers, such as that described in connection with the embodiment above, located in the same or different first and second preselected regions—or other regions if desired.
The treads 150 of this construction can differ somewhat from the treads of the embodiment above. For example, as shown in FIGS. 15 and 16, the treads can generally be of a hexagonal shape. Of course, other polygonal, rounded or other shapes can be selected if desired. The treads 150 are joined with an underlying outsole base 145 which includes an outer surface 146. The treads can project upwardly from the outsole base 145 a height H′, and in particular the base outer surface 146, a height of about 1.5 mm to about 2.5 mm. The individual treads 50A and 50B also can be separated from one another a distance D′. This distance D′ can be about 3.0 mm to about 6.0 mm from one another on the base along a reference line RL4, generally parallel to the longitudinal axis LA, or otherwise aligned with a forward direction of movement. Like the embodiment above, this enables a rocky terrain feature to fit between adjacent treads, thereby providing traction between the outsole and the rocky terrain feature. This can enable the treads to engage and hold against a rocky terrain feature without substantially bending upon such engagement. The distance between laterally disposed treads not necessarily on the same reference line RL4, can be the same distance D′. Of course, in some cases, the treads can overlap one another so that they are not spaced any lateral distance from one another, as with the embodiment above.
The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.

Claims

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

1. An article of footwear comprising:

an upper;

an outsole including a longitudinal axis, a base and a plurality of treads, each tread of the plurality of treads spaced about 3.0 mm to about 6.0 mm from one another on the base along a reference line parallel to the longitudinal axis so that a rocky terrain feature can fit between adjacent ones of the plurality of treads, thereby providing traction between the outsole and the rocky terrain feature, each tread of the plurality of treads extending from the base to a height of about 1.5 mm to about 2.5 mm so that each of the treads can engage the rocky terrain feature without substantially bending upon such engagement,

wherein the outsole includes a first preselected region having a first durometer, and a second preselected region having a second durometer, wherein the first durometer is different from the second durometer.

2. The article of footwear of claim 1, wherein the outsole is constructed from a monolithic molded, one-piece structure including at least one material having the first durometer in the first preselected region and the second durometer in the second preselected region, the first durometer being greater than the second durometer.

3. The article of footwear of claim 2,

wherein the first durometer is about 70 Asker C to about 80 Asker C, and

wherein the second durometer is about 55 Asker C to about 65 Asker C.

4. The article of footwear of claim 3,

wherein the first preselected region includes a phalanges region and a metatarsals region, and

wherein the second region includes an arch region of the outsole.

5. The article of footwear of claim 3, wherein the first preselected region includes the plurality of treads,

wherein the second preselected region includes at least a portion of the base of the outsole,

wherein the first durometer assists the treads in holding firmly against the rocky terrain feature without bending upon such engagement with the rocky terrain feature,

wherein the second durometer provides flexibility to the outsole, allowing the outsole to at least partially conform to the rocky terrain feature.

6. The article of footwear of claim 1 comprising a footbed disposed over the outsole base, the footbed including a footbed base and a plurality of zone pods extending from the footbed base, the zone pods arranged to align with the first and second preselected regions individually so that forces from the rocky terrain feature can be transferred though the first and second preselected regions and to respective aligned zone pods, whereby a wearer is provided sensory feedback regarding the rocky terrain feature through the wearer's foot from the outsole.

7. The article of footwear of claim 1,

wherein the footbed includes a plurality of secondary pods extending from the base that overlap the zone pods, and

wherein the secondary pods are substantially elliptical in shape.

8. The article of footwear of claim 1,

wherein the plurality of treads includes a first tread and a second tread,

wherein the first tread is bounded by a first tread sidewall and the second tread is bounded by a second tread sidewall,

wherein the first tread sidewall is spaced 3.0 mm to 6.0 mm from the second tread sidewall, and

wherein each of the plurality of treads are of an open delta shape projecting outwardly from the base.

9. The article of footwear of claim 1,

wherein the plurality of treads includes a first tread and a second tread,

wherein each of the plurality of treads are of a hexagonal shape projecting outwardly from the base.

10. An article of footwear comprising:

an upper;

an outsole joined with the upper, the outsole including a longitudinal axis, a base and a plurality of treads extending downward from a base, each of the plurality of treads including a ground contacting surface spaced a distance of 1.5 mm to 2.5 mm from the base, each of the plurality of treads bounded by a tread edge that transitions from the ground contacting surface to a tread side surface, the tread edge defining a right angle with a substantially non-radiused corner, each of the plurality of treads spaced 3.0 mm to 6.0 mm from adjacent ones of the plurality of treads along a reference line parallel to the longitudinal axis so that a rocky terrain feature can fit between adjacent ones of the plurality of treads with at least one of the tread edge and the tread side surface engaging the rocky terrain feature and thereby providing traction between the outsole and the rocky terrain feature,

whereby the incidence of slippage between the outsole and the rocky terrain feature is reduced where the rocky terrain feature is at least one of wet, slippery and slimy via engagement of the at least one of the tread edge and the tread side surface with the rocky terrain feature.

11. The article of footwear of claim 10, wherein the outsole is constructed from a monolithic molded, one-piece structure including at least one material having a first durometer in a first preselected region and a second durometer in a second preselected region, the first durometer being greater than the second durometer.

12. The article of footwear of claim 11,

wherein the first preselected region includes at least one of the plurality of treads, whereby the at least one tread holds firm against the rocky terrain feature, and

wherein the second preselected region includes at least part of the outsole base, whereby the outsole base remains flexible in the second preselected region so that the outsole can flex in the second preselected region.

13. The article of footwear of claim 12 wherein the first durometer is about 70 Asker C to about 80 Asker C.

14. The article of footwear of claim 13 wherein the second durometer is about 55 Asker C to about 65 Asker C.

15. The article of footwear of claim 10 comprising a footbed including a footbed base and a plurality of zone pods extending from the footbed base, the zone pods arranged to align with first preselected regions of the outsole so that forces from the rocky terrain feature can be transferred though the first preselected regions and to the zone pods, whereby a wearer is provided sensory feedback regarding the rocky terrain feature through the wearer's foot from the outsole.

16. The article of footwear of claim 15 wherein the footbed includes a plurality of secondary pods extending from the footbed base that overlap the zone pods.

17. An article of footwear comprising:

an upper having a lower peripheral portion and an opening for insertion of a wearer's foot, the upper defining a void to accommodate a wearer's foot,

an outsole extending from a heel region to a forefoot region, the outsole including a longitudinal axis, an outsole base having an upper surface facing toward the wearer's foot and a lower surface opposite the upper surface, the outsole including a plurality of treads extending downward from the lower surface of the outsole base, each of the plurality of treads including a ground contacting surface distal from the lower surface and bounded by a tread edge that transitions from the ground contacting surface to a tread side surface that extends to the outsole base, the tread edge defining a right angle and having a substantially non-radiused corner,

a footbed joined with the lower peripheral portion of the upper to form a Strobel construction, with the footbed closing the upper so that the void is bounded by a closed bottom formed by the footbed, the footbed including a footbed base having a first surface adapted to face the wearer's foot and a second surface opposite the first surface facing toward the outsole, the footbed including a plurality of pods extending from at least one of the first surface and the second surface, each of the plurality of pods movable independently of one another,

wherein the plurality of pods of the footbed are positioned to interact with the upper surface of the outsole so that forces applied to the plurality of treads are transferred to the plurality of pods with the plurality of pods providing sensory feedback regarding a rocky terrain feature to the wearer's foot from the outsole;

wherein each of the plurality of treads are of a height of about 1.5 mm to about 2.5 mm, so that each of the treads can engage the rocky terrain feature without substantially bending upon such engagement with the rocky terrain feature;

wherein each of the plurality of treads are spaced about 3.0 mm to about 6.0 mm from adjacent ones of the plurality of treads along a reference line parallel to the longitudinal axis so that the rocky terrain feature can fit between adjacent ones of the plurality of treads with at least one of the tread edge and the tread side surface engaging the rocky terrain feature and thereby providing traction between the outsole and the rocky terrain feature,

whereby the incidence of slippage between the outsole and the rocky terrain feature is reduced where the rocky terrain feature is at least one of wet, slippery and slimy,

wherein the outsole is constructed from a monolithic molded, one-piece structure including a material having a first durometer in a first preselected region and a second durometer in a second preselected region, the first durometer being greater than the second durometer,

wherein the first preselected region includes at least one of the plurality of treads,

whereby the at least one tread can hold firm against the rocky terrain feature, and

wherein the second preselected region includes at least part of the outsole base,

whereby the outsole base remains flexible in the second preselected region allowing the outsole to at least partially conform to the rocky terrain feature.

18. The article of footwear of claim 17 wherein each of the plurality of treads are in the shape of at least one of an open delta and a hexagon.

19. The article of footwear of claim 17 wherein the first durometer is about 70 Asker C to about 80 Asker C.

20. The article of footwear of claim 19 wherein the second durometer is about 55 Asker C to about 65 Asker C.