WO2001001807A1

WO2001001807A1 - Cushion midsole insert for an athletic shoe

Info

Publication number: WO2001001807A1
Application number: PCT/US2000/016305
Authority: WO
Inventors: Brian Keating
Original assignee: K-Swiss, Inc.
Priority date: 1999-07-01
Filing date: 2000-06-30
Publication date: 2001-01-11

Abstract

A lightweight and flexible midsole insert for an athletic shoe. The midsole insert includes a textile base (5) on which a plurality of spaced apart projections (3) are secured. These plurality of spaced apart projections (3) are cushioning elements which can be formed of a thermoplastic rubber (TPR) of a polyurethane foam. The textile base (5) may be a non-woven textile of polyester. The midsole insert can be implemented into an athletic shoe in various manners, including being placed on a top surface of a midsole, being placed between a midsole and an outer sole, or being formed as part of a shoe sock liner of strobel sock. In these implementations the midsole insert can be placed into the athletic shoe such that the plurality of spaced apart cushioning projections face either upward or downward.

Description

Cushion Midsole Insert For an Athletic Shoe

BACKGROUND OF THE INVENTION Field of the Invention:

This invention relates to a midsole insert for use in an athletic shoe, and particularly a lightweight and flexible midsole insert with a plurality of cushioning elements which is advantageous from a standpoint of reducing stress and dissipating energy associated with various athletic activities while also maintaining satisfactory stability.

Discussion of the Background:

In order to provide improved cushioning and impact absorption, athletic shoes have been provided with air cushions disposed within the sole structure of the shoe. However, air cushioned arrangements can be undesirable in that the stability of the shoe is diminished as a result of the air cushioned support. As an alternative to air cushions, athletic shoes have been provided with cushioning wedges disposed between the insole and the outsole of the shoe. By way of example, U.S. Pat. No. 5,222,311 to Lin discloses a shoe in which a cushioning wedge is disposed within a receptacle of an outsole. In the Lin arrangement, closely packed side-by-side cushioning elements are provided in the form of curved projections extending from a basic member. With such a closely packed arrangement, the cushioning elements effectively act as a unit. As a result, if a soft cushioning material is utilized the stability of the shoe is compromised, and the shoe can be hazardous when participating in various athletic activities. By contrast, when a harder cushioning material is utilized, the capacity of the cushioning wedge to relieve stresses to absorb impacts is reduced.

U.S. Pat. No. 4.485,863 also discloses a shoe in which cushioning elements are disposed in side-by-side relation. In addition a window extends through the side of the sole of the shoe so that the cushioning elements can be observed from the exterior of the shoe. As discussed above, with such an arrangement, the cushioning assembly is less than optima! from a combined stability and impact absorption standpoint. In addition, by providing a window which extends through the side of the shoe, the structural integrity of the shoe is diminished, or the shoe must be constructed to accommodate for the loss of strength resulting from the window opening. A further U.S. Patent No. 5,782,014 to Peterson discloses a midsole assembly having elements with cushioning projections. In the Peterson device the units including the cushioning projections are formed as solid units of a single material, i.e. the cushioning projections are formed of a same material as a base member. As a result, in the device of Peterson there is limited flexibility between the various cushioning elements, and the cushioning inserts are relatively heavy.

More particularly, with a structure such as disclosed in Peterson the cushioning elements are all supported on a solid base member, and the cushioning elements and the base member are formed as one solid unit of a single material. The result of this is that there is very little flexibility of each cushioning element relative to other cushioning elements. Stated another wa\ . there is no lateral movement between the individual cushioning elements because each individual cushioning element is an extension of the solid base. The results of this is that there is decreased flexibility of the midsole assembly as one cushioning element cannot be laterally displaced relative to another cushioning element.

Moreover, a drawback with such a midsole assembly as disclosed in Peterson is that the single solid unit of the base and the cushioning element is relatively heavy, which is undesirable in an athletic shoe.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an improved athletic shoe having desirable cushioning/impact absorbing qualities while maintaining a high level of stability .

It is another object of the invention to provide an athletic shoe having a midsole insert which is lightweight and flexible and which includes a cushioning unit having a textile base member with a plurality of projections extending therefrom, with the projections spaced with respect to one another so that the interaction between the projections and the modulator provide a spring cushioning arrangement which stably dampens impact forces.

The foregoing, and additional objects and advantages are achieved in the present invention which includes a midsole insert for an athletic shoe having a plurality of spaced projections extending from a textile base member. The plurality of cushioning elements are preferably formed of a soft low density thermoplastic rubber (TPR) or a polyurethane foam The midsole insert can be placed in an athletic shoe in a plurality of different configurations. including being placed on a top surface of an athletic shoe midsole, between a midsole and a rubber outsole of an athletic shoe, or in a bottom of a shoe sock or liner inside an upper of the athletic shoe. In any of these configurations the midsole insert of the present invention can be placed with the plurality of cushioning projections projecting either upward or downward. By forming a midsole insert with a plurality of spaced projections extending from a textile base member, the plurality of spaced projections are flexible and can move relative to one another because the textile base member is not a rigid support. This allows flexibility of the cushioning elements, and thereby enhances the comfort of the athletic shoe. Moreover, the textile base to which the cushioning elements are attached is a very lightweight material, and thus the weight of the midsole insert can be reduced. As a result, the overall weight of an athletic shoe including such a midsole insert can be reduced, adding to comfort and performance improvements in the athletic shoe.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which:

Figures 1A and IB respectively show top and perspective views of a first embodiment of the midsole insert of the present invention;

Figure 1C shows a top view of a modification of the first embodiment of the midsole insert of Figures 1A and IB;

Figure 2 shows a first manner in which the midsole insert of the present invention can be incorporated into an athletic shoe;

Figure 3 shows a second manner in which the midsole insert of the present invention can be incorporated into an athletic shoe;

Figure 4 shows a third manner in which the midsole insert of the present invention can be inserted into an athletic shoe; and

Figures 5 A and 5B show a fourth manner in which the midsole insert of the present invention can be inserted into an athletic shoe. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the figures, wherein like reference numerals designate identical or corresponding parts throughout the several views. Figures 1 A and IB show a midsole insert 1 for an athletic shoe according to the present invention. Figure 1A shows a top view of the midsole insert 1 and Figure IB shows a perspective view of cushioning elements in the midsole insert 1. The midsole insert 1 of the present invention includes a plurality of cushioning elements 3 spaced throughout the midsole insert 1. Materials which the Applicant has found as particularly effective for forming each of the plurality of cushioning elements 3 is a soft low density thermoplastic rubber (TPR), which is more like a solid gel than a foam, or a polyurethane foam. Further, each of these pluralities of cushioning elements 3 is secured to a textile base member 5. An edging 7 formed of the same material as the plurality of cushioning elements 3 is formed around an entire periphery of the textile base member 5, and forms portions of the projections 3 at the edge of the midsole insert 1.

A modification of this midsole insert shown in Figures 1A and 1C is further shown in Figure 1C, where Figure 1C shows only a section of the textile base member 5 and cushioning elements 3. This modification shown in Figure 1C has the same structure as the embodiment shown in Figure 1A with the exception that runners 9 are formed between the plurality of cushioning elements 3. The use of these runners 9 may simplify a molding process for forming the midsole insert 1.

The midsole insert 1 is formed in the following manner. The textile base member 5 is put into a mold, and the cushioning elements 3 are injection molded into the textile base member 5. The textile base member can take the form of a non-woven textile of polyester and, as noted above, the cushioning elements 3 can take the form of soft low density thermoplastic rubber (TPR) or a polyurethane foam. The materials of the textile base member 5 and cushioning elements 3 should be selected so that the plurality of cushioning elements 3 can be securely attached to the textile base member 5. The textile base member 5 could also be formed of a woven textile, such as nylon, cotton, etc. although cushioning materials 3 being formed of a thermoplastic polyurethane were found to be better secured to a non- woven textile of polyester. Other combinations of materials for the textile base member 5 and the plurality of cushioning elements 3 are clearly possible provided that the materials chosen for these elements ensure that the plurality of cushioning elements 3 can be secured to the textile base member 5.

Further, the plurality of cushioning elements should be appropriately spaced on the textile base member 5 to provide an adequate cushioning, without rendering the midsole insert 1 too heavy. One preferred spacing of the plurality of cushioning elements 3 may be 9 millimeters between center points of adjacent cushioning elements 3. Different spacings could, of course, be utilized, but again noting that if the cushioning elements 3 are too closeh spaced together the midsole insert 1 may become undesirably heavy, and whereas if the cushioning elements 3 are spaced too far apart the midsole insert 1 may not provide adequate cushioning.

The cushioning elements 3 may also have a width of 6 mm and a height of 5 mm. although of course other sizes of the cushioning elements 3 may be utilized.

Forming a midsole insert in the constructions as noted above in Figures 1 A-1C of the present invention provides a midsole insert with the advantages of being both lightweight and flexible. More particularly, the textile base member 5 is a lightweight material, and thus the overall weight of the midsole insert 1 can be limited. Further, the textile base member 5 is a flexible material, and thus allows movement of the plurality of cushioning elements 3. which increases flexibility of the midsole insert 1.

To further expound on the benefits of the midsole insert of the present invention, the midsole insert of the present invention has the advantages of being both lightweight and flexible, which both enhance comfort and performance in an athletic shoe. More particularly, the textile base member 5 is a lightweight material, and is significantly lighter than the material forming the cushioning elements 3. Therefore, the combination of the textile base member 5 and cushioning elements 3 is significantly lighter than a structure in which the cushioning elements 3 are formed of a same material and as a single unit with a base member. This weight saving in the midsole insert of the present invention is very desirable in an athletic shoe from both comfort and performance points of view.

Moreover, the textile base member 5 does not rigidly support the cushioning elements 3 relative to each other. Stated another way, as the cushioning elements 3 are supported on a flexible textile base member 5 in the present invention, the cushioning elements 3 can be slightly displaced relative to one another. Particularly, the cushioning elements 3 can move laterally relative to each other. This flexibility in the cushioning elements 3 provide added comfort to utilizing the midsole insert of the present invention.

The midsole insert 1 of Figure 1 can be implemented to an athletic shoe in various manners, examples of which are shown in Figures 2-5.

As shown in Figure 2, the midsole insert 1 of the present invention can be placed on a top surface of a midsole 20 of an athletic shoe. In this case, this midsole 20 of the athletic shoe can include a molded area 22 designed to receive the midsole insert 1. In this configuration of Figure 2, the midsole insert 1 can be placed into the molded area 22 of the midsole 20 with the plurality of cushioning elements 3 facing either upward or downward.

A further configuration for integrating the midsole insert 1 into an athletic shoe is shown in Figure 3. As shown in Figure 3, in this configuration the midsole insert 1 is placed in a foam midsole 33 of an athletic shoe body 35, and more particularly is placed within a molded area 34 of this foam midsole 33 shaped to receive the midsole insert 1. A rubber outsole 37 is then formed on the other side of the midsole insert 1.

In this configuration of Figure 3, it is also noted that the midsole insert 1 can be placed into the receiving molded area 34 of the midsole 33 with the plurality of cushioning elements 3 facing either upward towards the shoe body 35 or downwards towards the rubber outsole 37.

Figure 4 shows a further possible implementation of the midsole insert 1 into an athletic shoe body 40. In this implementation a shoe sock liner 41 is inserted into an athletic shoe body 40. The midsole insert 1 is included in an interior portion of the shoe sock liner 41. In this case the shoe sock liner 41 is placed into the athletic shoe body 41 on a top surface of a midsole therein.

Figures 5 A and 5B show a further possible implementation of the midsole insert 1 into an athletic shoe, Figure 5B showing a detail of the circled portion 55 in Figure 5 A. In this instance the athletic shoe includes a strobel sock 50. It is common in athletic shoes to utilize a strobel sock 50, which is typically a non-woven textile stitched to a bottom of an athletic shoe upper. Such a strobel sock 50 is normally provided to help give the athletic shoe its shape. In the instance in which an athletic shoe includes such a strobel sock 50, this strobel sock 50 can essentially take the place of the textile base member 5 such that cushioning elements 3 can be molded directly onto the strobel sock 50. The cushioning elements 3 will be molded onto the strobel sock 50 in the same manner as molding the cushioning elements 3 onto the textile base member 5 as discussed above.

Other configurations may also be possible for implementing the midsole insert 1 into an athletic shoe.

Obviously, numerous additional modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described herein.

Claims

CLAIMS:

1. A midsole insert for an athletic shoe, comprising: a textile base; a plurality of cushioning elements secured to the textile base.

2. A midsole insert according to claim 1. wherein the textile base is a non-woven textile of polyester.

3. A midsole insert according to claim 1 , wherein the plurality of cushioning elements are formed of one of a thermoplastic rubber and a polyurethane foam.

4. A midsole insert according to claim 2, wherein the plurality of cushioning elements are formed of one of a thermoplastic rubber and a polyurethane foam.

5. A midsole insert according to claim 1, further comprising an edging formed around an edge of the textile base, the edging being formed of a same material as a material forming the plurality of cushioning elements.

6. A midsole insert according to claim 1. wherein the plurality of cushioning elements are secured to the textile base by being injection molded in the textile base.

7. A midsole insert according to claim 1. further comprising runners connecting adjacent of the plurality of cushioning elements.

8. An athletic shoe comprising: a midsole insert including: a textile base: a plurality of cushioning elements secured to the textile base.

9. An athletic shoe according to claim 8. wherein the textile base is a non-woven textile of polyester.

10. An athletic shoe according to claim 8, wherein the plurality of cushioning elements are formed of one of a thermoplastic rubber and a polyurethane foam.

1 1. An athletic shoe according to claim 9, wherein the plurality of cushioning elements are formed of one of a thermoplastic rubber and a polyurethane foam.

12. An athletic shoe according to claim 8, wherein the midsole insert further includes an edging formed around an edge of the textile base, the edging being formed of a same material as a material forming the plurality of cushioning elements.

13. An athletic shoe according to claim 8, wherein the plurality of cushioning elements are secured to the textile base by being injection molded in the textile base.

14. An athletic shoe according to claim 8, wherein the midsole insert further includes runners connecting adjacent of the plurality of cushioning elements.

15. An athletic shoe according to claim 8, wherein the midsole insert is positioned on a top surface of a midsole of the athletic shoe.

16. An athletic shoe according to claim 15, wherein the plurality of cushioning elements face downward toward the midsole of the athletic shoe.

17. An athletic shoe according to claim 8, wherein the midsole insert is formed between a midsole and an outer sole of the athletic shoe.

18. An athletic shoe according to claim 17, wherein the plurality of cushioning elements face downward toward the outer sole of the athletic shoe.

19. An athletic shoe according to claim 8, wherein the midsole insert is formed in a liner placed on a midsole of the athletic shoe.

20. An athletic shoe according to claim 19, wherein the plurality of cushioning elements face downward toward the midsole of the athletic shoe.

21. An athletic shoe according to claim 8, wherein the textile base is a portion of a strobel stock.