US20140250723A1 - Flexible sole supports for articles of footwear - Google Patents

Flexible sole supports for articles of footwear Download PDF

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Publication number
US20140250723A1
US20140250723A1 US13/788,902 US201313788902A US2014250723A1 US 20140250723 A1 US20140250723 A1 US 20140250723A1 US 201313788902 A US201313788902 A US 201313788902A US 2014250723 A1 US2014250723 A1 US 2014250723A1
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United States
Prior art keywords
support member
plantar
plantar support
flexible foot
flex joint
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Abandoned
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US13/788,902
Inventor
Shane S. Kohatsu
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Nike Inc
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Nike Inc
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Priority to US13/788,902 priority Critical patent/US20140250723A1/en
Publication of US20140250723A1 publication Critical patent/US20140250723A1/en
Assigned to NIKE, INCORPORATED reassignment NIKE, INCORPORATED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BEREND, THOMAS, KOHATSU, SHANE S.
Abandoned legal-status Critical Current

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    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B7/00Footwear with health or hygienic arrangements
    • A43B7/14Footwear with health or hygienic arrangements with foot-supporting parts
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B3/00Footwear characterised by the shape or the use
    • A43B3/26Footwear characterised by the shape or the use adjustable as to length or size
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00Soles; Sole-and-heel integral units
    • A43B13/14Soles; Sole-and-heel integral units characterised by the constructive form
    • A43B13/141Soles; Sole-and-heel integral units characterised by the constructive form with a part of the sole being flexible, e.g. permitting articulation or torsion
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00Soles; Sole-and-heel integral units
    • A43B13/14Soles; Sole-and-heel integral units characterised by the constructive form
    • A43B13/16Pieced soles

Definitions

  • the present invention relates to the field of footwear and other foot-receiving devices. More specifically, some aspects of the present invention pertain to flexible foot support components for supporting some or all of a plantar surface of a wearer's foot. Additional aspects of this invention relate to sole structures and/or articles of footwear that incorporate such flexible foot support components.
  • Conventional articles of athletic footwear include two primary elements, namely, an upper and a sole structure.
  • the upper provides a covering for the foot that securely receives and positions the foot with respect to the sole structure.
  • the upper may have a configuration that protects the foot and provides ventilation, thereby cooling the foot and removing perspiration.
  • the sole structure is secured to a lower surface of the upper and generally is positioned between the foot and any contact surface.
  • the sole structure may provide traction and control potentially harmful foot motion, such as over pronation.
  • the upper forms a void on the interior of the footwear for receiving the foot.
  • the void has the general shape of the foot, and access to the void is provided at an ankle opening. Accordingly, the upper extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot.
  • a lacing system often is incorporated into the upper to allow selective changes to the size of the ankle opening and to permit the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet with varying proportions.
  • the upper may include a tongue that extends under the lacing system to enhance the comfort of the footwear (e.g., to moderate pressure applied to the foot by the laces).
  • the upper also may include a heel counter to limit or control movement of the heel.
  • the sole structure generally incorporates multiple layers that are conventionally referred to as an insole, a midsole, and an outsole.
  • the insole (which also may constitute a sock liner) is a thin member located within the upper and adjacent the plantar (lower) surface of the foot to enhance footwear comfort, e.g., to wick away moisture and provide a soft, comfortable feel.
  • the midsole which is traditionally attached to the upper along the entire length of the upper, forms the middle layer of the sole structure and serves a variety of purposes that include controlling foot motions and attenuating impact forces.
  • the outsole forms the ground-contacting element of footwear and is usually fashioned from a durable, wear-resistant material that includes texturing or other features to improve traction.
  • Some aspects of this invention relate to flexible foot support members for articles of footwear or other foot-receiving devices (such as ski or snowboard binders, devices for holding feet during play of video games, etc.).
  • Flexible foot support members of this type, sole structures, articles of footwear, and/or other foot-receiving devices that incorporate such support members may allow a more natural motion and flexion of a wearer's foot during a variety of motions or activities, such as during various phases of a walking or running step cycle, during turn or cutting events, when jumping, etc.
  • Flexible foot support members in accordance with at least some examples of this invention may include: (a) a first plantar support member including a first upper surface and a first lower surface; (b) a second plantar support member including a second upper surface and a second lower surface; and (c) a flex joint connecting the first plantar support member with the second plantar support member.
  • the flex joint may take on a variety of configurations that allow movement of the first plantar support surface with respect to the second plantar support surface in at least one direction (and optionally stops or limits this relative movement in one or more other directions). This rotational stop or limitation feature can help prevent over-flexing of the flexible foot support member in use (e.g., on the field of play).
  • the flex joint may include one or more hinge structures joining the first plantar support member with the second plantar support member.
  • footwear sole structures or other foot-receiving device foot support structures
  • articles of footwear or other foot-receiving devices
  • FIGS. 1A through 1F provide various views of an article of footwear, a sole structure, and a flexible foot support member in accordance with one example of this invention
  • FIG. 2 is a cross sectional view of an alternative sole structure and/or article of footwear in accordance with another example of this invention.
  • FIGS. 3A and 3B illustrate another example flexible foot support member in accordance with some examples of this invention.
  • FIGS. 4A and 4B illustrate another example flexible foot support member in accordance with some examples of this invention.
  • FIGS. 5A through 5E provide various views of an insole component, strobel member, sock liner, or other foot support member that may be used in some structures according to this invention.
  • aspects of this invention relate to flexible foot support members, sole structures or other foot support components including such support members, and articles of footwear (e.g., athletic footwear, including ski and/or snowboarding boots) or other foot-receiving devices that include such support members. Additional aspects of this invention will become more apparent from the detailed description below.
  • Such flexible foot support members may include: (a) a first plantar support member including a first upper surface and a first lower surface; (b) a second plantar support member including a second upper surface and a second lower surface; and (c) a flex joint connecting the first plantar support member with the second plantar support member.
  • plantar support member may be used synonymously and interchangeably in this specification with the term “plantar support portion.”
  • the flex joint may take on a variety of configurations that allow some movement of the first plantar support surface with respect to the second plantar support surface.
  • the flex joint may include one or more hinge structures joining the first plantar support member with the second plantar support member, wherein the hinge structure(s) is (are) at least partially located below the first and second lower surfaces (e.g., so as to provide an overall substantially smoothly contoured upper support surface for supporting the wearer's foot (or an overall upper support surface free from upward projections)).
  • the flex joint may be formed with the plantar support members as a unitary, one-piece construction.
  • the hinge structure may extend continuously over at least 30% of a length of an interface between the first plantar support surface and the second plantar support surface, and in some examples, the hinge structure may extend at least 60%, at least 80%, at least 90%, or even at least 95% of this interface length.
  • Flex joints in accordance with at least some examples of this invention may allow the plantar support members to freely flex in one direction while limiting an extent of the flex in the other (opposite) direction (e.g., to prevent over-flexing in that direction in use).
  • Any type of stop or motion limiting structure may be provided, e.g., in a hinge type structure, without departing from this invention.
  • at least one (and optionally all) of the flex joints connecting plantar support members in a flexible foot support member may include: (a) a first stop wall extending from the upper surface of one of the plantar support members and (b) a second stop wall extending from the upper surface of the other plantar support member.
  • These two stop walls may be positioned such that: (i) the upper surfaces can move relative to one another in a direction to increase a width of a gap between the upper surfaces and (ii) contact or other interaction between the stop walls limits or stops movement of the upper surfaces with respect to one another in a direction closing the gap.
  • the stop walls prevent over rotation or over-flexion of the plantar support members with respect to one another in at least one direction.
  • a connection structure may be provided to engage the bottom of the first stop wall with the bottom of the second stop wall to thereby join the first and second plantar support members together.
  • the entire flexible foot support member may be formed as a unitary, one-piece construction (so that the plantar support members and connection structure (and thus the flex joint) form a unitary, one-piece construction).
  • the plantar support surfaces may combine to support at least a majority of the plantar surface of a wearer's foot (i.e., the plantar support surfaces may be sized so as to support at least 50% of the wearer's foot's bottom surface).
  • the plantar support surfaces in a single flexible foot support member may combine to support at least 75%, at least 85%, at least 90%, or even at least 95% of the plantar surface of a wearer's foot.
  • the plantar support surfaces may extend continuously from the rearmost heel area of the sole structure to the forwardmost toe area of the sole structure and/or they may extend continuously from the medial side to the lateral side of the sole structure (and optionally may underlie or support 100% of the wearer's plantar surface and/or foot).
  • Flex joints may be provided at any desired locations in the footwear structure, and they may extend in any desired directions and/or over any desired extent of the flexible foot support structure without departing from this invention.
  • the plantar support member(s) and/or the flex joint(s) in a foot support member may take on one or more of the following characteristics:
  • Still additional aspects of this invention relate to sole structures for articles of footwear (e.g., including midsole and/or outsole components) that have flexible foot support members of the types described above, as well as to articles of footwear or foot-receiving devices incorporating flexible foot support members of the types described above.
  • FIG. 1A shows a side view of an article of footwear 100 in accordance with at least some examples of this invention.
  • the article of footwear 100 includes an upper 102 and a sole structure 104 engaged with the upper 102 .
  • the upper 102 may be made from any desired material or combinations of materials, in any desired constructions and/or configurations, without departing from this invention, including from conventional materials and in conventional constructions and/or configurations as are known and used in the art.
  • the upper 102 at least in part, defines an opening 106 for receiving the wearer's foot.
  • the size of the upper 102 and the opening 106 may be adjusted and controlled, e.g., using the laces 108 that extend along a throat or instep opening 110 of the shoe 100 , e.g., as is conventionally known in the art.
  • Other size adjustment mechanisms and/or footwear securing systems may be used in addition to or in place of the laces 108 , such as buckles, straps, hook-and-loop fasteners, zippers, drawstrings, ties, etc.
  • a tongue 112 , bootie member, or other structure may be provided between the securing system (e.g., laces 106 ) and the wearer's foot to moderate the feel of the securing system on the foot.
  • FIG. 1B provides a cross sectional view of the article of footwear structure 100 , e.g., taken along line 1 B- 1 B shown in FIG. 1A .
  • FIG. 1C provides a top view of a flexible foot support member 200 included in sole structure 104 in accordance with at least some examples of this invention, and
  • FIG. 1D provides a bottom view of this foot support member 200 .
  • FIG. 1E provides an enlarged, close up view of a flex joint area 250 in flexible foot support members 200 in accordance with at least some examples of this invention (and as is used in the foot support member 200 of FIGS. 1B through 1D ) in a closed position (e.g., at a stopped or motion limited position), and
  • FIG. 1F provides an enlarged, close up view of the flex joint area 250 in an open position.
  • FIG. 1B provides additional details of the overall footwear structure 100 and sole structure 104 in this example of the invention.
  • the upper 102 at least in part forms a foot receiving chamber 114 .
  • the bottom of the upper 102 in this example structure 100 is closed off by a strobel member 116 , lasting member, or other suitable connecting structure, although such bottom closing members may be omitted, if desired (and, optionally, the two lower free ends of the upper 102 could be engaged together, the bottom of the upper 102 could be closed off or integrally formed during its manufacture as a single piece structure, etc.).
  • the upper 102 may be attached to the strobel member 116 by stitching or in any other desired manner.
  • An insole member, sock liner 118 , orthotic, or other interior footwear component may overlie the strobel member 116 (and its connection to the upper 102 ), as shown in FIG. 1B .
  • the sole structure 104 of this example includes a flexible foot support member 200 , which may be directly engaged with the upper 102 at least at some areas, e.g., by adhesives or cements, by mechanical connectors, etc. Examples of flexible foot support members 200 will be described in more detail in conjunction with FIGS. 1C through 1F and 3 A through 4 B.
  • the sole structure 104 of this example further includes a midsole structure 120 , which may constitute one or more separate parts that are engaged with the upper 102 and/or the foot support member 200 .
  • the midsole structure 120 constitutes multiple separated parts that are engaged with both the outer surface of the flexible support member 200 and the outer surface of the upper 102 , e.g., by adhesives or cements.
  • the flexible foot support member 200 may be unsecured to the upper 102 and/or midsole 120 (at least at some locations) and held in place by being sandwiched between the midsole structure 120 and the upper 102 (and optionally held in place by a fixed connection between the midsole structure 120 and the upper 102 ).
  • Raised ridges or other suitable structures e.g., on the interior surface of midsole component(s) 120 ) also may be provided to help hold the foot support member 200 in place with respect to the midsole component(s) 120 .
  • the midsole structure 120 may take on any desired constructions and/or may be made of any desired materials without departing from this invention.
  • one or more of the midsole component parts may be made from polymeric foam materials, such as polyurethane foams, ethylvinylacetate foams, and/or phylon foams as are known and used in the footwear art.
  • at least some portions of the midsole structure 120 may include one or more fluid-filled bladders (e.g., sealed polymeric envelopes that include a gas under atmospheric pressure or an elevated pressure).
  • Fluid-filled bladder(s), when present, may be used in place of polymeric foam materials or may be at least partially incorporated into a polymeric foam material (e.g., at least partially housed within a chamber defined in the polymeric foam material).
  • at least some portion of the midsole structure 120 may include one or more mechanical type impact force attenuation elements (e.g., shock absorbing structures, such as springs) as are known in the art.
  • shock absorbing structures such as springs
  • Various different types of midsole components may be used in any desired combinations and/or arrangements without departing from this invention.
  • FIGS. 1A and 1B show the midsole structure 120 broken into multiple separated components. This type of structure helps allow the flex plate 200 to flex in the desired manners, as will be described in more detail below. Alternatively, if desired, at least some of the separations between portions of the midsole structure 120 could be omitted and the adjacent midsole components could be joined together, e.g., by a flexible joint, by a stretchable material, and/or in some other manner.
  • the upper 102 and/or strobel 116 also may include some stretchable or flexible joint features at appropriate locations (e.g., near the flex joints 250 of the foot support member 200 and/or the breaks in the midsole structure 120 ), if necessary, to provide improved durability and/or to better support the flexibility features of the flexible foot support member 200 , as will be described in more detail below.
  • the example sole structure 104 of FIGS. 1A and 1B further includes one or more outsole components 122 , which may include a durable material designed to contact the ground in use (e.g., to provide adequate wear resistance, to provide traction enhancing features, etc.).
  • the outsole component(s) 122 may be made from rubber, thermoplastic polyurethane, and/or any other desired material, including conventional outsole materials as are known and used in the footwear arts. While the outsole components 122 of this example sole structure 104 are shown as separate elements that are fixed to the midsole structure 120 (e.g., by cements or adhesives, by mechanical connectors, etc.), this is not a requirement.
  • the outsole component(s) 122 may be integrally formed as part of the midsole structure 120 , e.g., as an exposed surface of midsole material, as a hardened exterior surface of midsole material, etc. Also, while it may do so, the outsole component(s) 122 need not completely cover the bottom exterior surface of the midsole structure 120 .
  • the outsole 122 and midsole 120 include spacing to define a gap or channel 124 that houses the flex joint area 250 of the flexible foot support member 200 .
  • This gap or channel 124 provides room for the flex joint to move, as will be described in more detail below in conjunction with FIGS. 1E and 1F .
  • the strobel 116 shown in these figures may be made from a sufficiently flexible and/or stretchable material so as to support the flexion of flex joint area 250 described in more detail below (or it may include one or more gaps).
  • this example foot support member 200 constitutes a single, one-piece construction that spans to support an entire plantar surface of a wearer's foot. If necessary or desired, the top surface 202 of the foot support member 200 may be curved and/or contoured to better conform to the shape of the upper 102 and/or to a plantar surface of a wearer's foot.
  • the foot support member 200 may be made from a relatively hard but flexible material, such as plastics, fiber or other reinforced polymers (e.g., carbon fiber reinforced plastics, fiberglass, etc.), nylons, and the like.
  • a raised wall 204 extends upward from the plantar supporting top surface 202 at least partially around the perimeter of the foot support member 200 .
  • This raised wall 204 may help position and securely maintain the wearer's foot on the foot support surface 202 .
  • the main support surface 202 may be a thin, plate-like structure (e.g., less than 3 mm thick, and even less than 2 mm thick) and at least somewhat flexible even at locations away from the flex joints 250 such that it may flex under force (e.g., the user's weight) and then spring back to its original shape (and thus potentially provide some return energy to the foot).
  • the raised perimeter wall 204 may extend around at least 50% of the perimeter length of the foot support member 200 , and it may extend around at least 80%, at least 90% or even at least 95% of the perimeter length in some structures.
  • the raised perimeter wall 204 may be higher in some areas than other areas.
  • the raised perimeter wall 204 may be somewhat higher in the rear heel area, e.g., to provide a heel counter type structure (or other heel supporting structure), if desired.
  • the raised perimeter wall 204 may be somewhat higher around the lateral forefoot side area (e.g., adjacent the little toe area) to provide additional support for the foot during a cut maneuver or rapid turning action.
  • the perimeter wall 204 may include gaps 204 a at areas where the flex joint areas 250 of the foot support member 200 reach the outer edge or perimeter of the top surface 202 . These gaps 204 a in the perimeter wall 204 help enhance the freedom of movement of the flex joint areas 250 .
  • the gaps 204 a may extend any desired perimeter length around the support member 200 without departing from the invention.
  • the flexible foot support member 200 may be made in any desired manner without departing from the invention.
  • the flexible foot support member 200 may be made using molding techniques, such as by molding polymeric materials, e.g., by compression molding or injection molding.
  • the flexible foot support member 200 may be made from fiber reinforced polymeric “pre-preg” materials shaped using molds and/or in other manners as are known and used in that art.
  • the flexible foot support member 200 may be made using rapid manufacturing additive fabrication techniques, such as selective laser sintering, stereolithography, 3D printing, and the like.
  • This illustrated example foot support member 200 includes four separate flex joint areas 250 a through 250 d .
  • These flex joint areas 250 a through 250 d include a hinge or one-way joint type structure that allows the adjacent plantar support surfaces to rotate away from one another (i.e., so that the gap or channel 206 gets larger) but stops over rotation in the direction toward one another (e.g., to completely close the gap or channel 206 ).
  • This illustrated flexible foot support member 200 includes four flex joint areas 250 a through 250 d that divide the plantar support surface 202 into five regions 202 a through 202 e that are movable with respect to one another.
  • a heel flex joint area 250 a extends forward from a rear (or side) medial heel area to a lateral side heel area to separate the plantar support surface 202 into a lateral, rear heel support surface 202 a and a medial heel and arch support surface 202 b .
  • This flex joint area 250 a allows more natural motion to the foot as a wearer lands a step (e.g., when running or walking) More specifically, during a running or walking step cycle, the rear, lateral side (outside) of the heel typically contacts the ground first, and the foot rolls inward and forward as the step progresses.
  • the flex joint area 250 a allows freedom of motion for the heel area after initial ground contact and may allow the medial side of the foot to contact the ground more quickly and easily (e.g., without the wearer having to fight the stiffness of a support plate or other stiffening or flex limiting structure within the shoe sole construction).
  • a rear forefoot flex joint area 250 b extends across the plantar support surface 202 in a medial side-to-lateral side direction and separates the medial heel and arch support surface 202 b from the central forefoot support surface 202 c .
  • a central forefoot flex joint area 250 c extends across the plantar support surface 202 in the medial side-to-lateral side direction and separates the central forefoot support surface 202 c from a front forefoot support surface 202 d (which supports the big toe area of the foot, e.g., during a toe-off phase of a step cycle).
  • An angled or curved forefoot flex joint area 250 d extends across the plantar support surface 202 from a forward (or medial side) toe location to a forward lateral side toe location and separates the front forefoot support surface 202 d from a lateral toe support surface 202 e .
  • These flex joint areas 250 b , 250 c , and 250 d help provide flexibility and more natural motion capabilities for the latter parts of a step cycle, e.g., as the force on the user's foot rolls from back to front, during the rearward push (e.g., off the ball of the foot and/or toes) and toe off phases of a step cycle.
  • the flex joint areas 250 a through 250 d are structured so that at least some portions of the actual hinging joint are located below the main or major bottom surface 202 f of the plantar support surface 202 . While the flex joint areas 250 a through 250 d of FIGS. 1C and 1D are shown extending continuously from one end of the joint area to the other, other arrangements are possible without departing from this invention.
  • an individual flex joint area 250 a - 250 d may have its flex or hinging structure at plural, separated locations along the overall length of the interface or joint area (e.g., such that the combined lengths of the flex or hinging structures along a single joint area 250 a - 250 d extend at least about 35%, and in some examples, at least about 50% or even at least about 70% of an overall length of the interface between the adjacent plantar support members).
  • one or more of the individual flex joints 250 a - 250 d may have its flex or hinging structure extend continuously over at least 60% of a length of an interface between the adjacent plantar support surfaces 202 a - 202 e , and in some examples, extending continuously over at least 75%, over at least 90%, or even over at least 95% of the length of the interface between the adjacent plantar support surfaces 202 a - 202 e .
  • the flex joint areas 250 a - 250 d may be positioned so that their outermost edges are located somewhat inside the perimeter wall 204 a (e.g., recessed inward from the extreme side edges of the sole 104 ).
  • FIG. 1E shows a portion of the flex joint area 250 b between the medial heel and arch support surface 202 b and the central forefoot support surface 202 c (although any of the other flex joint areas 250 a , 250 c , and 250 d may have the same or a similar structure).
  • This example flex joint 250 b includes a first stop wall 252 a extending (e.g., downward) from plantar support surface 202 b and a second stop wall 252 b extending (e.g., downward) from the other, adjacent plantar support surface 202 c .
  • stop walls 252 a , 252 b may be coextensive with one another or they may extend over the overall length of the interface between support surfaces 202 b and 202 c over different extents (as long as they have some immediately adjacent area).
  • the first stop wall 252 a and the second stop wall 252 b are positioned such that: (a) plantar support surface 202 b can move relative to plantar support surface 202 c in a direction to increase a width of the gap 206 between the support surfaces 202 b , 202 c (note FIG.
  • the stop walls 252 a , 252 b may be shaped so as to limit rotation of the support surfaces 202 b , 202 c toward one another leaving any desired gap 206 size at the top surface 202 , without departing from this invention (including having the edges of the gap pressed against one another at the top surface of plantar support surface 202 , if desired).
  • the illustrated flex joint 250 b of this example structure 200 is formed from a rigid yet flexible material as a unitary, one-piece construction with the main plantar support surfaces 202 b and 202 c of the foot support member 200 .
  • the entire foot support member 200 of this example including all support surfaces 202 a through 202 e and flex joints 250 a through 250 d , is made as a unitary, one-piece construction.
  • Other types of flex joint structures are possible, however, without departing from the invention, including other hinge type structures located below the top surface of the plantar support surface 202 , and optionally flex joint structures that extend at least partially below the bottom major surface 202 f of the flexible foot support member 200 .
  • each flex joint area 250 may include one or more conventional hardware type hinge components.
  • the flex joint areas 250 could include crimping, pre-bends, or other structures to facilitate and help assure bending at the desired locations and/or over the desired line or arc of the overall joint structure.
  • the shoe 100 is constructed so that the flexible foot support member 200 is at least partially located between the upper 102 and one or more midsole components 120 .
  • the sole structure 302 includes one or more midsole components 304 (e.g., of any of the types described above) located between the flexible foot support member 200 and the upper 102 .
  • the flexible foot support member 200 in this example structure 300 is engaged with the upper 102 via cements or adhesives (or in other manners), e.g., along its raised periphery side walls 204 .
  • the midsole component(s) 304 may be engaged with any one or more of the upper 102 (e.g., at the upper 102 bottom surface and/or along the upper side(s)), the strobel member 116 , and/or the top surface 202 of the flexible foot support member 200 .
  • the midsole component(s) 304 may be unattached and simply held in place by the sandwiched arrangement between the flexible foot support member 200 and the other structures (optionally, with raised ribs or other retaining element structures provided on the top surface 202 of the flexible foot support member 200 and/or the bottom surface of the upper 102 to help hold the midsole component(s) 304 in the desired place(s).
  • gaps or spaces 308 may be provided in the midsole component(s) 304 at or near the location(s) of the flexible joint areas 250 , e.g., to help maintain and assure flexibility at these locations. This is not a requirement.
  • the midsole component(s) 304 is (are) made of sufficiently soft, flexible, and/or stretchable material (at least at the flex joint areas) so as not to substantially impede the flexing action shown in FIGS. 1E and 1F , then the gap 308 may not be needed.
  • the midsole component(s) 304 also may extend to fill in the spaces 310 at the sides (between the flexible foot support member 200 and the upper 102 ), if desired.
  • midsole components 304 may be provided at different areas of the footwear structure 300 (e.g., depending on the needs in the various areas). Also, if desired, midsole components 304 may be omitted at some areas of the overall sole structure 302 (e.g., in the arch or midfoot area).
  • the illustrated example sole structure 302 of FIG. 2 further includes one or more sole members 306 engaged with the bottom surface of the flexible foot support member 200 .
  • the sole member(s) 306 may include one or more midsole components (e.g., one or more of polymeric foam, fluid-filled bladder(s), mechanical impact force attenuating elements, etc.) and/or one or more outsole components (e.g., made from a wear resistant material, including one or more traction enhancing elements (potentially including permanent or removable cleats), etc.). If necessary, gaps or spaces 124 may be provided at appropriate locations in the overall sole component(s) 306 to enhance the flexibility of the overall sole structure 302 at the flex joint areas 250 .
  • sole members 306 may be provided at different areas of the footwear structure 300 (e.g., depending on the needs in the various specific areas). Also, if desired, sole members 306 outside of the flexible foot support member 200 may be omitted at some areas of the overall sole structure 302 (e.g., in the arch area).
  • FIGS. 3A and 3B illustrate another example flexible foot support member 400 in accordance with some examples of this invention.
  • This example flexible foot support member 400 may be incorporated into an overall footwear structure, e.g., in the various manners described above in conjunction with FIGS. 1A , 1 B, and/or 2 .
  • This example flexible foot support member 400 differs from the foot support member 200 shown in FIGS. 1A-1F primarily based on the orientation of the flex joint areas 250 (which may have the same general structure, including stop wall structures, as the flex joint areas 250 a - 250 d described above in conjunction with flexible foot support member 200 ).
  • this example flexible foot support member 400 includes an upper plantar support surface 202 ; a lower major surface 202 f ; raised perimeter side walls 204 extending at least partially around the perimeter of the foot support member 400 ; gaps or spaces 204 a at various locations around the raised perimeter wall 204 ; gaps 206 at the plantar support surface 202 between adjacent portions of the plantar support surface 202 that are separated by a flex joint area 250 ; and an overall unitary, one piece construction.
  • the flexible foot support member 400 of this example may be used to enhance longitudinal flexibility of the foot and to promote natural pronation during a walking or running step cycle by providing more flexibility along longitudinal lines of the wearer's foot (e.g., between adjacent sets of metatarsal bone components of the foot).
  • this flexible foot support member 400 includes five flex joint areas 250 a through 250 e that separate the plantar support surface 202 into five separate plantar support portions or members 202 a through 202 e .
  • the five flex joint areas 250 a through 250 e originate from (or converge to) a common area 250 P (located in the central heel area of the foot support member 400 in this example).
  • the side stop walls of at least some of the flex joint areas 250 a - 250 e may terminate short of the common area 250 P to promote flexibility in the different flex line directions. While more or fewer flex joint areas may be provided, in this illustrated example, at least three of the flex joint areas ( 250 a , 250 c , and 250 d ) extend generally or primarily in a front-to-back (heel-to-toe) direction. Continuous flex joint lines are provided from the rear heel to extreme forefoot areas in this example.
  • this illustrated example flexible foot support member 400 includes: (a) a plantar support member 202 a located at a rear lateral heel area of the flexible foot support member 400 ; (b) a plantar support member 202 b located at a rear medial heel area of the foot support member 400 ; (c) a flex joint 250 a connecting plantar support members 202 a and 202 b that extends from the central heel area (e.g., from common point 250 P) to a rear heel area of the foot support member 400 ; (d) a medial arch/forefoot plantar support member 202 c extending at least from a midfoot area to a forefoot area of the foot support member 400 ; (e) a flex joint 250 b connecting plantar support members 202 b and 202 c that extends from the central heel area (e.g., from common point 250 P) to a medial midfoot side area of the foot support member 400 ; (f) a central arch/forefoot plantar support member
  • FIGS. 4A and 4B illustrate another example flexible foot support member 500 in accordance with some examples of this invention.
  • This example flexible foot support member 500 may be incorporated into an overall footwear structure, e.g., in the various manners described above in conjunction with FIGS. 1A , 1 B, and/or 2 .
  • This example flexible foot support member 500 differs from the foot support members 200 , 400 shown in FIGS. 1A-1F , 3 A, and 3 B primarily based on the orientation of the flex joint areas 250 (which may have the same general structure, including stop wall structures, as the flex joint areas described above in conjunction with flexible foot support member 200 ).
  • this example flexible foot support member 500 includes an upper plantar support surface 202 ; a lower major surface 202 f ; raised perimeter side walls 204 extending at least partially around the perimeter of the foot support member 500 ; gaps or spaces 204 a at various locations around the raised perimeter wall 204 ; gaps 206 at the plantar support surface 202 between adjacent portions of the plantar support surface 202 that are separated by a flex joint area 250 ; and an overall unitary, one piece construction.
  • the flexible foot support member 500 of this example may be used to enhance flexibility of the foot, particularly in the heel and forefoot areas, under a range of different use conditions. As shown in FIGS. 4A and 4B , this flexible foot support member 500 includes eleven flex joint areas 250 a through 250 k that separate the plantar support surface 202 into nine separate plantar support portions or members 202 a through 202 i . As further shown, some of the flex joint areas originate from (or converge to) one or more common areas. Additionally, in the forefoot area, the flex joint areas are oriented so as to form continuous intersecting lines of flex for the foot support member 500 .
  • the side stop walls of at least some of the flex joint areas 250 a - 250 k may terminate short of any common or intersecting areas to promote flexibility in the various different directions. Also, while more or fewer flex joint areas may be provided, in this illustrated example, the flex joint areas are provided at locations to promote the natural flexibility and bending motions of a foot.
  • this illustrated example flexible foot support member 500 includes: (a) an arch/midfoot plantar support member 202 a ; (b) a medial forefoot plantar support member 202 b extending from a central foot area to a medial side area; (c) a first flex joint 250 a connecting the arch/midfoot plantar support member 202 a to the medial forefoot plantar support member 202 b ; (d) a lateral forefoot plantar support member 202 c ; (e) a second flex joint 250 b connecting the arch/midfoot plantar support member 202 a to the lateral forefoot plantar support member 202 c ; (f) a central forefoot plantar support member 202 d extending from a lateral side to a medial side of the foot support member 500 ; (g) a third flex joint 250 c connecting the medial forefoot plantar support member 202 b with the central forefoot plantar support member 202 d ; (h)
  • flex joints 250 i , 250 j , and 250 k meet at a common point 250 P located in a central heel area of the plantar support surface 202 (with flex joint 250 i extending to a medial side heel or midfoot area, flex joint 250 j extending to a lateral side heel or midfoot area, and flex joint 250 k extending to a rear heel area (to the lateral side of center)).
  • Flex joints 250 a , 250 b , 250 c , and 250 d meet at a common point 250 Q located at a central forefoot area of the plantar support surface 202 (with flex joints 250 a and 250 c extending to spaced locations at the medial side of the forefoot area and flex joints 250 b and 250 d extending to spaced locations at the lateral side of the forefoot area).
  • the flex joints 250 a - 250 d provide two intersecting lines of flex (e.g., with flex joint 250 a substantially continuous and/or collinear with flex joint 250 d and flex joint 250 b substantially continuous and/or collinear with flex joint 250 c ).
  • Flex joints 250 e , 250 f , 250 g , and 250 h meet at a common point 250 R located at a central forefoot area of the plantar support surface 202 and forward of common point 250 Q (with flex joints 250 e and 250 g extending to spaced locations at the medial side of the forefoot area and flex joints 250 f and 250 h extending to spaced locations at the lateral side of the forefoot area).
  • the flex joints 250 e - 250 h provide two intersecting lines of flex (e.g., with flex joint 250 e substantially continuous and/or collinear with flex joint 250 h and flex joint 250 f substantially continuous and/or collinear with flex joint 250 g ).
  • the flex joints meet the perimeter of the support member 500 at the gap areas 204 a in the raised perimeter side wall 204 , and in some instances, more than one flex joint will extend to a single gap area 204 a.
  • flexible foot support members 200 , 400 , 500 that underlie and support an entire plantar surface of a wearer's foot (e.g., extending completely and continuously from heel-to-toe and from the lateral side to the medial side)
  • flexible foot support members of the types described above may be located solely in the heel area of a shoe or sole structure, solely in the arch area, solely in the forefoot area, or in any combination of these areas (e.g., with separate heel and forefoot support plates).
  • FIGS. 1B and 2 show the flex joint area 250 recessed within a gap or channel 124 in the exterior sole structure, this is not a requirement.
  • at least some portion(s) of the flex joint areas 250 may be exposed so as to contact the ground in use, e.g., optionally, with at least some portion(s) of the flex joint area 250 serving as a traction element for the shoe 100 , 300 .
  • the vertical height(s) of sole component(s) 306 may be reduced so that flex joint area extends beyond the bottom surface of sole component(s) 306 and/or the sole component(s) 306 may be eliminated (adjacent at least some portion(s) of flex joint area 250 ) so that the flex joint area 250 is exposed to the ground surface.
  • the joint area at the bottom ends of side walls 252 a and 252 b may extend further downward to directly contact the ground and/or to serve as a base to which another traction element is mounted (e.g., a cleat, a hard rubber layer, etc.).
  • an individual flex joint area 250 may include separated extending structures for directly contacting the ground, optionally at spaced locations akin to conventional cleat locations in shoes.
  • Each separate extended length flex joint structure that functions as a traction element may have a relatively short length (e.g., separated lengths having an extended height for 1 inches along the joint area 250 or less).
  • Other specific structures and arrangements are possible to allow the exterior surface of flex joint area 250 to serve directly as a traction element and/or as a base for supporting a separate traction element.
  • FIGS. 5A through 5E illustrate an example sock liner 600 , insole member, and/or strobel member or the like that may be incorporated into sole structures, footwear structures, and/or foot-receiving device structures in accordance with at least some examples of this invention.
  • the bottom surface 602 as shown in FIG. 5A , may be relatively conventional, e.g., made from or covered with a textile element (and optionally, a continuous, single piece textile element), made from a foam material, etc.
  • the top surface 604 as shown in FIG. 5B , also may be made, at least in part, from a textile element, although it may be made (at least in part) from other materials as well.
  • the forefoot portion of the top surface 604 is made from a conventional textile material 604 a (optionally the same textile as on the bottom surface 602 ) while the heel and/or midfoot portion(s) is (are) made from a somewhat more rigid material 604 b (e.g., like a thin, rigid, yet flexible plastic sheet).
  • This more rigid material 604 b may overlay the textile material 604 a , if desired (and may be engaged with it, e.g., by adhesives or cements).
  • the more rigid material 604 b extends completely from the lateral side to the medial side of the sock liner 600 and extends from the rearmost heel area to the generally V-shaped border 606 in the midfoot/arch or forefoot area.
  • Other rigid material 604 b sizes and/or shapes are possible without departing from the invention (including no rigid material 604 b , if desired).
  • the top textile material 604 a may help wick away moisture and perspiration and help keep the foot cool and dry.
  • a soft polymeric foam material 608 is sandwiched between the upper textile layer 604 a /more rigid material layer 604 b and the bottom layer 602 , e.g., as shown in the cross sectional views of FIGS. 5C-5E .
  • This foam material 608 provides a comfortable surface for engaging the foot.
  • the polymeric foam material 608 may vary in thickness, if desired, at various different foot support areas of the sock liner structure 600 .
  • FIGS. 5B through 5E further illustrate that the materials 604 a and/or 604 b of the top surface 604 of sock liner 600 further include one or more gaps or cuts 610 defined therein. These cuts 610 help provide predetermined lines and locations of flex in the sock liner 600 to support natural motion while still providing a comfortable support surface for the foot.
  • FIG. 5E includes a cross sectional view at the location of section line 5 D- 5 D with the sock liner 600 bent. The cuts 610 allow the top layer 604 a and/or 604 b to be made from desired materials that may not have sufficient stretch or flexibility to support or allow the full flexibility of plates 200 , 400 , 500 .
  • the gaps or cuts 610 also may extend at least partially through the polymeric foam material 608 .
  • the sock liner 600 (or insole or strobel member) could be made as completely separate pieces or parts (e.g., cut or separated at one or more of the gaps 610 ). Gaps or cuts 610 may be provided at any desired locations, including at locations selected to support and enhance flexibility at the flex joints 250 in flexible foot support members 200 , 400 , 500 . While it may be so, the cut or gap pattern in the sock liner 600 need not exactly match the flex line numbers, orientations, and/or arrangements in the underlying flexible foot support member 200 , 400 , 500 .
  • flexible foot support members may be incorporated into a foot-support member (e.g., that, at least in part supports a plantar surface of a wearer's foot) of the foot-receiving device, and this foot-support member may be engaged with a foot-covering member of the foot-receiving device.
  • the foot-covering member may, at least partially, contain a wearer's foot, and optionally, at least in part, may help maintain the foot in position with respect to the foot-support member.
  • the foot-covering member may be similar in structure and/or function to a footwear upper.

Abstract

Flexible foot support members may include: (a) a first plantar support member; (b) a second plantar support member; and (c) a flex joint connecting the first and second plantar support members. The flex joint (e.g., one or more hinge structures) allows movement of the first plantar support surface with respect to the second plantar support surface in at least one direction, and optionally stops or limits this relative movement in the opposite direction. Footwear and sole structures including such flexible foot support members may allow more natural motion and flexion of a wearer's foot during a variety of motions, such as various phases of a walking or running step cycle, during turn or cutting events, when jumping, etc.

Description

    FIELD OF THE INVENTION
  • The present invention relates to the field of footwear and other foot-receiving devices. More specifically, some aspects of the present invention pertain to flexible foot support components for supporting some or all of a plantar surface of a wearer's foot. Additional aspects of this invention relate to sole structures and/or articles of footwear that incorporate such flexible foot support components.
  • BACKGROUND
  • Conventional articles of athletic footwear include two primary elements, namely, an upper and a sole structure. The upper provides a covering for the foot that securely receives and positions the foot with respect to the sole structure. In addition, the upper may have a configuration that protects the foot and provides ventilation, thereby cooling the foot and removing perspiration. The sole structure is secured to a lower surface of the upper and generally is positioned between the foot and any contact surface. In addition to attenuating ground reaction forces and absorbing energy, the sole structure may provide traction and control potentially harmful foot motion, such as over pronation. The general features and configurations of the upper and the sole structure are discussed in greater detail below.
  • The upper forms a void on the interior of the footwear for receiving the foot. The void has the general shape of the foot, and access to the void is provided at an ankle opening. Accordingly, the upper extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. A lacing system often is incorporated into the upper to allow selective changes to the size of the ankle opening and to permit the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet with varying proportions. In addition, the upper may include a tongue that extends under the lacing system to enhance the comfort of the footwear (e.g., to moderate pressure applied to the foot by the laces). The upper also may include a heel counter to limit or control movement of the heel.
  • The sole structure generally incorporates multiple layers that are conventionally referred to as an insole, a midsole, and an outsole. The insole (which also may constitute a sock liner) is a thin member located within the upper and adjacent the plantar (lower) surface of the foot to enhance footwear comfort, e.g., to wick away moisture and provide a soft, comfortable feel. The midsole, which is traditionally attached to the upper along the entire length of the upper, forms the middle layer of the sole structure and serves a variety of purposes that include controlling foot motions and attenuating impact forces. The outsole forms the ground-contacting element of footwear and is usually fashioned from a durable, wear-resistant material that includes texturing or other features to improve traction.
  • While numerous footwear models and characteristics are available on the market, new footwear models and constructions continue to be developed and are welcome advances in the art.
  • SUMMARY
  • This Summary is provided to introduce some general concepts relating to this invention in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the invention.
  • Some aspects of this invention relate to flexible foot support members for articles of footwear or other foot-receiving devices (such as ski or snowboard binders, devices for holding feet during play of video games, etc.). Flexible foot support members of this type, sole structures, articles of footwear, and/or other foot-receiving devices that incorporate such support members may allow a more natural motion and flexion of a wearer's foot during a variety of motions or activities, such as during various phases of a walking or running step cycle, during turn or cutting events, when jumping, etc.
  • Flexible foot support members in accordance with at least some examples of this invention may include: (a) a first plantar support member including a first upper surface and a first lower surface; (b) a second plantar support member including a second upper surface and a second lower surface; and (c) a flex joint connecting the first plantar support member with the second plantar support member. The flex joint may take on a variety of configurations that allow movement of the first plantar support surface with respect to the second plantar support surface in at least one direction (and optionally stops or limits this relative movement in one or more other directions). This rotational stop or limitation feature can help prevent over-flexing of the flexible foot support member in use (e.g., on the field of play). The flex joint may include one or more hinge structures joining the first plantar support member with the second plantar support member.
  • Additional aspects of this invention relate to footwear sole structures (or other foot-receiving device foot support structures) that include such flexible supports members, articles of footwear (or other foot-receiving devices) including such flexible support members, and methods of making such flexible foot support members, foot support structures, sole structures, articles of footwear, and/or foot-receiving devices.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • The foregoing Summary, as well as the following Detailed Description, will be better understood when considered in conjunction with the accompanying drawings in which like reference numerals refer to the same or similar elements in all of the various views in which that reference number appears. The features in the attached drawings are not necessarily shown to scale.
  • FIGS. 1A through 1F provide various views of an article of footwear, a sole structure, and a flexible foot support member in accordance with one example of this invention;
  • FIG. 2 is a cross sectional view of an alternative sole structure and/or article of footwear in accordance with another example of this invention;
  • FIGS. 3A and 3B illustrate another example flexible foot support member in accordance with some examples of this invention;
  • FIGS. 4A and 4B illustrate another example flexible foot support member in accordance with some examples of this invention; and
  • FIGS. 5A through 5E provide various views of an insole component, strobel member, sock liner, or other foot support member that may be used in some structures according to this invention.
  • DETAILED DESCRIPTION
  • In the following description of various examples of structures, components, and methods according to the present invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example structures, environments, and articles in which aspects of the invention may be practiced. It is to be understood that other structures, environments, and articles may be utilized and that structural and functional modifications may be made to the specifically described structures and methods without departing from the scope of the present invention.
  • I. GENERAL DESCRIPTION OF ASPECTS OF THIS INVENTION
  • As noted above, aspects of this invention relate to flexible foot support members, sole structures or other foot support components including such support members, and articles of footwear (e.g., athletic footwear, including ski and/or snowboarding boots) or other foot-receiving devices that include such support members. Additional aspects of this invention will become more apparent from the detailed description below.
  • A. Flexible Foot Support Members According to Aspects of this Invention
  • Some aspects of this invention relate to flexible foot support members for articles of footwear or other foot-receiving devices. Such flexible foot support members may include: (a) a first plantar support member including a first upper surface and a first lower surface; (b) a second plantar support member including a second upper surface and a second lower surface; and (c) a flex joint connecting the first plantar support member with the second plantar support member. The term “plantar support member” may be used synonymously and interchangeably in this specification with the term “plantar support portion.” The flex joint may take on a variety of configurations that allow some movement of the first plantar support surface with respect to the second plantar support surface. As some more specific examples, the flex joint may include one or more hinge structures joining the first plantar support member with the second plantar support member, wherein the hinge structure(s) is (are) at least partially located below the first and second lower surfaces (e.g., so as to provide an overall substantially smoothly contoured upper support surface for supporting the wearer's foot (or an overall upper support surface free from upward projections)). In some examples, the flex joint may be formed with the plantar support members as a unitary, one-piece construction.
  • In some example structures in accordance with this invention, the hinge structure may extend continuously over at least 30% of a length of an interface between the first plantar support surface and the second plantar support surface, and in some examples, the hinge structure may extend at least 60%, at least 80%, at least 90%, or even at least 95% of this interface length.
  • Flex joints in accordance with at least some examples of this invention may allow the plantar support members to freely flex in one direction while limiting an extent of the flex in the other (opposite) direction (e.g., to prevent over-flexing in that direction in use). Any type of stop or motion limiting structure may be provided, e.g., in a hinge type structure, without departing from this invention. As some more specific examples, at least one (and optionally all) of the flex joints connecting plantar support members in a flexible foot support member may include: (a) a first stop wall extending from the upper surface of one of the plantar support members and (b) a second stop wall extending from the upper surface of the other plantar support member. These two stop walls may be positioned such that: (i) the upper surfaces can move relative to one another in a direction to increase a width of a gap between the upper surfaces and (ii) contact or other interaction between the stop walls limits or stops movement of the upper surfaces with respect to one another in a direction closing the gap. The stop walls prevent over rotation or over-flexion of the plantar support members with respect to one another in at least one direction. A connection structure may be provided to engage the bottom of the first stop wall with the bottom of the second stop wall to thereby join the first and second plantar support members together. If desired, the entire flexible foot support member may be formed as a unitary, one-piece construction (so that the plantar support members and connection structure (and thus the flex joint) form a unitary, one-piece construction).
  • Multiple plantar support members and flex joints may be provided in an individual flexible foot support member without departing from this invention. If desired, the plantar support surfaces may combine to support at least a majority of the plantar surface of a wearer's foot (i.e., the plantar support surfaces may be sized so as to support at least 50% of the wearer's foot's bottom surface). In some more specific examples, the plantar support surfaces in a single flexible foot support member may combine to support at least 75%, at least 85%, at least 90%, or even at least 95% of the plantar surface of a wearer's foot. The plantar support surfaces may extend continuously from the rearmost heel area of the sole structure to the forwardmost toe area of the sole structure and/or they may extend continuously from the medial side to the lateral side of the sole structure (and optionally may underlie or support 100% of the wearer's plantar surface and/or foot).
  • Flex joints may be provided at any desired locations in the footwear structure, and they may extend in any desired directions and/or over any desired extent of the flexible foot support structure without departing from this invention. As some more specific examples, the plantar support member(s) and/or the flex joint(s) in a foot support member may take on one or more of the following characteristics:
      • a flex joint may be located in a forefoot area of the flexible foot support member;
      • a flex joint may extend in a back-to-front direction from a rear heel or medial heel area of the flexible foot support member to a lateral heel or lateral midfoot area of the flexible foot support member;
      • a flex joint may have an angular shape, e.g., having a first leg and a second leg joined together at a 45° to 135° angle, and in some examples, at a 60° to 120° angle (optionally at a curved junction between the legs);
      • a flex joint may have a curved or arced shape (and optionally located in a forward toe area of the flexible foot support member);
      • a flex joint may extend in a front-to-back direction of the flexible foot support member;
      • a flex joint may extend in a lateral side-to-medial side direction of the flexible foot support member;
      • multiple side-to-side flex joints may be provided in a forefoot area of the flexible foot support member;
      • a plantar support member may extend at least from a midfoot area to a forefoot area of the flexible foot support member;
      • one or more plantar support members may extend across the forefoot area of the flexible foot support member in the lateral side-to-medial side direction;
      • two or more plantar support members may be provided in a heel area of the flexible foot support member, and optionally, three plantar support members in a heel area may be interconnected by flex joints having a generally Y-shaped arrangement;
      • multiple flex joints may originate from the same point or area on a flexible foot support member structure; and/or
      • multiple flex joints may be oriented so as to provide overall lines of flexion that cross one another or intersect, e.g., in a forefoot area of a flexible foot support member.
  • Still additional aspects of this invention relate to sole structures for articles of footwear (e.g., including midsole and/or outsole components) that have flexible foot support members of the types described above, as well as to articles of footwear or foot-receiving devices incorporating flexible foot support members of the types described above.
  • II. DETAILED DESCRIPTION OF EXAMPLE FOOT SUPPORT MEMBERS ACCORDING TO THIS INVENTION
  • Referring to the figures and following discussion, various articles of footwear, footwear components, and features thereof in accordance with the present invention are described. The concepts disclosed with respect to various aspects of this invention may be applied to a wide range of athletic footwear styles, including, but not limited to: running shoes, walking shoes, cross training shoes, football shoes, hiking shoes, soccer shoes, baseball shoes, track shoes, basketball shoes, skateboard shoes, tennis shoes, golf shoes, cleated shoes, and the like. The concepts and aspects of this invention also may be applied to a range of other footwear and foot-receiving device products, such as dress shoes, casual shoes, boots, bindings (e.g., for skis or snowboards), devices for holding feet for the play of video games, etc. Accordingly, the present invention is not limited to the precise embodiments disclosed herein, but it applies more generally to other types of footwear and/or other product lines.
  • FIG. 1A shows a side view of an article of footwear 100 in accordance with at least some examples of this invention. The article of footwear 100 includes an upper 102 and a sole structure 104 engaged with the upper 102. The upper 102 may be made from any desired material or combinations of materials, in any desired constructions and/or configurations, without departing from this invention, including from conventional materials and in conventional constructions and/or configurations as are known and used in the art. The upper 102, at least in part, defines an opening 106 for receiving the wearer's foot. The size of the upper 102 and the opening 106 may be adjusted and controlled, e.g., using the laces 108 that extend along a throat or instep opening 110 of the shoe 100, e.g., as is conventionally known in the art. Other size adjustment mechanisms and/or footwear securing systems may be used in addition to or in place of the laces 108, such as buckles, straps, hook-and-loop fasteners, zippers, drawstrings, ties, etc. A tongue 112, bootie member, or other structure may be provided between the securing system (e.g., laces 106) and the wearer's foot to moderate the feel of the securing system on the foot.
  • The sole structure 104 of this article of footwear 100 will be described in more detail with additional reference to FIGS. 1B through 1F. FIG. 1B provides a cross sectional view of the article of footwear structure 100, e.g., taken along line 1B-1B shown in FIG. 1A. FIG. 1C provides a top view of a flexible foot support member 200 included in sole structure 104 in accordance with at least some examples of this invention, and FIG. 1D provides a bottom view of this foot support member 200. FIG. 1E provides an enlarged, close up view of a flex joint area 250 in flexible foot support members 200 in accordance with at least some examples of this invention (and as is used in the foot support member 200 of FIGS. 1B through 1D) in a closed position (e.g., at a stopped or motion limited position), and FIG. 1F provides an enlarged, close up view of the flex joint area 250 in an open position.
  • FIG. 1B provides additional details of the overall footwear structure 100 and sole structure 104 in this example of the invention. As shown in FIG. 1B, the upper 102 at least in part forms a foot receiving chamber 114. The bottom of the upper 102 in this example structure 100 is closed off by a strobel member 116, lasting member, or other suitable connecting structure, although such bottom closing members may be omitted, if desired (and, optionally, the two lower free ends of the upper 102 could be engaged together, the bottom of the upper 102 could be closed off or integrally formed during its manufacture as a single piece structure, etc.). The upper 102 may be attached to the strobel member 116 by stitching or in any other desired manner. An insole member, sock liner 118, orthotic, or other interior footwear component may overlie the strobel member 116 (and its connection to the upper 102), as shown in FIG. 1B.
  • The sole structure 104 of this example includes a flexible foot support member 200, which may be directly engaged with the upper 102 at least at some areas, e.g., by adhesives or cements, by mechanical connectors, etc. Examples of flexible foot support members 200 will be described in more detail in conjunction with FIGS. 1C through 1F and 3A through 4B. The sole structure 104 of this example further includes a midsole structure 120, which may constitute one or more separate parts that are engaged with the upper 102 and/or the foot support member 200. In this illustrated example, the midsole structure 120 constitutes multiple separated parts that are engaged with both the outer surface of the flexible support member 200 and the outer surface of the upper 102, e.g., by adhesives or cements. Alternatively, if desired, the flexible foot support member 200 may be unsecured to the upper 102 and/or midsole 120 (at least at some locations) and held in place by being sandwiched between the midsole structure 120 and the upper 102 (and optionally held in place by a fixed connection between the midsole structure 120 and the upper 102). Raised ridges or other suitable structures (e.g., on the interior surface of midsole component(s) 120) also may be provided to help hold the foot support member 200 in place with respect to the midsole component(s) 120.
  • The midsole structure 120 may take on any desired constructions and/or may be made of any desired materials without departing from this invention. As some more specific examples, one or more of the midsole component parts may be made from polymeric foam materials, such as polyurethane foams, ethylvinylacetate foams, and/or phylon foams as are known and used in the footwear art. As some additional examples, at least some portions of the midsole structure 120 may include one or more fluid-filled bladders (e.g., sealed polymeric envelopes that include a gas under atmospheric pressure or an elevated pressure). Fluid-filled bladder(s), when present, may be used in place of polymeric foam materials or may be at least partially incorporated into a polymeric foam material (e.g., at least partially housed within a chamber defined in the polymeric foam material). As still additional examples, at least some portion of the midsole structure 120 may include one or more mechanical type impact force attenuation elements (e.g., shock absorbing structures, such as springs) as are known in the art. Various different types of midsole components may be used in any desired combinations and/or arrangements without departing from this invention.
  • FIGS. 1A and 1B show the midsole structure 120 broken into multiple separated components. This type of structure helps allow the flex plate 200 to flex in the desired manners, as will be described in more detail below. Alternatively, if desired, at least some of the separations between portions of the midsole structure 120 could be omitted and the adjacent midsole components could be joined together, e.g., by a flexible joint, by a stretchable material, and/or in some other manner. Additionally or alternatively, the upper 102 and/or strobel 116 also may include some stretchable or flexible joint features at appropriate locations (e.g., near the flex joints 250 of the foot support member 200 and/or the breaks in the midsole structure 120), if necessary, to provide improved durability and/or to better support the flexibility features of the flexible foot support member 200, as will be described in more detail below.
  • The example sole structure 104 of FIGS. 1A and 1B further includes one or more outsole components 122, which may include a durable material designed to contact the ground in use (e.g., to provide adequate wear resistance, to provide traction enhancing features, etc.). The outsole component(s) 122 may be made from rubber, thermoplastic polyurethane, and/or any other desired material, including conventional outsole materials as are known and used in the footwear arts. While the outsole components 122 of this example sole structure 104 are shown as separate elements that are fixed to the midsole structure 120 (e.g., by cements or adhesives, by mechanical connectors, etc.), this is not a requirement. For example, the outsole component(s) 122 may be integrally formed as part of the midsole structure 120, e.g., as an exposed surface of midsole material, as a hardened exterior surface of midsole material, etc. Also, while it may do so, the outsole component(s) 122 need not completely cover the bottom exterior surface of the midsole structure 120.
  • In this illustrated example, the outsole 122 and midsole 120 include spacing to define a gap or channel 124 that houses the flex joint area 250 of the flexible foot support member 200. This gap or channel 124 provides room for the flex joint to move, as will be described in more detail below in conjunction with FIGS. 1E and 1F. Additionally, the strobel 116 shown in these figures may be made from a sufficiently flexible and/or stretchable material so as to support the flexion of flex joint area 250 described in more detail below (or it may include one or more gaps).
  • One example flexible foot support member 200 will be described in more detail below in conjunction with FIGS. 1C and 1D. As shown in these figures, this example foot support member 200 constitutes a single, one-piece construction that spans to support an entire plantar surface of a wearer's foot. If necessary or desired, the top surface 202 of the foot support member 200 may be curved and/or contoured to better conform to the shape of the upper 102 and/or to a plantar surface of a wearer's foot. The foot support member 200 may be made from a relatively hard but flexible material, such as plastics, fiber or other reinforced polymers (e.g., carbon fiber reinforced plastics, fiberglass, etc.), nylons, and the like. While not a requirement, in this illustrated example structure 200, a raised wall 204 extends upward from the plantar supporting top surface 202 at least partially around the perimeter of the foot support member 200. This raised wall 204 may help position and securely maintain the wearer's foot on the foot support surface 202. The main support surface 202 may be a thin, plate-like structure (e.g., less than 3 mm thick, and even less than 2 mm thick) and at least somewhat flexible even at locations away from the flex joints 250 such that it may flex under force (e.g., the user's weight) and then spring back to its original shape (and thus potentially provide some return energy to the foot).
  • As some more specific examples, the raised perimeter wall 204 may extend around at least 50% of the perimeter length of the foot support member 200, and it may extend around at least 80%, at least 90% or even at least 95% of the perimeter length in some structures. The raised perimeter wall 204 may be higher in some areas than other areas. For example, as shown in FIG. 1C, the raised perimeter wall 204 may be somewhat higher in the rear heel area, e.g., to provide a heel counter type structure (or other heel supporting structure), if desired. As another example, if desired, the raised perimeter wall 204 may be somewhat higher around the lateral forefoot side area (e.g., adjacent the little toe area) to provide additional support for the foot during a cut maneuver or rapid turning action.
  • As further shown in FIGS. 1C and 1D, the perimeter wall 204 may include gaps 204 a at areas where the flex joint areas 250 of the foot support member 200 reach the outer edge or perimeter of the top surface 202. These gaps 204 a in the perimeter wall 204 help enhance the freedom of movement of the flex joint areas 250. The gaps 204 a may extend any desired perimeter length around the support member 200 without departing from the invention.
  • The flexible foot support member 200 may be made in any desired manner without departing from the invention. As some more specific examples, the flexible foot support member 200 may be made using molding techniques, such as by molding polymeric materials, e.g., by compression molding or injection molding. As another example, the flexible foot support member 200 may be made from fiber reinforced polymeric “pre-preg” materials shaped using molds and/or in other manners as are known and used in that art. As still another example, if desired, the flexible foot support member 200 may be made using rapid manufacturing additive fabrication techniques, such as selective laser sintering, stereolithography, 3D printing, and the like.
  • This illustrated example foot support member 200 includes four separate flex joint areas 250 a through 250 d. These flex joint areas 250 a through 250 d include a hinge or one-way joint type structure that allows the adjacent plantar support surfaces to rotate away from one another (i.e., so that the gap or channel 206 gets larger) but stops over rotation in the direction toward one another (e.g., to completely close the gap or channel 206).
  • This illustrated flexible foot support member 200 includes four flex joint areas 250 a through 250 d that divide the plantar support surface 202 into five regions 202 a through 202 e that are movable with respect to one another. A heel flex joint area 250 a extends forward from a rear (or side) medial heel area to a lateral side heel area to separate the plantar support surface 202 into a lateral, rear heel support surface 202 a and a medial heel and arch support surface 202 b. This flex joint area 250 a allows more natural motion to the foot as a wearer lands a step (e.g., when running or walking) More specifically, during a running or walking step cycle, the rear, lateral side (outside) of the heel typically contacts the ground first, and the foot rolls inward and forward as the step progresses. The flex joint area 250 a allows freedom of motion for the heel area after initial ground contact and may allow the medial side of the foot to contact the ground more quickly and easily (e.g., without the wearer having to fight the stiffness of a support plate or other stiffening or flex limiting structure within the shoe sole construction).
  • A rear forefoot flex joint area 250 b extends across the plantar support surface 202 in a medial side-to-lateral side direction and separates the medial heel and arch support surface 202 b from the central forefoot support surface 202 c. Similarly, a central forefoot flex joint area 250 c extends across the plantar support surface 202 in the medial side-to-lateral side direction and separates the central forefoot support surface 202 c from a front forefoot support surface 202 d (which supports the big toe area of the foot, e.g., during a toe-off phase of a step cycle). An angled or curved forefoot flex joint area 250 d extends across the plantar support surface 202 from a forward (or medial side) toe location to a forward lateral side toe location and separates the front forefoot support surface 202 d from a lateral toe support surface 202 e. These flex joint areas 250 b, 250 c, and 250 d help provide flexibility and more natural motion capabilities for the latter parts of a step cycle, e.g., as the force on the user's foot rolls from back to front, during the rearward push (e.g., off the ball of the foot and/or toes) and toe off phases of a step cycle.
  • As further shown in these figures, in this illustrated example, the flex joint areas 250 a through 250 d are structured so that at least some portions of the actual hinging joint are located below the main or major bottom surface 202 f of the plantar support surface 202. While the flex joint areas 250 a through 250 d of FIGS. 1C and 1D are shown extending continuously from one end of the joint area to the other, other arrangements are possible without departing from this invention. For example, if desired, an individual flex joint area 250 a-250 d may have its flex or hinging structure at plural, separated locations along the overall length of the interface or joint area (e.g., such that the combined lengths of the flex or hinging structures along a single joint area 250 a-250 d extend at least about 35%, and in some examples, at least about 50% or even at least about 70% of an overall length of the interface between the adjacent plantar support members). As some more specific examples, if desired, one or more of the individual flex joints 250 a-250 d may have its flex or hinging structure extend continuously over at least 60% of a length of an interface between the adjacent plantar support surfaces 202 a-202 e, and in some examples, extending continuously over at least 75%, over at least 90%, or even over at least 95% of the length of the interface between the adjacent plantar support surfaces 202 a-202 e. In some structures, the flex joint areas 250 a-250 d may be positioned so that their outermost edges are located somewhat inside the perimeter wall 204 a (e.g., recessed inward from the extreme side edges of the sole 104).
  • The flex joint areas 250 a-250 d and the operation thereof will be described in more detail with additional reference to FIGS. 1E and 1F. FIG. 1E shows a portion of the flex joint area 250 b between the medial heel and arch support surface 202 b and the central forefoot support surface 202 c (although any of the other flex joint areas 250 a, 250 c, and 250 d may have the same or a similar structure). This example flex joint 250 b includes a first stop wall 252 a extending (e.g., downward) from plantar support surface 202 b and a second stop wall 252 b extending (e.g., downward) from the other, adjacent plantar support surface 202 c. These stop walls 252 a, 252 b may be coextensive with one another or they may extend over the overall length of the interface between support surfaces 202 b and 202 c over different extents (as long as they have some immediately adjacent area). The first stop wall 252 a and the second stop wall 252 b are positioned such that: (a) plantar support surface 202 b can move relative to plantar support surface 202 c in a direction to increase a width of the gap 206 between the support surfaces 202 b, 202 c (note FIG. 1F), and (b) contact between the first stop wall 252 a and the second stop wall 252 b stops and/or limits movement of support surface 202 b with respect to support surface 202 c in a direction closing the gap 206 (i.e., interaction between the stop walls 252 a and 252 b will limit rotation of the support surfaces 202 b and 202 c toward one another, as shown in FIG. 1E). The stop walls 252 a, 252 b may be shaped so as to limit rotation of the support surfaces 202 b, 202 c toward one another leaving any desired gap 206 size at the top surface 202, without departing from this invention (including having the edges of the gap pressed against one another at the top surface of plantar support surface 202, if desired).
  • The illustrated flex joint 250 b of this example structure 200 is formed from a rigid yet flexible material as a unitary, one-piece construction with the main plantar support surfaces 202 b and 202 c of the foot support member 200. In fact, the entire foot support member 200 of this example, including all support surfaces 202 a through 202 e and flex joints 250 a through 250 d, is made as a unitary, one-piece construction. Other types of flex joint structures are possible, however, without departing from the invention, including other hinge type structures located below the top surface of the plantar support surface 202, and optionally flex joint structures that extend at least partially below the bottom major surface 202 f of the flexible foot support member 200. As some additional examples, if desired, each flex joint area 250 may include one or more conventional hardware type hinge components. As yet additional examples, if desired, the flex joint areas 250 could include crimping, pre-bends, or other structures to facilitate and help assure bending at the desired locations and/or over the desired line or arc of the overall joint structure.
  • In the example shoe structure 100 of FIGS. 1A and 1B, the shoe 100 is constructed so that the flexible foot support member 200 is at least partially located between the upper 102 and one or more midsole components 120. Other structures are possible without departing from this invention. For example, as shown in the cross sectional view of FIG. 2 (which is a similar view to FIG. 1B), in this example footwear structure 300, the sole structure 302 includes one or more midsole components 304 (e.g., of any of the types described above) located between the flexible foot support member 200 and the upper 102. The flexible foot support member 200 in this example structure 300 is engaged with the upper 102 via cements or adhesives (or in other manners), e.g., along its raised periphery side walls 204. Optionally, if desired, the midsole component(s) 304 may be engaged with any one or more of the upper 102 (e.g., at the upper 102 bottom surface and/or along the upper side(s)), the strobel member 116, and/or the top surface 202 of the flexible foot support member 200. As another alternative, if desired, the midsole component(s) 304 may be unattached and simply held in place by the sandwiched arrangement between the flexible foot support member 200 and the other structures (optionally, with raised ribs or other retaining element structures provided on the top surface 202 of the flexible foot support member 200 and/or the bottom surface of the upper 102 to help hold the midsole component(s) 304 in the desired place(s).
  • As further shown in FIG. 2, if desired, gaps or spaces 308 may be provided in the midsole component(s) 304 at or near the location(s) of the flexible joint areas 250, e.g., to help maintain and assure flexibility at these locations. This is not a requirement. For example, if the midsole component(s) 304 is (are) made of sufficiently soft, flexible, and/or stretchable material (at least at the flex joint areas) so as not to substantially impede the flexing action shown in FIGS. 1E and 1F, then the gap 308 may not be needed. The midsole component(s) 304 also may extend to fill in the spaces 310 at the sides (between the flexible foot support member 200 and the upper 102), if desired. Different sizes, shapes, and/or structures of midsole components 304 may be provided at different areas of the footwear structure 300 (e.g., depending on the needs in the various areas). Also, if desired, midsole components 304 may be omitted at some areas of the overall sole structure 302 (e.g., in the arch or midfoot area).
  • The illustrated example sole structure 302 of FIG. 2 further includes one or more sole members 306 engaged with the bottom surface of the flexible foot support member 200. The sole member(s) 306 may include one or more midsole components (e.g., one or more of polymeric foam, fluid-filled bladder(s), mechanical impact force attenuating elements, etc.) and/or one or more outsole components (e.g., made from a wear resistant material, including one or more traction enhancing elements (potentially including permanent or removable cleats), etc.). If necessary, gaps or spaces 124 may be provided at appropriate locations in the overall sole component(s) 306 to enhance the flexibility of the overall sole structure 302 at the flex joint areas 250. Different sizes, shapes, and/or structures of sole members 306 may be provided at different areas of the footwear structure 300 (e.g., depending on the needs in the various specific areas). Also, if desired, sole members 306 outside of the flexible foot support member 200 may be omitted at some areas of the overall sole structure 302 (e.g., in the arch area).
  • FIGS. 3A and 3B illustrate another example flexible foot support member 400 in accordance with some examples of this invention. This example flexible foot support member 400 may be incorporated into an overall footwear structure, e.g., in the various manners described above in conjunction with FIGS. 1A, 1B, and/or 2. This example flexible foot support member 400 differs from the foot support member 200 shown in FIGS. 1A-1F primarily based on the orientation of the flex joint areas 250 (which may have the same general structure, including stop wall structures, as the flex joint areas 250 a-250 d described above in conjunction with flexible foot support member 200). More specifically, while not necessarily requirements, this example flexible foot support member 400 includes an upper plantar support surface 202; a lower major surface 202 f; raised perimeter side walls 204 extending at least partially around the perimeter of the foot support member 400; gaps or spaces 204 a at various locations around the raised perimeter wall 204; gaps 206 at the plantar support surface 202 between adjacent portions of the plantar support surface 202 that are separated by a flex joint area 250; and an overall unitary, one piece construction.
  • The flexible foot support member 400 of this example may be used to enhance longitudinal flexibility of the foot and to promote natural pronation during a walking or running step cycle by providing more flexibility along longitudinal lines of the wearer's foot (e.g., between adjacent sets of metatarsal bone components of the foot). As shown in FIGS. 3A and 3B, this flexible foot support member 400 includes five flex joint areas 250 a through 250 e that separate the plantar support surface 202 into five separate plantar support portions or members 202 a through 202 e. As further shown, the five flex joint areas 250 a through 250 e originate from (or converge to) a common area 250P (located in the central heel area of the foot support member 400 in this example). If desired, the side stop walls of at least some of the flex joint areas 250 a-250 e may terminate short of the common area 250P to promote flexibility in the different flex line directions. While more or fewer flex joint areas may be provided, in this illustrated example, at least three of the flex joint areas (250 a, 250 c, and 250 d) extend generally or primarily in a front-to-back (heel-to-toe) direction. Continuous flex joint lines are provided from the rear heel to extreme forefoot areas in this example.
  • More specifically, this illustrated example flexible foot support member 400 includes: (a) a plantar support member 202 a located at a rear lateral heel area of the flexible foot support member 400; (b) a plantar support member 202 b located at a rear medial heel area of the foot support member 400; (c) a flex joint 250 a connecting plantar support members 202 a and 202 b that extends from the central heel area (e.g., from common point 250P) to a rear heel area of the foot support member 400; (d) a medial arch/forefoot plantar support member 202 c extending at least from a midfoot area to a forefoot area of the foot support member 400; (e) a flex joint 250 b connecting plantar support members 202 b and 202 c that extends from the central heel area (e.g., from common point 250P) to a medial midfoot side area of the foot support member 400; (f) a central arch/forefoot plantar support member 202 d extending at least from the midfoot area to the forefoot area of the foot support member 400 and located toward a lateral side from the medial arch/forefoot plantar support member 202 c; (g) a flex joint 250 c connecting plantar support members 202 c and 202 d that extends from the central heel area (e.g., from common point 250P) to a forward toe area (optionally toward a medial side of center); (h) a lateral arch/forefoot plantar support member 202 e extending at least from the midfoot area to the forefoot area of the foot support member 400 and located toward a lateral side from the central arch/forefoot plantar support member 202 d; (i) a flex joint 250 d connecting plantar support member 202 d and plantar support member 202 e that extends from the central heel area (e.g., from common point 250P) to a forward toe area (and toward a lateral side from flex joint 250 c); and (j) a flex joint 250 e connecting plantar support member 202 e and plantar support member 202 a that extends from the central heel area (e.g., from common point 250P) to a lateral midfoot side area of the foot support member 400.
  • FIGS. 4A and 4B illustrate another example flexible foot support member 500 in accordance with some examples of this invention. This example flexible foot support member 500 may be incorporated into an overall footwear structure, e.g., in the various manners described above in conjunction with FIGS. 1A, 1B, and/or 2. This example flexible foot support member 500 differs from the foot support members 200, 400 shown in FIGS. 1A-1F, 3A, and 3B primarily based on the orientation of the flex joint areas 250 (which may have the same general structure, including stop wall structures, as the flex joint areas described above in conjunction with flexible foot support member 200). More specifically, while not necessarily requirements, this example flexible foot support member 500 includes an upper plantar support surface 202; a lower major surface 202 f; raised perimeter side walls 204 extending at least partially around the perimeter of the foot support member 500; gaps or spaces 204 a at various locations around the raised perimeter wall 204; gaps 206 at the plantar support surface 202 between adjacent portions of the plantar support surface 202 that are separated by a flex joint area 250; and an overall unitary, one piece construction.
  • The flexible foot support member 500 of this example may be used to enhance flexibility of the foot, particularly in the heel and forefoot areas, under a range of different use conditions. As shown in FIGS. 4A and 4B, this flexible foot support member 500 includes eleven flex joint areas 250 a through 250 k that separate the plantar support surface 202 into nine separate plantar support portions or members 202 a through 202 i. As further shown, some of the flex joint areas originate from (or converge to) one or more common areas. Additionally, in the forefoot area, the flex joint areas are oriented so as to form continuous intersecting lines of flex for the foot support member 500. If desired, the side stop walls of at least some of the flex joint areas 250 a-250 k may terminate short of any common or intersecting areas to promote flexibility in the various different directions. Also, while more or fewer flex joint areas may be provided, in this illustrated example, the flex joint areas are provided at locations to promote the natural flexibility and bending motions of a foot.
  • More specifically, this illustrated example flexible foot support member 500 includes: (a) an arch/midfoot plantar support member 202 a; (b) a medial forefoot plantar support member 202 b extending from a central foot area to a medial side area; (c) a first flex joint 250 a connecting the arch/midfoot plantar support member 202 a to the medial forefoot plantar support member 202 b; (d) a lateral forefoot plantar support member 202 c; (e) a second flex joint 250 b connecting the arch/midfoot plantar support member 202 a to the lateral forefoot plantar support member 202 c; (f) a central forefoot plantar support member 202 d extending from a lateral side to a medial side of the foot support member 500; (g) a third flex joint 250 c connecting the medial forefoot plantar support member 202 b with the central forefoot plantar support member 202 d; (h) a fourth flex joint 250 d connecting the lateral forefoot plantar support member 202 c with the central forefoot plantar support member 202 d; (i) another medial forefoot plantar support member 202 e; (j) a fifth flex joint 250 e connecting the central forefoot plantar support member 202 d with medial forefoot plantar support member 202 e; (k) another lateral forefoot plantar support member 202 f; (j) a sixth flex joint 250 f connecting the central forefoot plantar support member 202 d with lateral forefoot plantar support member 202 f; (k) a toe plantar support member 202 g; (l) a seventh flex joint 250 g connecting medial forefoot plantar support member 202 e with toe plantar support member 202 g; (m) an eighth flex joint 250 h connecting lateral forefoot plantar support member 202 f with toe plantar support member 202 g; (n) a medial heel plantar support member 202 h; (o) a ninth flex joint 250 i connecting the arch/midfoot plantar support member 202 a with the medial heel plantar support member 202 h; (p) a lateral heel plantar support member 202 i; (q) a tenth flex joint 250 j connecting the arch/midfoot plantar support member 202 a with the lateral heel plantar support member 202 i; and (r) an eleventh flex joint 250 k connecting the medial heel plantar support member 202 h with the lateral heel plantar support member 202 i.
  • As shown in FIGS. 4A and 4B, flex joints 250 i, 250 j, and 250 k meet at a common point 250P located in a central heel area of the plantar support surface 202 (with flex joint 250 i extending to a medial side heel or midfoot area, flex joint 250 j extending to a lateral side heel or midfoot area, and flex joint 250 k extending to a rear heel area (to the lateral side of center)). Flex joints 250 a, 250 b, 250 c, and 250 d meet at a common point 250Q located at a central forefoot area of the plantar support surface 202 (with flex joints 250 a and 250 c extending to spaced locations at the medial side of the forefoot area and flex joints 250 b and 250 d extending to spaced locations at the lateral side of the forefoot area). In this specific arrangement, the flex joints 250 a-250 d provide two intersecting lines of flex (e.g., with flex joint 250 a substantially continuous and/or collinear with flex joint 250 d and flex joint 250 b substantially continuous and/or collinear with flex joint 250 c). Flex joints 250 e, 250 f, 250 g, and 250 h meet at a common point 250R located at a central forefoot area of the plantar support surface 202 and forward of common point 250Q (with flex joints 250 e and 250 g extending to spaced locations at the medial side of the forefoot area and flex joints 250 f and 250 h extending to spaced locations at the lateral side of the forefoot area). In this specific arrangement, the flex joints 250 e-250 h provide two intersecting lines of flex (e.g., with flex joint 250 e substantially continuous and/or collinear with flex joint 250 h and flex joint 250 f substantially continuous and/or collinear with flex joint 250 g). Notably, the flex joints meet the perimeter of the support member 500 at the gap areas 204 a in the raised perimeter side wall 204, and in some instances, more than one flex joint will extend to a single gap area 204 a.
  • While the above figures illustrate flexible foot support members 200, 400, 500 that underlie and support an entire plantar surface of a wearer's foot (e.g., extending completely and continuously from heel-to-toe and from the lateral side to the medial side) other arrangements are possible without departing from this invention. For example, flexible foot support members of the types described above (e.g., with flex areas of the types described above) may be located solely in the heel area of a shoe or sole structure, solely in the arch area, solely in the forefoot area, or in any combination of these areas (e.g., with separate heel and forefoot support plates).
  • Additionally, while FIGS. 1B and 2 show the flex joint area 250 recessed within a gap or channel 124 in the exterior sole structure, this is not a requirement. For example, if desired, at least some portion(s) of the flex joint areas 250 may be exposed so as to contact the ground in use, e.g., optionally, with at least some portion(s) of the flex joint area 250 serving as a traction element for the shoe 100, 300. In other words, if desired, the vertical height(s) of sole component(s) 306 may be reduced so that flex joint area extends beyond the bottom surface of sole component(s) 306 and/or the sole component(s) 306 may be eliminated (adjacent at least some portion(s) of flex joint area 250) so that the flex joint area 250 is exposed to the ground surface. If desired, the joint area at the bottom ends of side walls 252 a and 252 b (or one or more of the side walls 252 a and 252 b themselves) may extend further downward to directly contact the ground and/or to serve as a base to which another traction element is mounted (e.g., a cleat, a hard rubber layer, etc.). When serving as a traction element, an individual flex joint area 250 may include separated extending structures for directly contacting the ground, optionally at spaced locations akin to conventional cleat locations in shoes. Each separate extended length flex joint structure that functions as a traction element may have a relatively short length (e.g., separated lengths having an extended height for 1 inches along the joint area 250 or less). Other specific structures and arrangements are possible to allow the exterior surface of flex joint area 250 to serve directly as a traction element and/or as a base for supporting a separate traction element.
  • FIGS. 5A through 5E illustrate an example sock liner 600, insole member, and/or strobel member or the like that may be incorporated into sole structures, footwear structures, and/or foot-receiving device structures in accordance with at least some examples of this invention. The bottom surface 602, as shown in FIG. 5A, may be relatively conventional, e.g., made from or covered with a textile element (and optionally, a continuous, single piece textile element), made from a foam material, etc. The top surface 604, as shown in FIG. 5B, also may be made, at least in part, from a textile element, although it may be made (at least in part) from other materials as well. In this illustrated example, the forefoot portion of the top surface 604 is made from a conventional textile material 604 a (optionally the same textile as on the bottom surface 602) while the heel and/or midfoot portion(s) is (are) made from a somewhat more rigid material 604 b (e.g., like a thin, rigid, yet flexible plastic sheet). This more rigid material 604 b may overlay the textile material 604 a, if desired (and may be engaged with it, e.g., by adhesives or cements). In this illustrated example, the more rigid material 604 b extends completely from the lateral side to the medial side of the sock liner 600 and extends from the rearmost heel area to the generally V-shaped border 606 in the midfoot/arch or forefoot area. Other rigid material 604 b sizes and/or shapes are possible without departing from the invention (including no rigid material 604 b, if desired). The top textile material 604 a may help wick away moisture and perspiration and help keep the foot cool and dry.
  • In this example structure 600, a soft polymeric foam material 608 is sandwiched between the upper textile layer 604 a/more rigid material layer 604 b and the bottom layer 602, e.g., as shown in the cross sectional views of FIGS. 5C-5E. This foam material 608 provides a comfortable surface for engaging the foot. The polymeric foam material 608 may vary in thickness, if desired, at various different foot support areas of the sock liner structure 600.
  • FIGS. 5B through 5E further illustrate that the materials 604 a and/or 604 b of the top surface 604 of sock liner 600 further include one or more gaps or cuts 610 defined therein. These cuts 610 help provide predetermined lines and locations of flex in the sock liner 600 to support natural motion while still providing a comfortable support surface for the foot. FIG. 5E includes a cross sectional view at the location of section line 5D-5D with the sock liner 600 bent. The cuts 610 allow the top layer 604 a and/or 604 b to be made from desired materials that may not have sufficient stretch or flexibility to support or allow the full flexibility of plates 200, 400, 500.
  • While shown extending only through the top layer 604 (e.g., textile material 604 a and/or the more rigid material 604 b) in FIGS. 5C-5E, if desired, the gaps or cuts 610 also may extend at least partially through the polymeric foam material 608. As yet another example, if desired, the sock liner 600 (or insole or strobel member) could be made as completely separate pieces or parts (e.g., cut or separated at one or more of the gaps 610). Gaps or cuts 610 may be provided at any desired locations, including at locations selected to support and enhance flexibility at the flex joints 250 in flexible foot support members 200, 400, 500. While it may be so, the cut or gap pattern in the sock liner 600 need not exactly match the flex line numbers, orientations, and/or arrangements in the underlying flexible foot support member 200, 400, 500.
  • III. CONCLUSION
  • The present invention is disclosed above and in the accompanying drawings with reference to a variety of embodiments. The purpose served by the disclosure, however, is to provide examples of the various features and concepts related to the invention, not to limit the scope of the invention. Those skilled in the art will understand that the structures, options, and/or alternatives for the foot support members, sole structures, footwear structures, and/or foot-receiving device structures described herein, including the features of the various different embodiments of the invention, may be used in any desired combinations, subcombinations, and the like, without departing from the invention. As other potential options and/or features, for foot-receiving devices in general, flexible foot support members according to the invention may be incorporated into a foot-support member (e.g., that, at least in part supports a plantar surface of a wearer's foot) of the foot-receiving device, and this foot-support member may be engaged with a foot-covering member of the foot-receiving device. The foot-covering member may, at least partially, contain a wearer's foot, and optionally, at least in part, may help maintain the foot in position with respect to the foot-support member. The foot-covering member may be similar in structure and/or function to a footwear upper.
  • Those skilled in the relevant art also will recognize that numerous variations and modifications may be made to the embodiments described above without departing from the scope of the present invention, as defined by the appended claims.

Claims (26)

What is claimed is:
1. A flexible foot support member, comprising:
a first plantar support member including a first upper surface and a first lower surface;
a second plantar support member including a second upper surface and a second lower surface; and
a flex joint connecting the first plantar support member with the second plantar support member, wherein the flex joint includes a hinge structure joining the first plantar support member with the second plantar support member, and wherein the hinge structure is located below the first and second lower surfaces.
2. A flexible foot support member according to claim 1, wherein the hinge structure extends continuously over at least 60% of a length of an interface between the first plantar support surface and the second plantar support surface.
3. A flexible foot support member according to claim 1, wherein the hinge structure extends continuously over at least 95% of a length of an interface between the first plantar support surface and the second plantar support surface.
4. A flexible foot support member according to claim 1, wherein each of the first and second plantar support members extends completely from a lateral side of the flexible foot support member to a medial side of the flexible foot support member.
5. A flexible foot support member according to claim 4, wherein the flex joint is located in a forefoot area of the flexible foot support member.
6. A flexible foot support member according to claim 1, wherein the first plantar support member, the second plantar support member, and the flex joint are formed as a unitary, one-piece construction.
7. A flexible foot support member according to claim 1, wherein the flex joint extends in a back-to-front direction from a rear heel or medial heel area of the flexible foot support member to a lateral heel or lateral midfoot area of the flexible foot support member.
8. A flexible foot support member according to claim 1, wherein the flex joint is angular having a first leg and a second leg joined together at a 60° to 120° angle.
9. A flexible foot support member according to claim 1, wherein the flex joint extends in a front-to-back direction of the flexible foot support member.
10. A flexible foot support member, comprising:
a first plantar support member extending at least from a midfoot area to a forefoot area of the flexible foot support member, the first plantar support member including a first upper surface and a first lower surface;
a second plantar support member extending across the forefoot area of the flexible foot support member and located forward of the first plantar support member, the second plantar support member including a second upper surface and a second lower surface;
a third plantar support member extending across the forefoot area of the flexible foot support member and located forward of the second plantar support member, the third plantar support member including a third upper surface and a third lower surface;
a first flex joint connecting the first plantar support member and the second plantar support member, the first flex joint extending from a medial side to a lateral side of the flexible foot support member, wherein the first flex joint includes a first hinge structure joining the first plantar support member and the second plantar support member, and wherein the first hinge structure is located below the first and second lower surfaces; and
a second flex joint connecting the second plantar support member and the third plantar support member, the second flex joint extending from the medial side to the lateral side of the flexible foot support member, wherein the second flex joint includes a second hinge structure joining the second plantar support member and the third plantar support member, and wherein the second hinge structure is located below the second and third lower surfaces.
11. A flexible foot support member according to claim 10, wherein the first plantar support member extends to a rear medial heel area of the flexible foot support member.
12. A flexible foot support member according to claim 11, further comprising:
a fourth plantar support member located at a rear lateral heel area of the flexible foot support member, the fourth plantar support member including a fourth upper surface and a fourth lower surface;
a third flex joint connecting the first plantar support member and the fourth plantar support member, the third flex joint extending in a back-to-front direction from a rear heel or medial heel area of the flexible foot support member to a lateral heel or lateral midfoot area of the flexible foot support member, wherein the third flex joint includes a third hinge structure joining the first plantar support member and the fourth plantar support member, and wherein the third hinge structure is located below the first and fourth lower surfaces.
13. A flexible foot support member according to claim 12, further comprising:
a fifth plantar support member located at a forward lateral toe area of the flexible foot support member, the fifth plantar support member including a fifth upper surface and a fifth lower surface;
a fourth flex joint connecting the third plantar support member and the fifth plantar support member, the fourth flex joint extending in a curved or angled manner from a front toe area to a lateral forefoot area of the flexible foot support member, wherein the fourth flex joint includes a fourth hinge structure joining the third plantar support member and the fifth plantar support member, and wherein the fourth hinge structure is located below the third and fifth lower surfaces.
14. A flexible foot support member according to claim 10, further comprising:
a fourth plantar support member located at a forward lateral toe area of the flexible foot support member, the fourth plantar support member including a fourth upper surface and a fourth lower surface;
a third flex joint connecting the third plantar support member and the fourth plantar support member, the third flex joint extending in a curved or angled manner from a front toe area to a lateral forefoot area of the flexible foot support member, wherein the third flex joint includes a third hinge structure joining the third plantar support member and the fourth plantar support member, and wherein the third hinge structure is located below the third and fourth lower surfaces.
15. A flexible foot support member, comprising:
a first plantar support member extending at least from a midfoot area to a forefoot area of the flexible foot support member, the first plantar support member including a first upper surface and a first lower surface;
a second plantar support member extending at least from the midfoot area to the forefoot area of the flexible foot support member and located toward a lateral side from the first plantar support member, the second plantar support member including a second upper surface and a second lower surface;
a third plantar support member extending at least from the midfoot area to the forefoot area of the flexible foot support member and located toward a lateral side from the second plantar support member, the third plantar support member including a third upper surface and a third lower surface;
a first flex joint connecting the first plantar support member and the second plantar support member, the first flex joint extending in a front-to-back direction of the flexible foot support member, wherein the first flex joint includes a first hinge structure joining the first plantar support member and the second plantar support member, and wherein the first hinge structure is located below the first and second lower surfaces; and
a second flex joint connecting the second plantar support member and the third plantar support member, the second flex joint extending in a front-to-back direction of the flexible foot support member, wherein the second flex joint includes a second hinge structure joining the second plantar support member and the third plantar support member, and wherein the second hinge structure is located below the second and third lower surfaces.
16. A flexible foot support member according to claim 15, further comprising:
a fourth plantar support member located at a rear medial heel area of the flexible foot support member, the fourth plantar support member including a fourth upper surface and a fourth lower surface;
a third flex joint connecting the first plantar support member and the fourth plantar support member, the third flex joint extending from a central heel area to a medial midfoot area of the flexible foot support member, wherein the third flex joint includes a third hinge structure joining the first plantar support member and the fourth plantar support member, and wherein the third hinge structure is located below the first and fourth lower surfaces.
17. A flexible foot support member according to claim 16, further comprising:
a fifth plantar support member located at a rear lateral heel area of the flexible foot support member, the fifth plantar support member including a fifth upper surface and a fifth lower surface;
a fourth flex joint connecting the third plantar support member and the fifth plantar support member, the fourth flex joint extending from the central heel area to a lateral midfoot area of the flexible foot support member, wherein the fourth flex joint includes a fourth hinge structure joining the third plantar support member and the fifth plantar support member, and wherein the fourth hinge structure is located below the third and fifth lower surfaces.
18. A flexible foot support member according to claim 17, further comprising:
a fifth flex joint connecting the fourth plantar support member and the fifth plantar support member, the fifth flex joint extending from the central heel area to a rear heel area of the flexible foot support member, wherein the fifth flex joint includes a fifth hinge structure joining the fourth plantar support member and the fifth plantar support member, and wherein the fifth hinge structure is located below the fourth and fifth lower surfaces.
19. A flexible foot support member according to claim 18, wherein two or more of the first through fifth flex joints extend from a common point.
20. A flexible foot support member according to claim 15, further comprising:
a fourth plantar support member located at a rear lateral heel area of the flexible foot support member, the fourth plantar support member including a fourth upper surface and a fourth lower surface;
a third flex joint connecting the third plantar support member and the fourth plantar support member, the third flex joint extending from a central heel area to a lateral midfoot area of the flexible foot support member, wherein the third flex joint includes a third hinge structure joining the third plantar support member and the fourth plantar support member, and wherein the third hinge structure is located below the third and fourth lower surfaces.
21. A flexible foot support member, comprising:
four plantar support members in a forefoot area of the flexible foot support member; and
two intersecting flex joints connecting the four plantar support members, wherein each of the two intersecting flex joints extends in a direction from a lateral side to a medial side of the flexible foot support member, wherein each of the two intersecting flex joints includes a hinge structure joining adjacent plantar support members, and wherein the hinge structure of each of the two intersecting flex joints is located below bottom surfaces of the plantar support members to which it is connected.
22. A flexible foot support member, comprising:
seven plantar support members in a forefoot area of the flexible foot support member;
a first set of two intersecting flex joints connecting a rearmost four plantar support members, wherein each flex joint of the first set extends in a direction from a lateral side to a medial side of the flexible foot support member, wherein each flex joint of the first set includes a hinge structure joining adjacent plantar support members, and wherein the hinge structure of each of the first set of two intersecting flex joints is located below bottom surfaces of the plantar support members to which it is connected; and
a second set of two intersecting flex joints connecting a forwardmost three plantar support members and one of the rearmost plantar support members, wherein each flex joint of the second set extends in a direction from the lateral side to the medial side of the flexible foot support member, wherein each flex joint of the second set includes a hinge structure joining adjacent plantar support members, and wherein the hinge structure of each of the second set of two intersecting flex joints is located below bottom surfaces of the plantar support members to which it is connected.
23. A flexible foot support member, comprising:
a first plantar support member in a forward heel area of the flexible foot support member, the first plantar support member including a first upper surface and a first lower surface;
a second plantar support member located at a lateral heel area of the flexible foot support member and rearward of the first plantar support member, the second plantar support member including a second upper surface and a second lower surface;
a third plantar support member located at a medial heel area of the flexible foot support member and rearward of the first plantar support member, the third plantar support member including a third upper surface and a third lower surface;
a first flex joint connecting the first plantar support member and the second plantar support member, wherein the first flex joint extends from a central heel area to a lateral heel or midfoot side of the flexible foot support member, wherein the first flex joint includes a first hinge structure joining the first plantar support member and the second plantar support member, and wherein the first hinge structure is located below the first and second lower surfaces; and
a second flex joint connecting the first plantar support member and the third plantar support member, the second flex joint extending from the central heel area to a medial heel or midfoot side of the flexible foot support member, wherein the second flex joint includes a second hinge structure joining the first plantar support member and the third plantar support member, and wherein the second hinge structure extends below the first and third lower surfaces.
24. A flexible foot support member according to claim 23, further comprising:
a third flex joint connecting the second plantar support member and the third plantar support member, the third flex joint extending from the central heel area to a rear heel area of the flexible foot support member, wherein the third flex joint includes a third hinge structure joining the second plantar support member and the third plantar support member, and wherein the third hinge structure is located below the second and third lower surfaces.
25. An article of footwear, comprising:
an upper; and
a sole structure engaged with the upper, wherein the sole structure includes a flexible foot support member according to claim 1.
26. A foot-receiving device, comprising:
a foot-covering member for at least partially containing a wearer's foot; and
a flexible foot support member according to claim 1 for supporting the wearer's foot engaged with the foot-covering member.
US13/788,902 2013-03-07 2013-03-07 Flexible sole supports for articles of footwear Abandoned US20140250723A1 (en)

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