Reactive energy fluid filled apparatus providing cushioning, support ...

REACTIVE ENERGY FLUID FILLED APPARATUS
PROVIDING CUSHIONING, SUPPORT,
STABILITY AND A CUSTOM FIT IN A SHOE

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BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a fluid-filled apparatus which reacts with the stimulus of an outside force, hereinafter referred to as a reactive energy apparatus, 10 incorporated into a shoe sole and shoe upper that provides a custom fit to the shoe wearer's foot in addition to providing cushioning, support and stability to the shoe wearer's foot. In particular, the present invention pertains to an apparatus comprised of one more 15 anatomically-shaped fluid-filled bladders that are positioned in the forefoot, arch and/or heel areas of a shoe and assume a complementary custom fitting configuration to the contours of a foot inserted in the shoe. In variant embodiments of the apparatus, the fluid-filled 20 bladders are positioned separate from each other in the forefoot, arch and heel areas of the shoe and are interconnected in fluid communication by fluid-conducting channels, or the bladders are positioned independent of each other in the forefoot, arch and heel areas of the 25 shoe.

Description of the Related Art

Various methods and devices have been employed in shoes in seeking to add cushioning to the shoe to absorb 30 the shock of footstep impact in walking, running and other activities, and thereby provide some protection to the shoe wearer's foot. This is particularly true in athletic footwear where the foot is exposed to repeated shocks from footstep impact in running and other ath- 35 letic activities. Various methods and devices have also been employed in shoes seeking to provide a custom fit of the shoe around the contours of the shoe wearer's foot while also providing support and stability to the foot. Typical prior art devices developed to provide 40 cushioning, custom fit, support or stability to the foot inside a shoe range from merely constructing the shoe sole from a softer, more resilient material, to incorporating fluid filled pads or bladders in the sole of a shoe.

In many shoe soles designed to increase the cushion- 45 ing effects of the sole, the increased resiliency or "softness" of the shoe sole provides little resistance to the tendency of the shoe wearer's foot to rotate relative to the leg upon footstep impact. In providing additional cushioning in the shoe sole, these shoes sacrifice or 50 reduce the support and stability provided to the foot by the shoe sole.

In shoe soles employing fluid filled pads or bladders to provide cushioning to the foot, the particular fluid filled bladders employed are often incapable of provid- 55 ing cushioning to the foot for all of the varying magnitudes of force exerted on the foot and the varying areas of the foot subjected to the forces in footstep impacts in jogging, running and other athletic activities. Prior art fluid filled bladders are typically designed to provide 60 cushioning in the particular area of the shoe sole where the bladder is located, for example in the heel or forefoot areas of the shoe sole. These prior art devices provide no cushioning for other areas of the shoe sole where footstep impact may occur. Many prior art fluid 65 filled bladders are effective in providing cushioning to the foot only when the force of footstep impact is concentrated at the center of the fluid filled bladder. Should

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forces from footstep impact occur along the outer or inner edge of the runner's foot, as is very often the case, the footstep impact forces exerted on the outer or inner edges of the prior art fluid bladders often cause the fluid to be forced from these areas to other areas of the bladders. With the fluid having been forced from the inner or outer areas of the bladders, these bladders are incapable of providing any cushioning of the force of footstep impact along the inner or outer edges of the foot.

What is needed to overcome the above-described disadvantages of prior art shoes is a shoe employing an apparatus that provides a custom fit by assuming a shape complementary to the contours of a foot inserted into the shoe and provides cushioning to various areas of the foot in response to varying magnitudes of footstep impact force and varying areas of force concentration on the foot. What is also needed to overcome the above-described disadvantages is an apparatus in a shoe that stabilizes the foot in the shoe and reduces the forces of footstep impact concentrated on one particular area of the foot by distributing these forces over a greater area of the foot.

SUMMARY OF THE INVENTION

The present invention overcomes the abovedescribed disadvantages associated with prior art shoes by providing a shoe comprising a reactive energy apparatus that provides cushioning, a custom fit, support and stability to a foot inserted into the shoe. The reactive energy apparatus enables the shoe to provide a supporting, custom fit to the foot of the shoe wearer, where the fit and support of the foot is dynamically changing as forces due to footstep impact are exerted on the foot.

The reactive energy apparatus of the present invention is generally comprised of fluid filled bladders provided in the forefoot, arch and heel areas of a shoe. The fluid filled bladders are provided in the interior of the shoe on the shoe sole, and on the shoe upper in an area adjacent the arch of the shoe wearer's foot. In variant embodiments of the invention the fluid filled bladders are connected in fluid communication with each other through several fluid conducting channels extending between the separate bladders, or are isolated from each others in the different areas of the shoe.

Each of the embodiments of the apparatus of the invention are described as being contained in an athletic shoe. However, the descriptions of the embodiments of the apparatus being employed in an athletic shoe are illustrative only and the various embodiments of the apparatus may be incorporated into various different types of shoes.

In each of the embodiments of the apparatus of the invention, the apparatus is comprised of one or more fluid filled forefoot, arch and heel bladders that are easily inserted into the sole of the shoe. The shoe sole is constructed with recessed cavities specifically configured to receive the forefoot, arch and heel bladders of the apparatus.

The apparatus is constructed of overlapping layers of a flexible, fluid tight, barrier material. The layers are bonded together along a peripheral boundary of the apparatus that extends completely around the one or more bladders of the apparatus. Each of the bladders are filled with a fluid. The top layer of the overlapping layers of each of the fluid filled bladders is formed with a plurality of depressions or clefts. The clefts extend from the top layer down through the fluid filled interior

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volumes of the bladders and are joined to the bottom layer inside the bladder interior volumes. The pluralities of clefts form fold lines in the bladders that enable the bladders to be easily folded along the lines of clefts in response to bending forces exerted on the bladders dur- 5 ing activities performed while wearing the shoe.

The plurality of clefts also form spatially arranged wall segments in the interior volumes of the bladders. The wall segments restrict or control the rate of fluid flow through the bladders from one area to another area 10 of the interior volumes of the bladders in response to forces exerted on the bladder during footstep impact. Spaces or openings between adjacent wall segment have calibrated cross-sectional areas that also regulate the rate of fluid flow through the bladders. 15

In the heel bladder of the apparatus a foam sponge is provided in the bladder interior volume. The foam-' sponge displaces a portion of the fluid filling the interior volume of the heel bladder and thereby reduces the weight of the heel bladder. The foam sponge also offers ^° increased resistance or cushioning to forces exerted on the heel bladder due to footstep impacts.

In the embodiments of the apparatus comprising fluid conducting channels, the channels are formed between ^ the overlapping layers of barrier material in the same manner as the bladders of the apparatus. The channels extend between the forefoot, arch and heel bladders and provide fluid communication between the fluid filled bladders. Each of the channels have cross-sectional areas calibrated to regulate the rate of fluid flow from one bladder to another bladder. The calibrated crosssectional areas of the channels serves to retain a portion of the fluid in a bladder subjected to a force of footstep impact and thereby maintain the cushioning and sup- 35 port of that bladder provided to the forefoot, arch or heel areas of the foot, while enabling a portion of the fluid to be forced from the bladder to another bladder, causing the other bladder to expand slightly and exert a reactive force on other areas of the foot and thereby 40 distribute the force of footstep impact over a greater area of the foot.

In operation of the apparatus, as forces of varying magnitudes are exerted on different areas of the shoe wearer's foot during running or other activities, the 45 forces exerted on the bladders of the apparatus cause the fluid contained in the bladders to flow from one area of the bladders to another, and cause the fluid to flow from one of the bladders to another through the fluid conducting channels. The flow of fluid to other blad- 50 ders or other areas of the bladders cause those bladders or bladder areas to expand. The expansion of the bladders and bladder areas exerts a reactive force on the bottom of the shoe wearer's foot at areas of the foot away from the area where the forces of footstep impact 55 are concentrated. In this manner, the apparatus of the invention provides a continuous supporting, custom fit to the shoe wearer's foot while distributing forces due to footstep impact over a greater area of the shoe wearer's foot. 60

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects and features of the present invention are revealed in the following Detailed Description of the Preferred Embodiment of the invention and in the 65 drawings figures wherein:

FIG. 1 is a side elevation view of a shoe employing the reactive energy apparatus of the present invention

showing the relative position of the apparatus in the shoe;

FIG. 2 is a plan view of the apparatus of the invention showing the position of the apparatus in the shoe sole depicted by phantom lines;

FIG. 3 is a perspective view of the shoe sole and the apparatus of the invention;

FIG. 4 is a partial end elevation view, in section, of the shoe sole and the apparatus of the invention taken along the line 4—4 of FIG. 1;

FIG. 5 is a partial end elevation view, in section, showing the shoe sole and the apparatus of the invention in the shoe sole taken along the line 5—5 of FIG. 1;

FIG. 6 is an elevation view, in section, of the apparatus of the invention taken along the line 6—6 of FIG. 2;

FIG. 7 is a plan view of a variant embodiment of the apparatus of the invention;

FIG. 8 is a perspective view of the apparatus of FIG. 7 and the shoe sole employed with the apparatus;

FIG. 9 is a plan view of a variant embodiment of the apparatus of the invention;

FIG. 10 is a partial perspective view of the apparatus of FIG. 9 and the shoe sole employed with the apparatus;

FIG. 11 is a plan view of a variant embodiment of the apparatus of the invention;

FIG. 12 is a partial perspective view of the apparatus of the invention shown in FIG. 11 and the shoe sole employed with the apparatus;

FIG. 13 is a plan view of a variant embodiment of the apparatus of the invention;

FIG. 14 is a partial perspective view of the apparatus of FIG. 13 and the shoe sole employed with the apparatus;

FIG. 15 is a plan view of a variant embodiment of the apparatus of the invention; and,

FIG. 16 is a partial perspective view of the apparatus of FIG. 15 and the shoe sole employed with the apparatus.

DETAILED DESCRIPTION OF THE
PREFERRED EMBODIMENT

The reactive energy fluid filled apparatus 20 of the present invention is shown in one operative environment of the apparatus in FIGS. 1 and 2. The apparatus is constructed from a flexible, fluid-tight barrier material, preferably a plastic-type film that is capable of being bonded. Although polyurethane is preferred, other types of flexible, fluid-tight barrier materials may be employed in constructing the apparatus of the invention without departing from the intended scope of the claims. In the preferred embodiment of the invention shown in the drawing figures, the apparatus 20 is employed with an athletic shoe 22. However, the apparatus of the invention is equally adapted for use with shoes other than the athletic shoe shown, and its description of being employed with an athletic shoe is illustrative only and should not be interpreted as limiting.

In the embodiment of the apparatus shown in FIGS. 1 and 2, the apparatus 20 is comprised of a first, forefoot bladder 24, a second, arch bladder 26, a third, upper arch bladder 28, and a fourth, heel bladder 32. Each of the four bladders of the apparatus 20 may be constructed with one or more interior chambers containing a fluid. In the embodiment of the invention to be described, only the heel bladder 32 is comprised of two interior chambers. The forefoot bladder 24, the arch 5

bladder 26, and the upper arch bladder 28 all are constructed having a single fluid-filled interior chamber.

The four hollow bladders 24,26,28,32 are formed as component parts of a single unit of the apparatus 20, the apparatus being constructed from a pair of overlapping S layers 34,36 of a flexible, fluid-tight barrier material. As is best seen in FIG. 2, the overlapping pair of material layers 34, 36 have a peripheral boundary 38 that is formed in a specific configuration to give each of the four bladders of the apparatus an anatomically-shaped 10 outline that is complementary to the forefoot, arch, and heel areas of the bottom of a foot. The top layer 34 of the apparatus has a predetermined surface configuration molded into it, where the bottom layer 36 is substantially flat. The configurations of the shapes molded into IS the top layer 34 form the four bladders and a pair of fluid-conducting channels 42, 44 communicating the interior volume of the forefoot bladder 24 with the interior volumes of the arch and upper arch bladders 26, 28, and a fluid-conducting channel 46 communicating 20 the interior volume of the heel bladder 32 with the interior volumes of the arch and upper arch bladders. .

Each of the forefoot, arch, upper arch and heel bladders, and each of the fluid-conducting channels, are formed when the top layer 34 of material is secured to 25 the bottom layer 36 in the relative positions of the two layers shown in the drawing figures. The molded configurations formed in the top layer 34 of material serve as flexible sidewalls or surfaces of each of the four bladders of the apparatus. The shapes may be molded into 30 the top layer by any known method. The particular configurations of the four bladders shown in the drawing figures enable the apparatus to cushion a foot inserted in the shoe 22 employing the apparatus, and enable the shoe to provide support, stability and a custom 35 fit to the foot inserted in the shoe.

The overlapping top and bottom layers of material 34,36 are sealed together along the peripheral flange 38 that completely surrounds and defines the borders of the four bladders 24,26,28,32 and the fluid-conducting 40 channels 42, 44, 46 extending between the bladders. Sealing the peripheral flange 38 of the apparatus encloses the interior volumes of the bladders 24,26,28,32 and the channels 42, 44, 46 between the two material layers. The top and bottom layers may be sealed to- 45 gether in the area of the flange 38 by adhesives, by radio frequency (RF) welding, or by other equivalent methods. The seal formed at the peripheral flange 38 is fluidtight and forms a completely enclosed interior volume in each of the bladders 24, 26, 28, 32. Although the 50 bladders, except for the heel bladder 32, are described as enclosing only one interior chamber each, in variant embodiments of the invention the bladders may enclose two or more separate chambers that may or may not be interconnected in fluid communication with each other. 55

Additional overlapping areas of the pair of material layers 34, 36 inside the apparatus peripheral boundary 38 are also secured together. As seen in FIG. 2, the top and bottom layers 34,36 are secured together at an area 48 of the two layers between the pair of fluid-conduct- 60 ing channels 42,44 communicating the forefoot bladder 24 interior volume with the arch and upper arch bladder 26, 28 interior volumes. The sealed area 48 of the two layers not only separates the pair of fluid-conducting channels 42, 44, but also serves to calibrate the 65 cross-sectional area of the fluid-conducting channels 42, 44. The calibration of the cross-sectional areas of the two channels 42,44 enables the channels to control the

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rate of fluid flow between the forefoot bladder 24 and the arch and upper arch bladders 26,28. The channel 46 provides fluid communication between the arch and upper arch bladders 26, 28 and the heel bladder 32. Each of the channels 42, 44, 46 are formed by the molded configuration of the top layer of material 34 and the portions of the sealed peripheral flange 38 on opposite sides of the channels and the sealed area 48 of the layers between the forward pair of channels 42, 44.

Each of the bladders is filled with a moderately viscus fluid 50. Several different types of fluids may be employed as the fluid filling the bladders. The fluid could include a composition of two fluids having different viscosities, or the fluid could include solids, including but not limited to hollow spheres or particles suspended in the fluid.

Pluralities of clefts 52 are formed in the top layer of material 34 covering the forefoot bladder 24. A second plurality of clefts 54 is also formed in the top layer 34 separating the arch bladder 26 from the upper arch bladder 28. A third plurality of clefts 56 is formed in the top layer 34 of the heel bladder 32.

The forefoot bladder clefts 52 are formed in the top layer 34 of the forefoot bladder and extend downward into the interior volume 62 of the forefoot bladder to the bottom layer 36 of material. As seen in the drawing figures, each of the forefoot clefts 52 are formed as indentations or depressions in the top layer 34 of material. Each of the clefts 52 have set lengths arranged end to end in rows that extend laterally across the forefoot bladder 24, and are arranged side by side in columns that extend longitudinally across the top layer of the bladder. The depressions of the clefts 52 extend downward below the top layer 34 of material, through the fluid 50 filling the interior volume 62 of the forefoot bladder, and the bottoms of each of the clefts 52 are secured to the bottom layer 36 of material. The bottoms of the clefts may be sealed to the bottom layer of material by adhesives, by radio frequency welding, or by other equivalent methods.

By forming the clefts 52 in the top layer 34 of the forefoot bladder in the manner described above, and by arranging the plurality of forefoot clefts 52 in an array of rows extending laterally across the bladder and in columns extending longitudinally across the bladder, the rows of clefts form lateral fold lines extending across the top layer 34 of the forefoot bladder 24. The fold lines formed by the clefts 52 facilitate the folding or bending of the forefoot bladder 24 along the fold lines formed by the clefts. This enables the forefoot bladder 24 to be folded over at the cleft fold lines when the forefoot area of the shoe 22 is bent in walking or running activities.

A portion of the forefoot pad 24 extends forward in an area of the pad corresponding to the position of the hallux digit of the foot. An additional cleft 64 is provided in the top layer 34 of the forefoot pad in the hallux area of the pad. Like the rows and columns of clefts 52 described earlier, the hallux cleft 64 facilitates the bending of the forefoot bladder 24 in the hallux area of the bladder.

In addition to forming lateral fold lines across the forefoot bladder 24, the plurality of clefts 52 form wall segments having opposite sides and opposite ends in the interior volume 62 of the bladder. The wall segments formed by each of the clefts 52 in the interior of the forefoot bladder 62 divide the interior volume into separate areas and secure the top layer 34 to the bottom

cushioning and support for the portion the foot exerting the force.

The heel bladder 32 is formed in two separate chambers, a center chamber 72 and a rim chamber 74. The center chamber 72 is separated from the rim chamber 74 by the third plurality of clefts 56. Like the previously described clefts of the forefoot bladder 24 and the arch and upper arch bladders 26, 28, the third plurality of clefts 56 are formed as indentations or depressions in the top layer 34 of material. The depressions extend downward from the top layer 34, through the fluid 50 filling the interior volume 68 of the heel bladder, and are joined to the bottom layer 36 of material in the same manner as described above in reference to the clefts of the forefoot bladder. As seen in FIGS. 2 and 3, the third plurality of clefts 56 extend in a general U shape around the heel bladder separating the center chamber 72 of the bladder from the rim chamber 74. The third plurality of clefts 56 also serve to connect the top layer 34 of the heel bladder to the bottom layer 36 in a spaced relationship and prevent excessive expansion of the center and rim chambers of the heel bladder as fluid enters the chambers.

A resilient pad 76 is provided in the interior volume 66 of the center chamber 72. In the preferred embodiment of the invention, the resilient pad 76 is formed of a resilient foam sponge material. However, the pad may be constructed of other similar types of resilient materials. The purpose of the pad is to add cushioning to the center chamber 72 of the heel bladder in addition to the cushioning provided by the fluid 50 filling the chamber. The presence of the pad 76 inside the center chamber 72 also displaces fluid 50 from the center chamber, and thereby reduces the weight of the heel bladder.

Like the previously described clefts of the forefoot 35 and arch bladders, the third plurality of clefts 56 are spaced from each other a predetermined distance forming calibrated openings between adjacent clefts. This enables the clefts to serve as wall segments extending

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chamber 74 to the opposite side of the rim chamber from the side on which the force of foot impact is exerted. The flow of fluid to the opposite side of the rim chamber will cause the fluid pressure to increase on the opposite side and cause this side of the bladder to expand slightly, exerting a reactive force against the opposite side of the foot heel bottom from the side exerting the force on the heel bladder. This causes a redistribution of the force of impact over a greater area of the foot heel and stabilizes the foot heel in the shoe. Should the footstep impact occur at the opposite side or outside of the heel bladder, the force exerted on this side of the heel bladder will cause the heel bladder to compress on this side. This, in turn, will cause the fluid contained at the compressed side of the heel bladder to flow around the rim chamber to the opposite side or inside of the rim chamber, causing fluid pressure to increase and causing this side of the rim chamber to expand. This expansion exerts a reactive force on the inside of the foot heel stabilizing the foot heal and redistributing the force of impact over a greater area of the foot heel. By distributing the force of footstep impact occurring on the edges of the shoe sole over an increased area of the foot heel, the heel bladder serves to stabilize and support the foot heel in its reaction to the off-center footstep impact.

The reactive energy distributing function of the apparatus 20 is performed in substantially the same manner between the several fluid-filled bladders of the apparatus. When a footstep impact force is exerted on the heel bladder 32 of the apparatus, the fluid contained in the heel bladder is forced from the bladder through the channel 46 to the arch bladders 26, 28 and the forefoot bladder 24. The fluid supplied from the heel bladder to the arch and forefoot bladders causes the arch and forefoot bladders to expand slightly from their at-rest configurations. The expansion of the arch and the forefoot bladders exert reactive forces on the bottom of the foot at the forefoot and arch areas of the foot, thereby distributing the force of footstep impact concentrated in

with fluid flow restricting openings being provided between adjacent wall segments. The openings between adjacent clefts 56 have cross-sectional areas calibrated to control the rate of fluid flow between the center chamber 72 and the rim chamber 74 of the heel bladder. 45 The calibrated cross-sectional areas of the spaces between adjacent clefts 56 in the interior of the heel bladder 32, and the calibrated cross-sectional area of the channel 46 communicating the heel bladder with the forefoot and the arch bladders, control the rate at which 50 the fluid 50 is forced from the interior volume 68 of the heel bladder in response to a force being exerted on the heel bladder, and thereby maintains the ability of the heel bladder to cushion the foot heel against the shock of footstep impact and to support and stabilizes the foot 55 heel in the heel area of the shoe.

The U-shaped or horseshoe-shaped configuration of the rim chamber enables the rim chamber to provide a stabilizing, reactive force to the bottom of the foot in response to footstep impacts. For example, as a footstep 60 impact force is exerted on the rim chamber 74 adjacent the arch area or along the inside of the foot, the inside portion of the rim chamber will compress forcing the fluid contained in the heel bladder to move around the rim chamber to the opposite side of the chamber. Be- 65 cause the spacing between adjacent clefts 56 of the heel bladder restricts the free flow of fluid between the adjacent clefts, the fluid flows more readily around the rim

the foot.

When a footstep impact force is exerted on the arch bladders 26, 28 of the apparatus, the fluid contained in the arch bladders is forced from the bladders through the channels 42, 44 to the forefoot bladder 24 and through the channel 46 to the heel bladder 32. The fluid supplied from the arch bladders to the forefoot and heel bladders causes the forefoot and heel bladders to expand slightly from their at-rest configurations. The expansion of the forefoot and heel bladders exert reactive forces on the bottom of the foot at the forefoot and heel areas of the foot, thereby distributing the force of footstep impact concentrated at the arch area of the foot over the forefoot and heel areas of the foot.

In the operation of the forefoot bladder 24, as a force of footstep impact is exerted on the bladder the bladder compresses, forcing the fluid 50 contained in the interior volume 62 of the bladder out through the fluid-conducting channels 42, 44. As explained earlier, the crosssectional areas of the channels 42, 44 are calibrated to restrict the free flow of fluid through the channels. The calibration of the channels limits the rate at which fluid may exit the interior volume 62 of the forefoot bladder, causing a portion of the fluid to be retained in the bladder as a force is exerted on the bladder. The portion of fluid forced out of the forefoot bladder interior 62 fills the arch bladders 26,28 and the heel bladder 32 causing these bladders to expand slightly. The expansion of the