US20070119076A1 - Enhanced unitary sole assembly - Google Patents

Abstract

A sole assembly including a unitary midsole having an upper support surface configured to support a plantar region of a human foot, and a substantially contiguous lower surface extending from a heel portion of the sole assembly to a toe portion of the sole assembly. A semi-rigid heel cradle is coupled to the upper support surface and configured to cradle and support a heel region of the foot from beneath the foot and to support a plurality of sides of the foot when the foot is rested in a heel area of the sole assembly. Further, an outsole is provided on the substantially contiguous lower surface and configured to provide traction with a ground surface.

Description

FIELD OF THE INVENTION
• The present invention relates to a device that supports a person's foot, and more specifically, to a sole assembly including a unitary midsole extending from a heel portion to a toe portion of a sole assembly.
BACKGROUND OF THE INVENTION
• Contemporary shoes provide a complex combination of cushion, traction, and body-fitting elements that facilitate the natural progression of the foot along the ground during wear. When walking or running, the first part of the foot to strike the ground is the heel at the instant of “heelstrike.” Then the foot rolls forward from the heel region, through the midfoot region and the ball of the foot, and finally to the toe region where the foot breaks contact with the ground in a “toe-off” action. In addition to the above-described progression from the heel to the toe, the foot typically rolls from the outside to the inside (lateral side to the medial side), a process called “pronation” which disperses some of the energy generated during the impact of the foot with the ground. In some cases, the foot may not pronate enough, a condition called “underpronation” or “supination.” Furthermore, persons with underdeveloped arches may suffer from “overpronation,” wherein the foot rolls inward excessively. Either condition is unhealthy for the foot and can cause shin or joint pain.
• A shoe generally includes a “sole assembly” that provides the main weight bearing support at the plantar region of the foot, and an “upper” that connects to the sole assembly and surrounds other areas of the foot. The sole assembly typically includes an outsole and a midsole. The outsole is generally the portion of the sole assembly that makes contact with the ground, while the midsole is positioned just above (as the shoe normally touches the ground) the outsole and usually provides a cushioning affect. An insole, typically separate from the sole assembly, is normally positioned above the midsole and within the upper of the shoe to make contact with the wearer's foot. As the main support for the wearer's weight, the sole assembly of a shoe plays an important role in providing a healthful, natural stride.
• Early sole assemblies included a continuous midsole formed of a single piece of foam cushion material that formed a continuous bottom surface on which a tread outsole was provided. This design was initially adopted by the footwear industry because of its simple structure, which made manufacturing easy and cost effective. However, conventional continuous midsole designs required thick slabs of foam material in order to effectively absorb and disperse impact and propulsion forces generated during athletic use. Further, these conventional unitary sole designs were heavy and held the foot relatively high above the ground surface, thereby reducing lateral stability. Based on these characteristics, the footwear industries has perceived the unitary sole to be unsuitable for athletic footwear and has developed alternative designs for performance footwear.
• For example, a split sole assembly design has evolved as an industry standard for lightweight athletic shoes. With split soles, the heel and toe sections of the midsole are separated by a pronounced arch or deep groove, and a lightweight rigid shank is typically used to structurally connect the heel and toe regions of the midsole. As the shank allows removal of a substantial portion of the midsole foam, the split sole design generally provides a lightweight sole assembly. However, the present inventors have recognized that the shank region of the split sole is typically raised from ground contact (particularly along a periphery), which reduces traction capabilities and lateral support in this region of the split sole design. Further, the arched shank region requires a vertical dimension that increases the overall height of the split sole assembly, thus further reducing lateral stability. Yet another problem with the split sole is that the discrete heel region of this design generally concentrates heel strike forces in a small area making it more difficult for the wearer to naturally transition heel impact forces to midstance and toe off during stride.
• Various known footwear devices have also been developed to enhance performance of athletic shoes. For example, U.S. Pat. No. 4,821,430 to Flemming et al. describes a heel counter having a U-shaped side wall extending about a heel portion of a shoe upper, and a flexible membrane connected to a bottom portion of the U-shaped wall. Under the wearer's weight, the membrane flexes to draw the U-shaped wall inward to laterally support the wearer's foot. However, while not specified in the '430 patent, such support features have been implemented only in non-unitary sole designs such as the split sole described above. Moreover, the heel counter does nothing to reduce the overall height of the sole assembly, and the thin membrane provides only weak support for wearer's heel and little dispersion of heel impact forces. Still further, the flexible membrane may be a barrier to ventilation of the foot.
• Footwear features have also been developed to provide improved ventilation to the wearer's foot. For example, air passages that extend from a bottom surface of the sole assembly to an interior of the shoe upper have been used to increase air flow to the wearer's foot. As these through holes remove outsole and midsole material they also reduce the weight of the sole assembly. Again, however, these ventilation features have been implemented in non-unitary sole designs. Moreover, passages that extend from the bottom of the outsole can function as suction cups on the outsole, thus causing additional resistance to lifting the foot, especially in wet or muddy areas. While side surface air passages are also known, these passages typically extend only from a lateral to medial side of the sole assembly, thus providing no ventilation to the interior of the shoe. Further, placement of side passages is typically based only on weight considerations or aesthetics, making other footwear design considerations necessary to address unique characteristics of a wearer such as under pronation or over pronation.
SUMMARY OF THE INVENTION
• Accordingly, one object of the present invention is to address at least some of the above described and/or other problems of conventional footwear sole assemblies.
• Another object of the present invention is to provide a unitary sole assembly that mitigates the problems of a split sole assembly, but includes enhancements for mitigating conventional problems with unitary midsoles.
• Yet another object of the present invention is to provide a unitary sole assembly having a heel cradle for facilitating a natural transition of impact and propulsion forces during the wearer's stride.
• Still another object of the present invention is to provide a unitary sole assembly having an air passages that facilitate air flow to an interior of the shoe.
• Yet another object of the present invention is to provide a sole assembly air passage that facilitate air flow to an interior of the shoe and is also placed in a predetermined location to accommodate a characteristic of the wearer.
• These and/or other objectives of the present invention can be provided by a sole assembly according to an embodiment of the invention. One aspect of the present invention includes a sole assembly including a unitary midsole having an upper support surface configured to support a plantar region of a human foot, and a substantially contiguous lower surface extending from a heel portion of the sole assembly to a toe portion of the sole assembly. A semi-rigid heel cradle is coupled to the upper support surface and configured to cradle and support a heel region of the foot from beneath the foot and to support a plurality of sides of the foot when the foot is rested in a heel area of the sole assembly. Further, an outsole is provided on the substantially contiguous lower surface and configured to provide traction with a ground surface.
• Another aspect of the present invention includes a sole assembly with an outsole, a unitary midsole with a substantially contiguous support surface extending from a heel portion of the sole assembly to a toe portion of the sole assembly, and means for supporting a heel of a human foot when the human foot is rested within the means for supporting.
• Another non-limiting embodiment of the present invention includes a sole assembly including a unitary midsole having an upper support surface configured to support a plantar region of a human foot, a substantially contiguous lower surface extending from a heel portion of the sole assembly to a toe portion of the sole assembly, and sidewalls connecting the upper and lower surfaces. An outsole is provided on the substantially contiguous lower surface and configured to provide traction with a ground surface. Further included is a ventilation structure having a first hole disposed in a sidewall of the unitary midsole, and a second hole disposed in the outsole and in fluid communication with the first hole.
• Still another aspect of the present invention includes a sole assembly including a unitary midsole having an upper support surface configured to support a plantar region of a human foot, a substantially contiguous lower surface extending from a heel portion of the sole assembly to a toe portion of the sole assembly, and sidewalls connecting the upper and lower surfaces. An outsole is provided on the substantially contiguous lower surface and configured to provide traction with a ground surface. Also included is a means for ventilating the foot through the sole assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
• A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
• FIG. 1 is a perspective view of a left-foot shoe incorporating a sole assembly according to a first non-limiting embodiment of the present invention;
• FIG. 2 is a front view of a shoe incorporating a sole assembly according to the first exemplary embodiment of the present invention;
• FIG. 3 is a top view of a shoe incorporating a sole assembly according to the first exemplary embodiment of the present invention;
• FIG. 4 is a bottom view of a shoe and various section lines incorporating a sole assembly according to the first exemplary embodiment of the present invention;
• FIG. 5ashows the lateral side of a sole assembly according to the first exemplary embodiment of the present invention;
• FIG. 5bshows a lateral side of a sole assembly according to the first exemplary embodiment of the present invention;
• FIG. 5cshows a cross-section along line5cof the sole assembly shown inFIGS. 4 and 5a;
• FIG. 6 shows the medial side of a sole assembly according to the first exemplary embodiment of the present invention;
• FIG. 7ashows a rear side of a shoe incorporating a sole assembly according to the first exemplary embodiment of the present invention;
• FIG. 7bshows a cross-section alongline7bof the sole assembly shown inFIGS. 4 and 7a;
• FIG. 8 is a perspective view of a left-foot shoe incorporating a sole assembly according to a second non-limiting embodiment of the present invention;
• FIG. 9 is a front view of a shoe incorporating a sole assembly according to the second exemplary embodiment of the present invention;
• FIG. 10 is a top view of a shoe incorporating a sole assembly according to the second exemplary embodiment of the present invention;
• FIG. 11 is a bottom view of a shoe incorporating a sole assembly according to the second exemplary embodiment of the present invention;
• FIG. 12 shows the lateral side of a sole assembly according to the second exemplary embodiment of the present invention;
• FIG. 13 shows the medial side of a sole assembly according to the second exemplary embodiment of the present invention;
• FIG. 14 shows a rear side of a shoe incorporating a sole assembly according to the second exemplary embodiment of the present invention;
• FIG. 15 is a perspective view of a right-foot shoe incorporating a sole assembly according to a third non-limiting embodiment of the present invention;
• FIG. 16 is a front view of a shoe incorporating a sole assembly according to the third exemplary embodiment of the present invention;
• FIG. 17 is a top view of a shoe incorporating a sole assembly according to the third exemplary embodiment of the present invention;
• FIG. 18 is a bottom view of a shoe incorporating a sole assembly according to the third exemplary embodiment of the present invention;
• FIG. 19 shows the lateral side of a sole assembly according to the third exemplary embodiment of the present invention;
• FIG. 20 shows the medial side of a sole assembly according to the third exemplary embodiment of the present invention; and
• FIG. 21 shows a rear side of a shoe incorporating a sole assembly according to the third exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
• As discussed in the Background section above, while split sole designs can provide reduced weight, these designs also reduce traction and lateral stability, and impede the natural transition from heel to toe off during the wearer's stride. In view of these problems, the present inventors have recognized that a unitary midsole design can reduce or eliminate the problems of the split sole structure. Specifically, a unitary midsole design provides more ground surface contact area than a split sole, particularly along the periphery of the sole assembly. This ground contact area can provide improved traction and lateral support in the midfoot region during athletic activities. Thus, the present inventors have developed athletic shoes having an enhanced unitary midsole that mitigates the problems with split sole structures, while also reducing conventional unitary sole problems that have led the footwear industry to develop alternative sole assembly designs for athletic shoes.
• Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views,FIG. 1 is a perspective view of ashoe1 incorporating asole assembly3 according to the first non-limiting embodiment of the present invention. As seen inFIG. 1, the shoe includes an upper2 attached to thesole assembly3. The upper2 is preferably made of durable sheets of non-elastic material such as leather, canvas, synthetic material or any other upper material known to those skilled in the art of shoes. In a preferred embodiment, the upper is a breathable nylon mesh material reinforced with outer layer regions of nylon netting. The upper2 may be attached to thesole assembly3 by stitching, adhesion or any other method known in the art.
• In the non-limiting embodiment ofFIG. 1, thesole assembly3 includes aheel cradle4, anoutsole5, and aunitary midsole7. The term “unitary midsole” is meant to indicate a midsole that is substantially continuous from the heel region to the toe region in that it has no major split or rift between the these regions. However, the unitary midsole may include features such as seams, framework, or holes as long as theunitary midsole7 forms a substantially continuous lower surface upon which theoutsole5 can be supported. In some cases, the substantially continuous surface will be formed of a combination of foam cushion material and rigid or semi-rigid structure.
• As shown inFIGS. 1, 2,4 and5 theoutsole5 extends from the heel area of thesole assembly3 to the toe area. The portion of theoutsole5 at the very end of the toe is tapered such that theoutsole5 does not interfere with turning or pivoting of the foot. In other embodiments, theoutsole5 may wrap upward and around the toe of the shoe to a lesser extent than shown in the figures. In fact, such a wrapping arrangement is not necessary, but is merely one way of enhancing the flow of the foot from heel-strike to toe-off. Furthermore, theoutsole5 may taper differently or even not taper at all, depending on the application for which the shoe is designed.
• FIG. 3 shows a typical shoe “upper” configured to attach to thesole assembly3. In the heel region of upper shown inFIG. 3, the location of pellet-sized holes22 andfine mesh21 are shown. Although the pellet-sized holes22 andfine mesh21 are not normally visible in this view because they are covered byinsole9, they are schematically represented inFIG. 3 to clarify later detailed discussion of theheel cradle4.
• FIG. 4 shows one exemplary embodiment of the bottom of thesole assembly3 with emphasis on theoutsole5. Theoutsole5 is substantially continuous from the heel portion of thesole assembly3 to the toe portion. In particular, theoutsole5 has a substantially continuous peripheral edge that allows the full periphery of the outsole to contact the ground during sporting activities. As seen inFIG. 4, theoutsole5 is not a perfectly smooth or planar surface, but rather is a surface with grooves and indentations which supply traction. Theoutsole5 includes a tread portion which can be made of various tough, flexible materials such as, for example, carbon rubber, and is designed to provide gripping of various surfaces.
• In the embodiment shown inFIG. 4, the tread portion includes atread11 on its outer portion and atread13 located within theouter tread11. Thetread13 is separated from thetread11 bylongitudinal gaps17 which are low profile areas of relatively flexible material that facilitate width expansion of the forefoot of the sole assembly during activities. It should be noted that the tread types are not limited to thetread11 and tread13 shown inFIG. 3. Furthermore, theoutsole5 may have more types of tread, only one type of tread, or even a substantially smooth surface. Additionally, thegaps17 are optional. For example, thetread11 and thetread13 may be placed next to each other. In outsoles with only a single type of tread, thegaps17 may still be included to form channels around the tread.
• As further shown inFIG. 4, therear tread14 is separated from the tread in the front of the shoe byheel groove15. Theheel groove15 is relatively shallow. In other words, unlike outsoles used in combination with split midsoles, theoutsole5 is able to remain substantially continuous (when one appreciates that the width of thegroove15 is such that the groove does not allow the heel portion and toe portions of theoutsole5 to move or undergo stress without substantially affecting each other). Thegroove15 demarks an inflection point in the curvature of theoutsole5. In front of thegroove15, theoutsole5 is generally parallel with the surface of the ground when theshoe1 is resting on the ground. Behind thegroove15, thetread14 is angled upward such that a space is formed between theoutsole5 and the ground when the shoe is at rest on the ground. This space enhances the flow of the foot from heel-strike to toe-off during walking.
• Also shown inFIG. 4 is theoutsole hole19 andscreen20. Theoutsole hole19 penetrates through theoutsole5,midsole7, and heel cradle4 (if present), exposing theinsole9 and the heel of the foot to airflow. Thescreen20 protects theinsole9 from objects on the ground and provides support to the heel of the foot while providing good ventilation to the foot, as will be further described below. InFIG. 4, thescreen20 is depicted as having a series of pellet-sized holes22. However, thescreen20 can include afine mesh21 made of wire or plastic with barely visible holes. A combination of screens may be used. For example, thescreen20 may include one coarse screen and one fine screen or a fine screen that further includes some larger holes.
• In one alternative embodiment, the coarse screen is provided by making multiple pellet-sized holes22 in the bottom of theheel cradle4 itself. In other embodiments, thescreen20 merely covers a single large hole in theheel cradle4. In both cases, the bottom of theheel cradle4 is made more flexible in the center, thus enhancing the heel centering effect of the heel cradle while also providing ventilation. Accordingly, the hole in the base of theheel cradle4 not only provides a port for air to reach the bottom of the wearer's heel, but assists in centering the heel of the foot onto the sole assembly.
• It should be noted that theoutsole hole19 is shown in the embodiment ofFIG. 4 as having a teardrop shape. However, other shapes such as ovals, circles and angular shapes are possible. In alternate embodiments, theoutsole hole19 may be formed of two or more holes. For example, theoutsole hole19 may be formed of two holes located next to each other and separated by a wall of material from theunitary midsole7 and/oroutsole5.
• InFIG. 5a, the lateral side of one embodiment of theshoe1 is shown. In this embodiment, thesole assembly3 includeslateral side hole23 andheel hole25 formed integrally with theunitary midsole7. Thelateral side hole23 ofFIG. 5ais formed directly into theunitary midsole7 such that no further structure is incorporated into theunitary midsole7. Thelateral side hole23 proceeds inward toward the center of theunitary midsole7 such that it is in fluid communication with thebottom hole19 and theheel hole25. Thus, thelateral side hole23 andheel hole25 can function as an exhaust to enhance refreshed air flow to the bottom of the foot and reduce problems associated with the suction cup effect.
• The present inventors have also recognized that placement of the holes affects how the sole assembly responds to the pressures generated during walking. Thus, in addition to providing airflow to the foot, the holes may be used to enhance the transition of the foot from heel to toe as the wearer walks. Further, strategic placement of holes or structural alteration of through holes may be used to provide functionality that accommodates a particular characteristic of the wearer, such as over-pronation or under-pronation. Provisional Application Ser. No. 60/709792 discloses various methods of measuring a characteristic of the wearer in order to determine a footwear designs such as ventilation hole placement, suitable for the wearer. This provisional application is hereby incorporated herein in its entirety. It is noted that the midsole hole placement feature described herein may be used with any sole assembly and is not limited to the unitary midsole assembly.
• In the embodiment ofFIGS. 1-7, thelateral hole23 is placed so as to preferentially cushion the lateral side of theunitary midsole7 to prevent over-pronation of the foot during striding. In other words, instead of (or in addition to) augmenting the medial side of the shoe to prevent collapse of the arch, the lateral side of theunitary midsole7 incorporateslateral hole23 to soften this side of theunitary midsole7. By changing the size, location, and shape of thelateral hole23, theunitary midsole7 can be tuned to provide different levels of compliance on the lateral side. Thus, no augmentation and associated addition of material on the medial side of the sole assembly is necessary. Theheel hole25 can also be positioned to accommodate a particular characteristic of the wearer, as will be discussed below.
• As also seen inFIG. 5a, theheel cradle4 extends from the heel of the shoe toward the forefoot of the shoe and forms an upper surface of thelateral side hole23 andheel hole25, thus providing a bridge across these holes. The addition of theheel cradle4 can enhance the effect of the lateral hole23 (or other strategically placed holes in the unitary midsole7) by improving a position of the wearer's heel as the heel of the foot lifts and descends during walking or running. The present inventors have realized that by consistently centering the heel of the foot in relation to the sole assembly, the support function of the midsole is improved. That is, proper positioning of the heel allows thesole assembly3 to smoothly accommodate the natural gait of the wearer and to provide support where needed.
• In addition to foot positioning, theheel cradle4 can enhance the absorption and dispersion characteristics of the unitary sole. Thus, the heel cradle is preferably a rigid or semi-rigid structure that can support the bottom of the heel and disperse impact and propulsion forces across a large area of theunitary midsole7 during stride. This allows theunitary midsole7 to be thinner than conventional midsoles, which reduces the weight and overall height of the sole assembly. For example, the typical height of an athletic shoe sole assembly is approximately 12 mm or 13 mm in the forefoot region and 24 mm or 25 mm in the heel region, while a sole assemble having a unitary midsole according to the present invention can be between 16 and 24 mm in the heel region and/or 6-12 mm in the forefoot region. In a preferred embodiment the sole assembly is approximately 18 mm in the heel region and 9 mm in the forefoot region, or more preferably approximately 16 mm in the heel region and 6 mm in the forefoot. This reduced height brings the wearer's heel closer to the ground surface thereby providing improved lateral stability. Still further theheel cradle4 can enhance durability of the cushion by dispersing the force of the heel-strike so as to prevent any particular part of the cushion from suffering compaction due to repeated, concentrated impact.
• In the embodiment ofFIG. 5a, theheel cradle4 is external to anupper heel support27 which is typically made of flexible material such as leather, sheeted plastic, or canvas etc. However, theheel cradle4 may be formed inside theupper heel support27 so as to be invisible to the wearer.
• Theheel cradle4 also curves upward on the medial and lateral sides of the foot so as to center the foot within thesole assembly3. Theheel hole25 can further enhance the centering effect of the heel cradle by providing a compliant area directly under the heel bone. In the embodiment ofFIG. 5a, the heel cradle has a much greater height in the back of the heel than it does on the sides. However, typically the height of theheel cradle4 is not made so large that theheel cradle4 impacts the Achilles tendon during striding.
• In alternative embodiments, theheel cradle4 and theheel support27 are integrally formed together. In this case, theheel cradle4 andheel support27 are differentiated by marked differences is stiffness. This arrangement allows a simpler manufacturing setup and can provide enhanced durability. On the other hand, in embodiments where theheel cradle4 andheel support27 are formed separately, the stiffness of theheel cradle4 can be more specifically tuned to the needs of the wearer than if theheel cradle4 andheel support27 are made integrally.
• FIG. 5bshows thesole assembly3 ofFIG. 5ain isolation. As shown inFIG. 5b, the heel cradle is slightly concave downward. This shape conforms to the arch of the foot and provides a naturally supportive arch structure. The thickness of the material of theheel cradle4 is shown with a dashed line T. In general, the thickness of the heel cradle will be from 1 mm to 10 mm, more preferably 0.5-5 mm. Of course, the heel cradle may be shaped differently for functional or aesthetic purposes. The heel cradle is typically made of plastic or a carbon fiber material, but other materials may be used.
• FIG. 5cis a cross-section view of the lateral side of theunitary midsole7 taken along section line5cshown inFIG. 4a. As is clearly shown inFIG. 5c, theheel cradle4 extends from the heel of the shoe to approximately the midfoot area. One beneficial effect of having a large heel cradle between the foot and theunitary midsole7 is that theheel cradle4 can be enhanced as a force dispersing plate to further reduce concentration the force generated during heel-strike into the same area of the cushion. In other words, theheel cradle4 spreads the impact energy generated in each footstep so that theunitary midsole7 does not compact small areas of themidsole7. This spreading or dispersion effect helps maintain the cushioning properties of theunitary midsole7 and can be lead to a thinner sole assembly as noted above. Without such a dispersion effect, theunitary midsole7 may plastically deform such that it becomes molded into the shape of the bottom of the foot. As theheel cradle4 is typically made from relatively stiff material, theheel cradle4 still functions to disperse the impact energy generated during striding, even though the heel cradle can be as thin as approximately 1 mm.
• FIG. 5cfurther shows pellet-sized holes22 andfine mesh21 of thescreen20 in cross-section. In this embodiment, the pellet sized holes are formed in theheel cradle4 itself. It is also possible that the pellet-sized holes22 or thescreen20 are formed in separate components inserted into thesole assembly3. Forming the pellet-sized holes22 in a separate component allows theheel cradle4 and the separate component to be made of different materials, and, therefore, the amount of support provided to the heel of the foot can be tuned more precisely to optimize the centering effect of theheel cradle4.
• As discussed above, thelateral side hole23 is in fluid communication with thebottom hole19 and theheel hole25. Thus, air may flow into any of the holes and out through any of the others, and no problems with a “suction-cup” effect occur. Additionally, thescreen20 allows air to be “pumped” directly to the heel of the foot. As thelateral side hole23 andbottom hole19 typically face the direction of motion of the shoe1 (sideways and downward), air typically flows into these holes and out theheel hole25,fine mesh21, and pellet sized holes22. The lateral and bottom holes may be streamlined to enhance this effect.
• As the cross-section along line5cis taken near the center of the shoe, the connection point between thelateral side hole23 and thebottom hole19 is not shown inFIG. 5c, but it should be understood that thelateral side hole23 is in fluid communication with thebottom hole19.
• As shown inFIG. 5c,bottom hole19 is shaped with a larger opening on the bottom than on the top. In other words, thebottom hole19 is somewhat funnel or conical shaped. One benefit of the funnel shape is that dirt and rocks are less likely to become trapped inside the hole. Another benefit of the funnel shape is that more air is directed to the bottom of the heel during the downward motion of the foot as discussed above.
• FIG. 6 shows a medial side view of the first embodiment of the present invention. As shown inFIG. 6, theunitary midsole7 has no hole on its medial side. Thus, the location of thelateral side hole23 softens the lateral side of thesole assembly3 relative to the medial side, thereby providing an effect similar to an arch support. The amount of support provided can be adjusted by changing the shape or thickness of theheel cradle4, thehole frame24, and the shape and size of thelateral side hole23.
• FIG. 7adepicts a rear view of the first embodiment of the present invention. InFIG. 7a, theheel hole25 is positioned approximately in the center of the heel region, but with a slight bias toward the lateral side of the shoe. Thus, theheel hole25 provides a centering effect, while also facilitating proper pronation of the foot by softening the lateral side of theunitary midsole7, even if no heel cradle is present. If the heel cradle is present, the centering effect of theheel cradle4 is enhanced by theheel hole25. For purposes of ventilation, theheel hole25 is in fluid communication with thebottom hole19 and thelateral hole23.
• FIG. 7bshows a cross-section of the sole assembly ofFIG. 7ataken alongline7bshown inFIG. 4a. In this view, the conical shape of thebottom hole19 and the cup-like shape of theheel cradle4 are clearly shown. Thebottom hole19 and theheel hole25 work in combination to control the stiffness profile of theunitary midsole7.
• FIGS. 8-14 show a second embodiment of the present invention. Corresponding structures from the first embodiment are shown with reference numbers including a prime symbol. For example,reference number1 becomes1′.
• As shown inFIGS. 8-15, thesole assembly3′ includes aheel cradle4′,outsole5′ and aunitary midsole7′. As best seen inFIG. 11, theoutsole5′ is substantially continuous, with only a small recessed area50 on a medial side of the periphery. This recess corresponds to a medialside hole structure29, which was not provided in the embodiment ofFIG. 1. However, the relatively small size of the recess50 does not substantially detract from the peripheral stability provided by the unitary midsole design. Other differences between the first and second embodiments will become apparent from the discussion below.
• As best shown in the embodiment ofFIG. 12, and in contrast to the lateral hole depicted in the embodiment ofFIG. 5a, thelateral hole23′ is formed in the bottom of theunitary midsole7′ with theoutsole5′ bordering the bottom boundary of the hole. Another difference between the two embodiments is that thelateral hole23 depicted inFIG. 12 includes ahole frame24. Thehole frame24 is typically formed of a different material than the rest ofunitary midsole7′ and provides a rigid or semi-rigid structure to thelateral hole23′. Thus, theheel cradle4′ and thehole frame24 sandwich cushion material in theunitary midsole7′. Thehole frame24 is streamlined to facilitate airflow into thelateral hole23′ and also to enhance aesthetic appeal. For example, to enhance visual impact, thehole frame24 typically has a different color than the rest of theunitary midsole7.
• As further shown inFIG. 12, theheel cradle4′, attached to the outside ofupper heel support27′, has a more uniform height than does the heel cradle of the first embodiment. Thus, increased support is provided to the sides of the foot, and theheel cradle4′ can provide a different centering effect of the foot within the shoe.
• FIG. 13 shows the medial side of theshoe1′ with amedial hole29 similar to thelateral hole23′ shown inFIG. 12 except that thehole frame24 surroundingmedial hole29 includesfins31 to enhance the stiffness ofmedial hole29. As discussed above, to achieve a proper amount of pronation, the lateral hole is included to soften the lateral side of the unitary midsole. However, in some embodiments, to enhance air flow and/or adjust the stiffness of the sole assembly, both medial and lateral holes are included in the unitary midsole. Thus, various methods of stiffening the area around themedial hole29 are used. For example, the size or shape of themedial hole29 can be changed to make theunitary midsole7′ in the vicinity of themedial hole29 stiffer. In the embodiment shown inFIG. 13,fins31 strengthen the structure around the medial hole. In this case, thefins31 are thin, blade-like structures which allow air to pass freely into themedial hole29 while still providing structural rigidity. Aesthetic touches such as slanting the tops of the fins forward are also sometimes included.
• FIG. 14 shows a rear view of the second embodiment of the present invention. In this view, theheel hole25′ is filled with aheel cushion33. Theheel cushion33 is typically a softer material than theunitary midsole7′. Therefore, theheel cushion33 enhances the centering effect of theheel cradle4′ in a similar way that the heel hole of the first embodiment does. For aesthetic purposes, theheel cushion33 may be textured and have a different color than theunitary midsole7′.
• FIGS. 15-21 depict a third embodiment of the present invention. Note that for this embodiment, a shoe for the right-side foot is depicted. Features corresponding to the first embodiment, shown inFIGS. 1-7, will be shown with reference numbers having a double prime mark. For example,reference numbers1 and1′ become1″.
• Unlike the first two embodiments, theunitary midsole7″ of the third embodiment does not have a lateral hole. The lateral side of theshoe1″ is best shown inFIG. 19. The lateral hole may be omitted when the wearer has a tendency to underpronate. Thus, without the lateral hole, the lateral side of theunitary midsole7″ is stiffer and the outside edge of the foot will compress thesole assembly3 to a lesser extent.
• FIG. 20 shows thesole assembly3″ withmedial hole29″ andhole frame24, but nofins31. Thus,fins31 are optional and are included when additional stiffness is required, or to enhance aesthetic appearance. Like the lateral holes described above, the medial holes are in fluid communication with thebottom hole19. The inclusion of themedial hole29″ enhances the effect of the exclusion of the lateral hole regarding pronation of the foot. In other words, asole assembly3″ with amedial hole29″, but no lateral hole will typically have a stronger tendency to pronate the foot of the wearer.
• FIG. 21 shows a rear view of the third exemplary embodiment of the present invention. In this embodiment, theheel hole25″ is greatly biased toward one side of the sole assembly. As shown inFIG. 21, the bias is toward the medial side of the shoe. However, in other embodiments, the bias is toward the lateral side of the shoe. By biasing the heel hole toward one side or the other, the tendency for pronation of a given sole assembly is controlled. For example, for feet with weak arches, thesole assembly3″ may be designed with aheel hole25″ strongly biased toward the lateral side of theunitary midsole7. To compliment the effect of theheel hole25″, alateral hole23 may be included. Conversely, for feet that tend to under-pronate, aheel hole25″ shifted to the medial side would be preferable. Again, to enhance the effect of theheel hole25, a medial hole could be included as discussed above.
• Aside from the specific embodiments described above, any combination or permutation of medial holes, lateral holes, heel holes and bottom holes is possible. For example, asole assembly3 could include amedial hole29, alateral hole23, a heel hole25 (biased in either the lateral or medial directions), and abottom hole19. Moreover, either or both of the medial and lateral holes could includefins31. In addition, many of the items depicted in the drawings include purely aesthetic features, and, therefore, may be reshaped without altering their functionality. Still further, it is to be understood that features of specific embodiments may be used with other embodiments.
• Clearly, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. For example, one advantage of the unitary midsole structure is that it provides an opportunity to develop structural enhancements to the sole assembly that extend into the midfoot region. U.S. patent application titled “Footwear Sole Assembly Having Spring Mechanism” filed on Nov. 10, 2005 and having attorney docket number 280500US discloses a sole assembly spring mechanism implemented into a unitary midsole. The entire content of this application is incorporated herein by reference.

Claims (25)

1. A sole assembly comprising:

a unitary midsole having an upper support surface configured to support a plantar region of a human foot, and a substantially contiguous lower surface extending from a heel portion of the sole assembly to a toe portion of the sole assembly;

a semi-rigid heel cradle coupled to the upper support surface and configured to cradle and support a heel region of the foot from beneath the foot and to support a plurality of sides of the foot when the foot is rested in a heel area of the sole assembly; and

an outsole provided on the substantially contiguous lower surface and configured to provide traction with a ground surface.

2. The sole assembly ofclaim 1, wherein the heel cradle comprises lateral, medial, and rear sidewalls for supporting the plurality of sides of the foot.

3. The sole assembly ofclaim 2, wherein the heel cradle increases in depth in a direction from the toe portion to the heel portion.

4. The sole assembly ofclaim 3, wherein the heel cradle extends from the heel portion to a midfoot portion of the sole assembly.

5. The sole assembly ofclaim 1, wherein the heel cradle comprises a through hole in a surface facing the outsole and configured to guide the heel of a human foot toward a central region of the sole assembly.

6. The sole assembly ofclaim 5, wherein the through hole is tear-drop shaped and oriented such that a widest part of the tear-drop is closer to the heel portion than is a narrowest part.

7. The sole assembly ofclaim 5, wherein the through hole is oval or circular shaped.

8. The sole assembly ofclaim 5, wherein the through hole comprises pellet-sized holes.

9. The sole assembly ofclaim 5, wherein the through hole comprises a fine mesh.

10. The sole assembly ofclaim 1, further comprising:

a flexible upper attached to the sole assembly to form a shoe cavity; and

an insole provided within the cavity and in contact with the sole assembly.

11. The shoe ofclaim 10, wherein the flexible upper includes a material different than a material comprising the heel cradle, and the flexible upper is disposed at least partially between the heel cradle and the heel area.

12. The shoe ofclaim 10, further comprising a flexible upper, including a material different than a material comprising the heel cradle, disposed on a side of the heel cradle opposite a side of the heel cradle facing the heel area.

13. The shoe ofclaim 10, wherein the upper extends farther in a direction away from the outsole to the insole than does the heel cradle.

14. A sole assembly comprising:

an outsole;

a unitary midsole with a substantially contiguous support surface extending from a heel portion of the sole assembly to a toe portion of the sole assembly; and

means for supporting a heel of a human foot when the human foot is rested within the means for supporting.

15. A sole assembly comprising:

a unitary midsole having an upper support surface configured to support a plantar region of a human foot, a substantially contiguous lower surface extending from a heel portion of the sole assembly to a toe portion of the sole assembly, and sidewalls connecting the upper and lower surfaces;

an outsole provided on the substantially contiguous lower surface and configured to provide traction with a ground surface; and

a ventilation structure comprising:

a first hole disposed in a sidewall of the unitary midsole, and

a second hole disposed in the outsole and in fluid communication with the first hole.

16. The sole assembly ofclaim 15, wherein the first hole is disposed on a bottom edge of the unitary midsole.

17. The sole assembly ofclaim 16, wherein the first hole comprises a hole frame.

18. The sole assembly ofclaim 17, wherein the hole frame comprises fins.

19. The sole assembly ofclaim 15, wherein the first hole is disposed on a top edge of the unitary midsole.

20. The sole assembly ofclaim 15, further comprising a third hole, in fluid communication with the first and second holes, and disposed in the midsole.

21. The sole assembly ofclaim 20, wherein the first and third holes are disposed on different sides of the midsole.

22. The sole assembly ofclaim 21, wherein the third hole is disposed in a heel portion of the midsole.

23. The sole assembly ofclaim 22, further comprising fourth hole in a different side of the midsole than either of the first and third holes.

24. The sole assembly ofclaim 20, wherein the third hole is disposed on a lateral side or a medial side of the midsole.

25. A sole assembly comprising:

a unitary midsole having an upper support surface configured to support a plantar region of a human foot, a substantially contiguous lower surface extending from a heel portion of the sole assembly to a toe portion of the sole assembly, and sidewalls connecting the upper and lower surfaces;

an outsole provided on the substantially contiguous lower surface and configured to provide traction with a ground surface; and

means for ventilating the foot through the sole assembly.

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