US20110146110A1 - Integral spine structure for footwear - Google Patents

Abstract

A support structure for footwear includes a longitudinally extending member to which a plurality of laterally extending supports members are secured at spaced apart locations along a length of the longitudinal member. The support structure may extend along the entire length of a footwear or may be specifically designed for the forefoot, midfoot, or hindfoot areas of a footwear. The support structure may be combined with plate-like structures or may include a plurality of longitudinally extending members. The lateral supports may extend in a generally horizontal plane or may extend in an upward or downward direction out of the horizontal plane. Furthermore, the longitudinal and lateral members may be made of different materials, or each may be made of a plurality of different materials to provide the desired characteristics of the support structure at a given location in the footwear. Different portions of the longitudinal member may be more or less flexible than the lateral supports.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
• This application is a continuation of U.S. Pat. No. 7,818,897 which issued from U.S. patent application Ser. No. 12/204,274, filed Sep. 4, 2008, which claims priority to U.S. patent application Ser. No. 10/893,114, filed Jul. 16, 2004, which claims benefit of U.S. Provisional Application Ser. No. 60/488,476, filed on Jul. 17, 2003, which applications are hereby incorporated by reference in their entireties.
BACKGROUND OF THE INVENTION
• 1. Technical Field
• The present invention generally relates to footwear, and more specifically relates to structures for supporting a footwear.
• 2. Related Art
• A common objective for most types of footwear designs is to address at least one of the following three biomechanical issues: shock attenuation, stability, and support. Shock attenuation involves the absorption of shock, shock diffusion and pressure distribution. The ability of a footwear to attenuate shock forces can greatly reduce the pain and discomfort to a user of the footwear for any given application. Shock absorption may be addressed by the type of materials that are used in the footwear. Various types of materials have excellent shock absorption properties, especially for the thin layers that are typically required for a footwear. Shock diffusion relates to dampening of shock forces to reduce how much of the shock force is transferred to the user. Again, the type of material as well as the structure of the footwear may significantly affect shock diffusion by a footwear. Pressure distribution relates to the distribution or spreading out of a point force or pressure point such as, for example, a heel strike pressure point at the heel of a footwear when walking or running. Pressure distribution is often accomplished using a plate-like structure wherein the amount of pressure distribution is controlled by the type and thickness of the plate material.
• The stability of a footwear is a another important biomechanical issue and may be controlled by the material properties and structure of various features of a footwear. For example, a footwear with a very thick sole that raises an individual's center of gravity beyond a natural position may provide a very unstable scenario. Further, some types of materials used in footwear are very flexible and if used alone without any other support features may create an unstable footwear. Some types of material that do not allow flexibility may effect the natural motion of the foot and further create instability.
• The support provided by a footwear is also important. A common objective for a footwear is to obstruct as little as possible the natural movements of the foot while supporting the foot where it is necessary for a given footwear application. In some applications such as sports like soccer and tennis, lateral support is extremely important, while arch support and support along the longitudinal axis of the footwear may be a greater consideration for applications such as running and walking. Other applications that require standing for long periods of time may require the type of support which reduces the amount of work the users foot muscles must exert in order to maintain proper posture and balance while standing.
• A further biomechanical consideration for footwear is the flexibility of the forefoot, midfoot and hindfoot portions of the footwear. A natural motion of the foot requires significant flexing and bending in a longitudinal direction as well as some complex lateral and torsional motion. While some types of inflexibility may be important for certain performance enhancement objectives, most footwear applications require a range of flexibility in each major section of the footwear. For example, undue amounts of torsional flexibility about a transverse axis of the footwear in the area of the arch of the foot may result in inadequate guiding and holding of the foot if the footwear bottom also provides too much longitudinal flexibility in that region of the footwear.
• One known attempt at an “all day comfort” footwear that addresses shock attenuation, stability, support and flexibility includes a firm lasting insole that is layered in the footwear just above the midsole and extends along the hind of the footwear up to the midfoot of the footwear. This plate-like structure provides support and diffuses forces in the heel. In an effort to attenuate shock forces, the footwear may include a gel or other type of insert material at the outsole or within the midsole of the footwear. Although the plate structure may distribute pressure, the heel strike and other significant shock forces are not dissipated very well. Furthermore, because there is no support structure in the forefoot of the footwear, the footwear may be entirely too flexible for a given application and fails to provide the torsional rigidity that is necessary for support and stability of the footwear.
• Another known footwear design that attempts to address the biomechanical issues described above includes a sole structure that has multiple horizontal and/or vertical layers of foam materials that each have different properties. The outsole may also include certain structures that provide some lateral support. This type of design is difficult to alter for the support, stability and shock attenuation needs of different applications while concurrently providing necessary flexibility along the length of the footwear.
• The cost and feasibility of a footwear design is a further consideration when designing a footwear that addresses the above-mentioned biomechanical issues. Some footwear designs may include materials or structures that are not conducive to cost effective manufacturing and assembly of the footwear.
SUMMARY OF THE INVENTION
• The present invention relates to a support structure for use in a footwear that can be altered to meet the shock attenuation, stability, support and flexibility needs for a given footwear application. One aspect of the invention relates to a footwear support structure that includes an elongate member and a plurality of lateral supports coupled to the elongate member. In some embodiments, the elongate member may be more flexible than the lateral supports by using, for example, different materials or different cross-sectional shapes for the elongate member verses the lateral supports. In other embodiments, the support structure may have different flexibility properties in the forefoot, midfoot and hindfoot sections of the support structure. The support structure may be positioned at various locations within a footwear sole assembly between various layers of the sole assembly. The support structure may also be coupled to a carrier or base member and used as an insert piece in the sole assembly.
• Another aspect of the invention relates to a footwear sole structure that includes a sole member having a heel portion defining a void, and a spine structure that includes an elongate spine extending along a first axis and a plurality of laterally extending support ribs secured to the elongate spine at spaced apart locations along a length of the spine. The spine structure is at least partially positioned over the void and supported by the heel portion of the midsole member, and a portion of the spine structure is movable into the void. In other embodiments, the void is positioned in other portions of the midsole or another sole member of a footwear sole assembly. The void may be filled with a material different properties from the material that defines the void.
• Another aspect of the invention relates to a footwear construction that includes a midsole member having a heel section that includes first and second portions having different properties, an upper member coupled to the midsole, and a spine support structure that includes an elongate spine member and a plurality of laterally extending supports coupled to the elongate spine member. The first portion of the heel section supports the laterally extending supports and the second portion of the heel section supports the elongate spine member.
• A further aspect of the invention relates to a method of manufacturing a footwear that includes an upper, a sole, and a spine support structure that includes an elongate spine member and a plurality of transverse supports. The method includes positioning the spine support structure in a mold and positioning the upper adjacent to the mold, filling the mold with a moldable material to form the sole, and curing the moldable material to secure the sole and the spine support structure to the upper.
• Another aspect of the invention relates to a method of forming a footwear support structure that includes forming an elongate member along a first axis, and forming a plurality of support members that are secured to the elongate member and that extend in a lateral direction relative to the first axis.
• Another aspect of the invention relates to a method of assembling a footwear support structure that includes an elongate member extending along a first axis and a support member. The method may include the steps of securing the support member to the elongate member, and aligning the support members in a substantially lateral direction relative to the first axis.
• A further aspect of the invention relates to a footwear support structure that includes a longitudinal spine structure and a plurality of support members secured to the spine and that extend in a generally lateral direction relative to a direction of extension of the spine structure. The support structure may include separate segments having different stiffening properties unique for certain areas of the footwear.
• Another aspect of the invention relates to a footwear that includes a midsole, an outsole, a lasting insole, an upper, and a support structure positioned between lasting insole and the outsole. The support structure may include an elongate member and a plurality of spaced apart laterally extending supports.
• A further aspect of the invention relates to a method of supporting a footwear that includes an upper, a midsole, an outsole, and a support structure having a longitudinally extending spine and a plurality of laterally extending supports secured to the spine at spaced apart locations along a length of the spine. The steps of the method may include positioning the support structure in the midsole and securing the midsole to the upper and the outsole.
• A further aspect of the invention relates to a method of supporting a footwear having a outsole, a midsole, an upper, and a support structure having an elongate spine and a plurality of laterally extending supports secured to the spine at spaced apart locations along a length of the spine. The method may include positioning the support structure within the upper and above the outsole, and resisting lateral movement in the footwear with the support structure.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a side cross-sectional view of a footwear known in the art.
• FIG. 2 is a side cross-sectional view of a footwear having an embedded support structure according to principles of the invention.
• FIG. 3 is a bottom plan view of the footwear ofFIG. 2.
• FIG. 4 is a lateral cross-sectional view of the footwear ofFIG. 3 taken along cross-sectional indicators4-4.
• FIG. 5 is a lateral cross-sectional view of the footwear ofFIG. 3 taken along cross-sectional indicators5-5.
• FIG. 6 is a lateral cross-sectional view of the footwear ofFIG. 3 taken along cross-sectional indicators6-6.
• FIG. 7 is a top view illustrating one example longitudinal member according to principles of the invention that follows a centerline a footwear through the toe and heel centerlines.
• FIG. 8 is a top view illustrating another example longitudinal member according to principles of the invention that follows a pressure line for a footwear.
• FIG. 9 is a top view illustrating a further example longitudinal member according to principles of the invention that follows a random line in a footwear.
• FIG. 10 is a perspective view of a portion of one example support structure according to principles of the invention.
• FIG. 11 is a lateral cross-sectional view taken along cross-sectional indicator11-11 shown inFIG. 10.
• FIG. 12 is a top view of one example support structure that includes the longitudinal member ofFIG. 7.
• FIG. 13 is a top view of another example support structure that includes the longitudinal member ofFIG. 8.
• FIG. 14 is a top view of anther example support structure that includes lateral supports with a single flared end.
• FIG. 15 is a top view of anther example support structure that includes lateral supports with two flared ends.
• FIG. 16 is a top view of anther example support structure that includes a longitudinal support that is exposed where attached to the lateral supports.
• FIG. 17 is a top view of anther example support structure that includes lateral supports at a mid section that act as shank for a footwear.
• FIG. 18 is a top view of anther example support structure that includes multiple longitudinal supports.
• FIG. 19 is a top view of anther example support structure that includes webbing material that extends between some of the lateral supports.
• FIG. 20 is a top view of anther example support structure that includes a heel plate.
• FIG. 21 is a top view of anther example support structure that is configured as a blocker unit with connecting webbing between lateral supports of the support structure.
• FIG. 21A is a side view of the blocker unit configuration shown inFIG. 21.
• FIG. 21B is a side view of another example blocker unit configuration that includes a layer of connecting webbing above and below the support structure.
• FIG. 22 is a side cross-sectional view of one example support structure according to principles of the present invention mounted in a footwear having a continuous flat outsole.
• FIG. 23 is a side cross-sectional view of one example support structure according to principles of the present invention mounted in a footwear having a cut out arch section of the footwear.
• FIG. 24 is a side cross-sectional view of one example support structure according to principles of the present invention mounted in a footwear having a partial cut out arch section of the footwear.
• FIG. 25 is a side cross-sectional view of one example support structure wherein the mid section of the support structure is a continuous piece of material and acts as a shank for the footwear.
• FIG. 26 is a side cross-sectional view of another example support structure wherein the mid section of the support structure is exposed at the outsole of the footwear.
• FIG. 27 is a side cross-sectional view of another example support structure wherein the hindfoot section of the support structure extends through a midsection of the midsole.
• FIG. 28 is a side cross-sectional view of one example support structure wherein the mid section of the support structure includes a continuous piece of material having a longitudinal support with an increased cross-section.
• FIG. 28A is a top perspective view of the support structure shown inFIG. 28.
• FIG. 28B is a lateral cross-sectional view taken alongcross-sectional indicator28B-28B shown inFIG. 28A.
• FIG. 29 is a side cross-sectional view of one example support structure wherein the support structure extends along the outsole of the footwear.
• FIG. 29A is a top perspective view of the support structure shown inFIG. 29.
• FIG. 29B is an lateral cross-sectional view of the footwear shown inFIG. 29 taken alongcross-sectional indicators29B-29B.
• FIG. 30 a side cross-sectional view of one example support structure wherein the support structure extends in the middle of the midsole of the footwear.
• FIG. 31 a side cross-sectional view of one example support structure wherein the support structure includes lateral supports in the toe section and a plate support in the mid section and heel section.
• FIG. 31A is a top perspective view of the support structure shown inFIG. 31.
• FIG. 32 is a lateral cross-sectional view of an example footwear that includes a support structure that includes upward and downward extending lateral supports.
• FIG. 32A is a top perspective view of support structure shown inFIG. 32.
• FIG. 33 is a top perspective view of another example support structure that includes upward, downward and horizontally extending lateral supports.
• FIG. 33A is an end view of the support structure shown inFIG. 33.
• FIG. 34 is a top perspective view of a portion of the support structure shown inFIG. 16.
• FIG. 35 is lateral cross-sectional view of another support structure in which the longitudinal support and the lateral support have a coplanar top surface and the longitudinal support includes a curved cross-section.
• FIG. 36 is lateral cross-sectional view of another support structure in which the longitudinal support and the lateral support have a coplanar top surface and the longitudinal support includes a rectangular cross-section.
• FIG. 37 is lateral cross-sectional view of another support structure in which the longitudinal support extends above a top surface of the lateral support and the longitudinal support has a circular cross-section.
• FIG. 38 is lateral cross-sectional view of another support structure in which the longitudinal support extends across a top surface of the lateral support.
• FIG. 39 is a side view of a portion of an example support structure in which the lateral support extends continuously along the longitudinal axis and the longitudinal support extends between the lateral supports.
• FIG. 39A is a side cross-sectional view of the support structure shown inFIG. 39 taken alongcross-sectional indicator39A-39A.
• FIG. 40 is a side view of a portion of another example support structure in which the longitudinal support extends continuously along the longitudinal axis and the lateral supports are mounted to the longitudinal support.
• FIG. 40A is a cross-sectional view of the support structure shown inFIG. 40 taken alongcross-sectional indicator40A-40A and further supported in a mold.
• FIG. 41 is a perspective view of one example support structure according to principles of the invention integrated into a padded footwear insert.
• FIG. 42A is a top view of forefoot or toe portion of a support structure according to principles of the invention.
• FIG. 42B is a top view of midfoot portion of a support structure according to principles of the invention.
• FIG. 42C is a top view of hindfoot or heel portion of a support structure according to principles of the invention.
• FIG. 43 is a top view of another example support structure according to principles of the invention that supports midfoot and hindfoot portions of a footwear.
• FIG. 44 is a top view of another example support structure according to principles of the invention that supports forefoot and midfoot portions of a footwear.
• FIG. 45 is a top view of a footwear that includes another example support structure according to principles of the invention that extends the entire length of the footwear.
• FIG. 46 is a side cross-sectional view of the footwear shown inFIG. 45 taken along cross-sectional indicators46-46.
• FIG. 47 is a lateral cross-sectional view of the footwear shown inFIG. 45 taken along cross-sectional indicators47-47.
• FIG. 48 is a lateral cross-sectional view of the footwear shown inFIG. 45 taken along cross-sectional indicators48-48
• FIG. 49 is a top view of a footwear that includes another example support structure according to principles of the invention that extends along a partial length of the footwear.
• FIG. 50 is a side cross-sectional view of the footwear shown inFIG. 45 taken along cross-sectional indicators50-50.
• FIG. 51 is a lateral cross-sectional view of the footwear shown inFIG. 45 taken along cross-sectional indicators51-51.
• FIG. 52 is a lateral cross-sectional view of the footwear shown inFIG. 45 taken along cross-sectional indicators52-52.
• FIG. 53 a lateral cross-sectional view of the footwear shown inFIG. 45 taken along cross-sectional indicators53-53.
• FIG. 54 is a top perspective view of an example footwear sole insert according to principles of the present invention.
• FIG. 55 is a side cross-sectional view of an example footwear sole that includes the insert member shown inFIG. 54.
• FIG. 55A is lateral cross-sectional view of the footwear sole shown inFIG. 55.
• FIG. 56 is a side cross-sectional view of an example footwear sole that includes separate forefoot and heel sections of the insert member shown inFIG. 54 positioned as outsole members.
• FIG. 56A is a lateral cross-sectional view of the footwear sole shown inFIG. 56.
• FIG. 57 is a side cross-sectional view of an example footwear sole that includes separate forefoot and heel sections of the insert member shown inFIG. 54 positioned respectively adjacent to a midsole and as a portion of the outsole.
• FIG. 58 is a side cross-sectional view of an example footwear sole that includes separate forefoot and heel sections of the insert member shown inFIG. 54 positioned adjacent to a midsole of the footwear sole.
• FIG. 59 is a side cross-sectional view of an example footwear sole that includes a support structure secured to an underside of a midsole of a welt sole construction.
• FIG. 59A is a lateral cross-sectional view of the footwear sole shown inFIG. 59.
• FIG. 60 is a side cross-sectional view of an example footwear sole that includes a support structure secured to an underside of a lasting insole of lasting sole construction.
• FIG. 61 is a side cross-sectional view of an example footwear sole that includes a support structure completely embedded in an sole insert member that is positioned as a portion of the footwear outsole.
• FIG. 61A is a lateral cross-sectional view of the footwear sole shown inFIG. 61.
• FIG. 62 is a side cross-sectional view of example footwear sole that includes a support structure molded in the footwear sole in a welt sole construction.
• FIG. 62A is a lateral cross-sectional view of the footwear sole shown inFIG. 62.
• FIG. 63 is a lateral cross-sectional view of another example footwear sole that includes a support structure with lateral supports that extend vertically downward.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
• The present invention generally relates to a support structure for footwear. The support structure includes a longitudinally extending member to which a plurality of laterally extending supports members are secured at spaced apart locations along a length of the longitudinal member. The support structure may extend along the entire length of a footwear or may be specifically designed for the forefoot, midfoot, or hindfoot areas of a footwear. The support structure may be combined with plate-like structures or may include a plurality of longitudinally extending members. The lateral supports may extend in a generally horizontal plane or may extend in an upward or downward direction, or combination of upward, downward, horizontal or generally curved upward or downward directions. Furthermore, the longitudinal and lateral members may be made of different materials, or each may be made of a plurality of different materials to provide the desired characteristics of the support structure at a given location in the footwear. In some embodiments, the longitudinal member is more flexible than the lateral supports. The term “flexible” or “flexibility” is defined as the ability of a member to flex in various direction under different loads, such as flexibility in bending or in torsion, wherein the member at least temporarily changes shape or size. The invention may be more completely understood with reference to the above descriptions and the following examples. The examples included herein are given for illustrative purposes only and should not be construed as limiting the scope of the invention to what is illustrated and described herein.
• Anexample footwear10 known in the art is shown inFIG. 1.Footwear10 includes aforefoot section12, amidfoot section14, and ahindfoot section16, and further includes an upper18, a lastinginsole20, amidsole22, anupper midsole23, anoutsole24, and a paddedinsert26. Theoutsole24 may include a variety of different materials, but is typically made from rubber or a rubber composite material compression molded into a given shape. Theoutsole24 may be cupped upward, as shown inFIG. 1, so as to extend upward at edges of the outsole to cover those parts of the footwear that may otherwise contact the ground. Themidsoles22,23 are typically the primary cushioning and shock attenuation components of the footwear and may be one of two types of construction. A first type of construction includes a molded EDA material or polyurethane (typically known as foam or a foam product), as shown inFIG. 1. This type of construction is common in athletic and casual footwear but also has a wide variety of other uses. The second type of construction is a masting design in which the midsole is hard and relatively thin. This type of construction is common for dress footwear and some types of boots and other work footwear. A paddedinsole26 may be removable from the footwear, or in other instances may be bonded to thelasting insole20.
• Footwear10 is generally orientated along an XYZ coordinate system wherein the direction along a length of the footwear is the Y direction, the direction transverse across a width of the footwear is the X direction, and a direction vertical upward relative to theoutsole24 is the Z direction. The same or similar reference numbers used to describe features offootwear10 will be used for like components in the following examples.
• Anexample footwear100 having asupport structure30 according to principles of the invention is illustrated with reference toFIGS. 2-6.Footwear100 includes forefoot, midfoot andhindfoot sections12,14,16; an upper118, alasting insole120, amidsole122, anoutsole124 and apadded insert126. Thesupport structure30 may include a longitudinally extending support32 (referred to herein as a “spine”, “elongate spine”, “longitudinal spine”, or “longitudinal member”) and a plurality of laterally extending supports34 (referred to herein as “ribs”, “support ribs”, “rib supports”, “lateral supports”, or “lateral ribs”), and may further include awindow38 that provides viewing into a void39 inmidsole122 andoutsole124. Thewindow38 provides viewing of a portion ofsupport structure30 afterfootwear100 is assembled.Spine32 may extend along anaxis36 that defines a spatial centerline or a pressure centerline offootwear100.
• Referring toFIGS. 4-6, a cross-section taken in each ofsections12,14,16 offootwear100 illustrate example shapes and configurations for thespine32 andribs34. The section ofspine32 that corresponds to the forefoot, midfoot and hindfoot sections offootwear100 are referred to asspine section32a,32b,32c, respectively. Likewise, groups ofribs34 corresponding with the forefoot, midfoot and hindfoot sections offootwear100 are referred to asribs34a,34b,34c, respectively.FIGS. 4-6 illustrate that the ribs and spine may have different shapes and sizes at various locations along a length asupport structure30 in order to provide the needed support, stability and shock attenuation offootwear100 at each section of the footwear. Some of these variations will be described in the further example that follows.
• Spine32 may include first and second ends48,50 and extend along different “centerlines” of a footwear. In one example embodiment shown inFIG. 7,first end48 is aligned with atoe centerline42 andsecond end50 is aligned with aheel centerline40. Theaxis36 ofspine32 may change direction in themidfoot section32b. Another example embodiment shown inFIG. 8 includes aspine32 that follows anaxis36 that corresponds to a pressure centerline of a footwear. In this configuration,first end48 aligns with acenterline46 of toe push off pressure andsecond end50 aligns with acenterline44 of heel strike pressure. The curvature ofaxis36 shown inFIG. 8 may be altered for different footwear designs depending on the footwear structure and the intended use of the footwear.
• A further example embodiment shown inFIG. 9 includes aspine32 that follows a complex centerline pattern.First end48 in this configuration aligns with acenterline42 of a footwear toe while thesecond end50 aligns with acenterline44 of heel strike pressure. In other embodiments, the first and second ends48,50 may be aligned differently or in different combinations of pressure centerlines and feature centerlines of a footwear than shown inFIG. 7-9. Furthermore,spine32 may extend along an axis that is offset from theaxis36 shown inFIG. 7-9, or there may be two or more spine members that extend along different portions of a footwear or that extend across only certain sections of the footwear.
• FIG. 10 provides anexample support structure30 that illustrates some of the features and benefits of a support structure disclosed herein.Support structure30 includesspine32 and a plurality ofribs34. Eachrib34 includes first andsecond sides52,54, amid section56 and a cut-outportion58 sized to engagespine32.Rib34 may also include a turned-upportion60 or a turned-downportion61 at ends of the ribs.Spine32 andribs34 may be made of the same or different materials depending on the application for thesupport structure30. In one example embodiment,ribs34 are made from a material having less flexibility than the material ofspine32. In other embodiments, the structure ofspine32 compared to that of theribs34 alone may provide greater flexibility in the spine than in the ribs. In some applications it is preferred to have greater flexibility in the spine than in the ribs so as to allow flexibility along a length of the footwear at certain areas of the footwear while providing desired amounts of lateral support with the ribs. In other embodiments it is desired to have a spine that has the same flexibility characteristics or being less flexible thanribs34 if the intended purpose is to reduce longitudinal flexibility at certain sections in the footwear.
• Thesupport structure30 shown inFIG. 10 illustrates direction of motion ofribs34 about the X, Y and Z-axis.Arrow66 illustrates rotational motion about the Y-axis, which generally corresponds to an axis ofspine32,arrow68 illustrates rotational motion ofrib34 about the Z-axis, andarrow70 illustrates rotational motion about the X-axis, which axis is generally aligned in a lateral direction across a width of the footwear. The amount of movement ofribs34 about the X, Y and Z-axis may be controlled by both the structure and materials used forribs34 andspine32. For example,spine32 may include different materials in different “zones” ofsupport structure30 to provide varying amounts of movement ofribs34 in each zone. In other embodiments, the cross-section ofspine32 may be such that there is little flexibility for a given material that would otherwise provide greater flexibility if using a smaller cross-section.
• FIGS. 10 and 11 further illustrate features related to an optional method of mountingribs34 tospine32. Althoughsupport structure30 may be most easily generated using a co-molding process in which the spine and ribs are secured together during the molding process, thespine32 andribs34 may be separately formed and then individually mounted to each other. One example of such a separate mounting includes the use ofposition fins72,74 that extend outward fromspine32 and corresponding locking recesses76,78 formed inrib34. In this configuration,spine32 may be inserted into opening58 in the rib untilposition fin72,74 engage lockingrecesses76,78 to hold therib34 in a fixed position relative tospine32. In other embodiments (not shown),spine32 may include at least one recess formed around a circumference of the spine and the rib may include positioning fins extending radially inward fromaperture58 of the rib so that the positioning fins of the rib engage the recesses formed in the spine to lock the rib into a predetermined position.
• FIG. 12 illustrates anothersupport structure130 that includes aspine132 corresponding to the spine arrangement shown inFIG. 7. First and second ends148,150 ofspine132 are aligned with respective toe andheel centerlines142,140. Anaxis136 ofspine132 changes direction in an area corresponding to a midfoot of a footwear and includes generally linear sections between the first and second ends148,150 and the point at which direction changes.Spine132 includes forefoot, midfoot andhindfoot sections132a,132b,132cthat correspond to groups ofribs134a,134b,134c.Support structure130 may also include aheel plate162 secured atsecond end150.
• FIG. 13 illustrates asupport structure230 that includes aspine232 extending along anaxis236 that is similar to the configuration shown inFIG. 8. First and second ends248,250 ofspine232 align with respective centerlines of toe push-off pressure andheel strike pressure246,244, andaxis236 follows a pressure centerline of a given footwear. Ribs234 are separated intogroups234a,234b,234ccorresponding to the forefoot, midfoot and hindfoot sections of a footwear.Spine232 includes correspondingzones232a,232b,232c.Support structure230 may also include aheel plate262 secured atend250 and atoe plate264 secured atfirst end248.
• FIG. 14 illustrates anotherexample support structure330 that is a variation ofsupport structure230. Thefirst side352 of some of the ribs inzones334b,334cinclude a flared, wider top profile than thesecond side354 of those same ribs. In addition, thesecond side354 of some of theribs334a,334bare flared so as to have a wider top profile than thefirst side352 of those same ribs. In other embodiments, different combinations of ribs in various sections of the support structure may include flared ends at the first or second sides, or both the first and second sides may include flared ends as shown bysupport structure430 inFIG. 15. The first andsecond sides452,454 ofsupport structure430 are flared in a generally oval shape, but may, in other embodiments, have other shapes and different sizes from those flares shown inFIGS. 14 and 15.
• FIGS. 14 and 15 illustratesupport structures330,430 in which thespine332,432 extends through an internal cavity of each of the ribs334,434.Support structure530 shown inFIG. 16 includes a connection betweenspine532 andribs534 in which thespine532 is exposed as it passes through and connects to each ofribs534.Spine532 includes a pair ofposition fins572,574 at the location where eachrib534 is to be secured tospine532, and acorresponding recess558 is formed inmidsection556 of each rib. In one embodiment shown inFIG. 34, a top surface ofspine532 is coplanar with a top primary surface ofrib534. This type of flush mounting of the top surfaces of the spine and ribs may be advantageous for supporting the lasting insole directly or for directly engaging an outsole of a footwear (if thesupport structure530 is turned upside down). A similar configuration may be useful for securing thetoe plate564 andheel plate562 to thespine532 at respective first and second ends548,550. Further example configurations for securing the spine and ribs are shown and described with reference toFIGS. 34-38.
• FIG. 17 illustrates a variation ofsupport structure530 in which thespine532bassociated withribs534bis formed of the same material as the ribs of that section. Thus, ifribs534cinclude a material that has little flexibility andspine532bincludes the same low flexibility material, the section ofsupport structure530 associated with the midfoot of a footwear would have less flexibility than those sections ofsupport structure530 at the forefoot and the hindfoot areas of the footwear. As a result, the midfoot “zone” of thesupport structure530 has a low flexibility, which may be useful for replacing a shank element that would otherwise be required in the footwear.
• FIG. 18 illustrates a yet further variation ofsupport structure530 that includes multiple longitudinally extendingspine members532a,532b,532cin addition tospine532. Each of theadditional spine members532a,532b,532cmay have a different curvature and may extend along different sections ofsupport structure530. For example,spine member532cis secured at afirst side552 ofribs534 between theribs534a, whilespine member532ais secured atsecond side554 and connects ribs along allsections532a,532b,532c. Theadditional spine members532a,532b,532cmay be made of the same material asspine532, or may be made of different materials having different properties fromspine532, and may in some instances completely eliminate the need forspine532.
• A yet further variation ofsupport structure530 is shown inFIG. 19 and includes awebbing material580 interposed between and connectingvarious ribs534 insections532a,532b,532c. Such a webbing member may limit movement of theribs534 about the Z-axis while still permitting movement of the ribs about the X and Y-axis. In some embodiments, webbing580 may extend between only the second sides ofribs534, while in other embodiments webbing580 may extend between only the first sides of theribs534. A yet further embodiment may include the configuration shown inFIG. 38 in whichwebbing580 further extends across a top or a bottom, or both a top and a bottom surface of each of theribs534.
• FIG. 20 illustrates anothersupport structure630 that includes a greater number of ribs inzones634a,634bthan in those embodiments shown previously.Support structure630 includes aheel plate662 that takes the place ofribs634c.Heel plate662 includes recesses682a-dto increase the flexibility in theheel plate662.Support structure630 also includes atoe plate664. In yet further embodiments,rib634aand634bmay be even narrower and closely spaced apart than the configuration shown inFIG. 20, or such ribs may replace theheel plate662 withinzone634candplate662 may replaceribs634aorribs634b.
• Anotherexample support structure730 shown inFIG. 21 may be used as a blocker unit that can be cut or otherwise formed for use in multiple footwear sizes. For example, anouter periphery784 ofsupport structure730 may be used for one footwear size, or thesupport structure730 may be cut or otherwise formed to have the smallerouter periphery786 such thatsupport structure730 may fit in a smaller footwear size. The relatively simple design ofspine732 andribs734 may be advantageous for providing consistent performance ofsupport structure730 in any of several sizes.
• FIGS. 21A and 21B illustrate side views of possible configurations forsupport structure730 when using awebbing780 between and/or aroundribs734.FIG. 21A illustratesrib734 encapsulated between layers ofwebbing780 and connected together withspine32. As discussed above, webbing780 may be made of the same or different materials fromspine732.FIG. 21bshowswebbing780 betweenribs734. In some embodiments, the webbing and spine may be colored differently than each other and different fromribs734 so that a side view of the footwear provides a visual indicator of certain features ofsupport structure730.
• FIGS. 22-31 are cross-sectional views taken along a length of an example footwear and illustrate various example footwear and support structure embodiments. In any of these examples or other embodiments using the principles disclosed herein, the support structure may be secured to a footwear in a number of ways. One example securing method includes molding a portion of the footwear around the support structure and then securing that portion of the footwear to the remaining portions of the footwear. Another method may include forming a portion of the footwear with recessed areas sized to receive the support structure such that the support structure may be “dropped in” to the recess. In a yet further method, the support structure may be configured as a complete layer that can be added as a separate layer during construction of a footwear.
• Each of the examples shown inFIGS. 22-31 include forefoot, midfoot andhindfoot sections12,14,16, an upper18, a lastinginsole20, amidsole22, anoutsole24, and asupport structure30 having aspine32 andribs34. Some of the examples further include anupper midsole23. These features have been referenced in each figure. Of further note, many of the layers and features shown inFIGS. 22-31 are not shown with complete cross-section hatching so as to more clearly illustrate the various features shown in those figures.
• Anexample footwear200 having a generallyflat outsole24 is shown inFIG. 22.Outsole24 is generally flat and extends along forefoot, midfoot andhindfoot sections12,14,16.Support structure30 is mounted inmidsole22 along an upper portion of themidsole22 adjacent the lasting upper20 and further includes toe andheel plates64,62 at opposing first and second ends48,50 ofspine32.
• Anotherexample footwear300 having aheel breast108 shown inFIG. 23.Footwear300 includes asupport structure30 that has alongitudinally extending spine32, lateral support structures orribs34, at aheel plate62. Theoutsole24 andmidsole22 are recessed in the area ofmidsole14 so as to create a heel portion of the footwear defined byheel breast108. Theupper midsole23 may be co-molded withmidsole22 or may be a separate midsole member made of a different material having different properties thanmidsole22. For example,upper midsole23 may be a firm, plate-like layer or a foam having little flexibility whilemidsole22 includes a foam having greater flexibility.Support structure30 is positioned along an upper part ofmidsole22 adjacent toupper midsole23, but may in other embodiments be positioned above theupper midsole23 or within other areas ofmidsole22.
• Example footwear400 shown inFIG. 24 includes a “fiddle”shank88. A fiddle shank is constructed such that themidfoot region14 includes recesses in the midsole and outsole portions, but includes a shank-like feature made from the midsole and outsole that extends downward to be supported by the ground in the area ofmidfoot14. In some embodiments, the recessed portion of the fiddle shank area may be recessed completely in a vertical direction so as to expose a portion ofsupport structure30, or may include a window feature so as to view a portion of the support structure either from a side or a bottom view offootwear400.
• A yetfurther example footwear500 shown inFIG. 25 includes asupport structure30 having a section of the support structure acting as a shank.Support structure30 includes a plurality ofribs34aand aspine32ain the region offorefoot12,ribs34bandspine32bin the area ofmidfoot14, andribs34candspine32cin the area ofhindfoot section16. Another example support structure having similar features is shown assupport structure530 inFIG. 17.Spine32bandribs34bmay be made of the same or similar materials so as to have a reduced flexibility in themidfoot section14 where additional support is typically desired because of the recesses inmidsole22 andoutsole24 that define theheel breast108.Footwear500 may also include awindow38 throughoutsole24 for viewing a portion ofsupport structure30 from a bottom side of the footwear.
• A further example offootwear600 having a portion of asupport structure30 exposed at a bottom side of the footwear is shown inFIG. 26.Support structure30 includes separate zones or sections along a length of the footwear, which include aspine32aandribs34aat theforefoot12,spine32bandribs34batmidfoot14 andspine32candribs34cathindfoot section16. Thespine32bandribs34bmay have significantly larger cross-sectional sizes as compared to the spine and ribs in other sections of the footwear, and may be made of material that has a greater resistance to wear and increased resistance to deformation because of its exposure outside of the footwear. The material in this section ofsupport structure32 may also have less flexibility, or may be the same material as the other sections of the support structure, but have less flexibility as a whole because of the larger cross-section of that section. In other embodiments, there may be additional or fewer layers that midsole22 andupper midsole23, or there may be layers of midsole between thelasting insole20 and the support structure features34b,34b. Theribs34bmay be covered by a protective coating such as a clear polyurethane material to protect theribs34bfrom damage.
• Anexample footwear700 having a portion of thesupport structure30 that extends into a midsection of themidsole22 is shown inFIG. 27.Support structure30 has at least three sections or zones that align with the forefoot, midfoot orhindfoot sections12,14,16. A forefoot section ofsupport30 includesspine32aand a plurality of ribs in34athat extend along an upper portion ofmidsole22 adjacent the lasting insole. A second section or zone includes aspine32band a plurality ofribs34bthat are enlarged in comparison to features of the other support structure sections, and extend along an upper area ofmidsole22 adjacent the lastinginsole20. A third section includes aspine32cand a plurality ofribs34cat the hindfoot section of the footwear that extend into a midsection ofmidsole22 between thelasting insole20 andoutsole24.Support structure30 may also include aheel plate62 and atoe plate64. Further,footwear700 may include awindow38 in themidfoot section14 of the footwear for viewing the support structure from a bottom side of the footwear.
• Anexample footwear800 that includes an alternative shank-like feature in thesupport structure30 is shown inFIGS. 28,28aand28B.Support structure30 may include at least three separate zones or sections that are align with the forefoot, midfoot and hindfoot sections of the footwear. A forefoot section of the support structure includes aspine32aand a plurality ofribs34balong with atoe plate64. A midfoot section of the support structure may include aspine32bwith a substantial height and width along with a plurality ofribs34b. The size and materials ofspine32bandribs34bthey provide a shank-like feature forfootwear800. A hindfoot section of the support structure may includespine32cand a plurality ofribs34chave a different cross-section and shape than the other sections of the support structure. As with many of the other examples described herein, the features ofsupport structure30 may be turned upside down and mounted at a bottom side ofmidsole22 so as to extend thelong outsole24 rather than extending along lastinginsole20.
• Anexample footwear900 that includes asupport structure30 with features facing upward such that the support structure extends along an outsole of footwear (as mentioned above) is shown inFIGS. 29,29A and29B. Thesupport structure30 extends alongmidsole22 adjacent to outsole24 and further includes upward extendingsupport structures60 at opposing ends of theribs34aand34c. Thespine32bextends throughmidfoot section14 and may be configured to extend along the lastinginsole20 as well as theoutsole24. Theribs34binmidfoot section14 may be a single plate as shown inFIG. 29A or maybe a plurality of ribs similar toribs34aand34c.Support structure30 may also include aheel plate62 and atoe plate64.
• A further example offootwear1000 that includes a support structure extending through a midportion ofmidsole22 is shown inFIG. 30. Thesupport structure30 includes aspine32 and a plurality ofribs34, and may further include aheel plate62 and atoe plate64. Asupport structure30 may extend through a mid portion ofmidsole22 so as to be spaced between thelasting insole20 and theoutsole24 along the entire length ofsupport structure30 from afirst end48 to asecond end50, or may in other embodiments extend along the outsole and the lasting insole, or both the lasting insole and the outsole at various locations along a length of the support structure.
• Anexample footwear1100 that includes asupport structure30 having an extended plate feature in combination with a spine and plurality of ribs is shown inFIG. 31. Thesupport structure30 includes a plate-like structure similar toheel plate62 that extends along the hindfoot andmidfoot sections16,14, and further includes a forefoot section having aspine32aand a plurality ofribs34a, including atoe plate64. This particular embodiment may be useful for providing lateral support and additional pressure dissipation in high impact areas in the hindfoot and midfoot sections of the footwear while providing necessary flexibility with limited lateral support through the forefoot section of the footwear.FIG. 31A illustrates oneexample support structure30 that includes features illustrated inFIG. 31. Theheel plate62 may include a cupping fin orwall63 that extend upward or downward (not shown) that can be used to engage portions of themidsole22,outsole24, upper18, or other portions of thefootwear1100.
• FIGS. 32-38 illustrate several further example support structure embodiments, any of which may be included in the above listed examples. Oneexample support structure830 that includes upward and downward extendingribs90,92 is shown inFIGS. 32,32A.Support structure830 includes a longitudinally extendingspine member32 and a plurality of upward extending lateral supports orribs92 as well as a plurality of downward extending lateral supports orribs90. Each of theribs90,92 may further include generally vertically extending tabs or supports60 at ends of the ribs. As shown inFIG. 32A, thevertical support60 may extend along an exterior side wall of the midsole or extend upward to support a vertically extending portion of an upper18 of afootwear1200. Afootwear1200 may include awindow38 that is viewable through eitherlasting insole20 andmidsole22 from a top of the footwear, or from a bottom of the footwear throughoutsole24 andmidsole22. In further embodiments, a window may be positioned along a sidewall of the midsole so as to view thesupport structure30 from a side or back of the footwear.
• The upward extendingtabs60 may be configured to extend outside of the sole structure offootwear1200 and around the upper18 as astrap feature65 inFIG. 32. Thestrap65 may be integrally coupled to one of theribs90,92, or any other portion of thesupport structure830. Thestrap65 may be detachable for optional use, or may extend only partially around the upper18 such thatstrap65 includes multiple pieces that are separately coupled to portions of the upper18.
• Another supportstructure example embodiment930 is shown inFIGS. 33 and 33a.Support structure930 includes alongitudinally extending spine32, at least one horizontally extending lateral support orrib34, at least one downward supporting lateral support orrib34, at least one downward extending lateral support orrib90, and at least one upward extending lateral support orrib92. Each ofribs34,90,92 may include a vertical tab orextension60, or a vertically downward extending tab, such astab61 shown in the followingFIG. 36.
• FIG. 34 illustrates a close-up perspective view of a portion of thesupport structure530 shown inFIG. 16. As discussed above related toFIG. 16,spine32 includes a top surface that is generally coplanar with a top surface ofrib34, and includesposition fins72,74 that engagerib34 to holdrib34 in position relative to thespine32. This type of configuration could be either upward (as shown) or downward facing depending on whether thesupport structure530 is aligned adjacent a lasting insole of the footwear or against the outsole of the footwear.
• Thespine32 shown inFIG. 34 has a partial cylindrical cross-section andrib34 is generally flat between first andsecond sides52,54. In other embodiments shown inFIGS. 35-38,spine32 may have a parabolic, cylindrical, rectangular, or combination of cylindrical and rectangular cross-sections. Furthermore, a top surface of therib34 may have a generally upwardly sloping curvature (to mirror the curvature of the lasting insole) that may further include vertically upward or vertically downward extendingtabs60,61.
• Support structure1030 shown inFIG. 35 includes oneexample spine32 with a parabolic cross-section and a top surface that is flush with a top surface ofrib34. Amidsection56 ofrib34 in support structure1030 generally outlines the parabolic shape of thespine32.Support structure1130 shown inFIG. 36 includes a spine with a rectangular cross-section and themidsection56 has a shape that is unrelated to the shape of the spine. The top surface ofspine32 is coplanar with the top surface of therib34.Support structure1230 shown inFIG. 37 includes a spine with a cylindrical cross-section that extends above an upper surface ofrib34. This configuration may be useful when thesupport structure1230 is embedded in a midsole rather than being flush against an outsole or a lasting insole of a footwear.Support structure1330 shown inFIG. 38 includes aspine32 with a partial cylindrical cross-section and further includes anextension32dthat extends across at least a portion ofrib34 beyondmidsection56. In some embodiments, thespine material32dmay extend across the entire upper surface ofrib34 and may further extend in between a plurality of ribs positioned along a length of the spine to act as a webbing between the ribs.
• The support structure shown inFIGS. 34-38 may be especially useful for co-molding the support structure or for creating a configuration in which theribs34 can be snap fit or otherwise separately secured tospine32 using methods other than co-molding.
• FIGS. 39-40 illustrate two examples of co-molding arrangements.Support structure1430 shown inFIGS. 39 and 39A include aspine32,ribs34, and right and leftflex sections94,96 ofrib34. Eachrib34 is connected via alongitudinal connector98 such that theribs34 are connected together in a continuous string. Once the string ofribs34 is molded, thespine32 may be co-molded using aroundlongitudinal connector98 and to flexsections94,96 usingmold100. This type of molding may provide advantages of strength and performance when using thesupport structure1430, as well making it easier to handle the ribs during manufacture of the support structure.
• Asupport1530 is shown inFIGS. 40 and 40A having a continual longitudinal extendingspine32 that is held in a mold101 and co-molded withribs34 havingflex sections94,96 around thespine32. This type of construction may also provide certain performance and manufacturing advantages over other support structure designs. A molded structure manufactured using the examples shown inFIGS. 39 and 40 may be very cost effective for both initial tool and die preparation and ongoing production of parts over time.
• A support structure as disclosed herein may be integrated into various portions of the sole of a footwear (described above), or may be integrated into apadded insert126 for a footwear, as shown inFIG. 41.Insert126 includes asupport structure30 that includes alongitudinally extending spine32 and a plurality of laterally extending supports orribs34 that are secured to thespine32.Support structure30 may also include aheel plate62 and atoe plate64 and may also include vertically extendingtabs60 formed at ends of theribs34.Support structure30 is encapsulated within apadding27 that provides a comfortable interface betweensupport structure30 and a user foot, and further provide an proper interface between thesupport structure30 and a lasting insole or other feature of the footwear.
• Any of the above examples, including the paddedinsert126 show inFIG. 1 may include one or multiple sections of a support structure at various location along a length of a footwear. For example,FIGS. 42A,42B,42C illustrate separate support structure sections that may be used for certain forefoot, midfoot or hindfoot sections of a footwear.Forefoot insert102 shown inFIG. 42A includes aspine32athat extends along a pressure centerline and further includes a plurality of laterally extending supports orribs34aand atoe plate64.Midfoot insert103 includes alongitudinally extending spine32band a plurality of laterally extending supports orribs34b.Hindfoot insert104 shown inFIG. 42C includes alongitudinally extending spine32cand a plurality of laterally extending support orribs34cas well as aheel plate62.Spine sections32a,32b,32cshown inFIGS. 42A-C may extend along a pressure centerline of a footwear or may be aligned with an actual centerline of the footwear. Furthermore, theribs34a,34b,34cmay have a variety of different shapes and sizes and be aligned relative to the respective spine member at a variety of different angles.
• A yet further example embodiment may include a combined hindfoot andmidfoot insert105 shown inFIG. 43, or a combined forefoot andmidfoot insert106 shown inFIG. 44.Insert105 includesspine sections32band32cas well as groups ofribs34band34c. Likewise, insert106 includesspine sections32a,32bas well asribs34a,34b.
• In addition to the separate “zones” or sections of the spine or groups of ribs discussed above, the spine material between each individual rib may also vary along the length of the support structure. In one embodiment, the spine material between every rib member may have a different composition or set of physical characteristics. In another example, the spine material beginning at the toe and heel areas is very flexible and the spine material becomes less flexible between every rib or between every few ribs leading toward the midfoot region of the support structure.
• In a yet further embodiment, the support structure may include a plurality of wire or hair-like laterally or vertically extending support structures that extend from either the ribs or the spine for specialized support in certain areas of a footwear.
• Referring now toFIGS. 45-48, an example footwearsole assembly1601 that includes asupport structure1630 is shown and described. Thesupport structure1630 is shown extending along substantially the entire length of the footwearsole assembly1601. The support structure includes alongitudinal spine1632 andlateral support1634 that extend in only themidfoot section1603 andhind foot section1604. Theforefoot section1602 includes a plate-like structure1662 that may include a plurality ofrecesses1635 to increase flexibility of the plate structure. Various features of thesupport structure1630 cooperate with features of themidsole1622 and outsole1624 of the footwearsole assembly1601, as described below.
• Thelongitudinal spine1632 andlateral supports1634 may have different configurations along the length of the footwear to provide desired results in the footwearsole assembly1601. In many cases, it is preferable to provide high shock absorption and shock attenuation in the hindfoot portion of a footwear. To address these criteria, thehindfoot portion1632cof the longitudinal spine is relatively small in cross section and may include a recessed portion to increase flexibility of the spine where the spine attaches to the lateral supports1634cin thehindfoot portion1604. Aspine insert piece1633 may be inserted in the recessed portion (seeFIGS. 46 and 47), wherein theinsert piece1633 may include different flexibility properties or other characteristics to help “fine tune” the support structure characteristics for a given footwear. Thelongitudinal spine1632cmay also include different materials from the lateral supports1634cthat also promotes increased flexibility spine and movement of the lateral supports relative to the spine.
• Thelateral support1634cmay be relatively long and narrow as shown inFIG. 45 or may be relatively short and wide depending on the desired result. Ends of the lateral supports1634copposite thelongitudinal spine1632cmay be supported on asupport shelf1683 defined by arecess1681 in themidsole1622. Aseparate void1685 formed in themidsole1622 beneath the remaining portions of thelateral support1634cand thelongitudinal spine portion1632cestablish a trampoline-like design that provides the desired shock attenuation and shock absorption benefits while still providing sufficient support due to the remaining relatively firm midsole material around a periphery of the hindfoot section of the footwearsole assembly1601.
• A separatespine support member1687 may be positioned within thevoid1685 in a further effort to “fine tune” overall performance of thesupport structure1630. Thismember1687 may either partially or completely fill thevoid1685, and preferably is position in alignment thelongitudinal spine section1632c(seeFIG. 47) to provide engagement of the spine when a load is applied to thespine structure1630.
• The midfoot section of a footwear typically requires greater stiffness to support the arch of a users foot. In many footwear constructions, a shank member is required to bridge between the forefoot of the footwear and the heel portion of the footwear defined by a heel breast. Thesupport structure1630 may be modified to include different materials or a different structure to provide the desired support and stiffness. Thelongitudinal spine portion1632bincludes a greater cross sectional area, which in combination with the shorter length oflateral support1632band the absence of a recess or void beneath the support structure in the midfoot portion of the footwear, results in a shank-like structure or effect. An alternative embodiment of a support structure that includes a shank-like structure is shown with reference toFIGS. 49-53.
• In many types of footwear, the forefoot area is relatively thin for purposes of aesthetics and styling. The preferred reduced thickness in the forefoot is in conflict with another objective to provide additional support, shock absorption, and shock attenuation in the forefoot to balance toe off forces and the like when the footwear is used for walking, which objective typically requires additional thickness in the forefoot area. Thesupport structure1630 is modified in theforefoot area1602 to eliminate the lateral supports1634 and a definedlongitudinal spine1632 and to include a plate-like structure1662 that is surrounded by first and secondforefoot padding layer1689,1691. Theforefoot section1602 may be configured such that thefirst padding layer1689 may be flush with a top surface of the midfoot andhindfoot sections1603,1604 as shown inFIG. 46. Other embodiments may use a single padding layer in the forefoot or may replace the plate-like structure with a material or member that includes more flexibility and/or padding.
• The footwearsole assembly1601 may also include aviewing window1638 that is positioned vertically below thehindfoot section1604 to provide viewing of some of the support structure features. Thewindow1638 may be embedded in theoutsole1634 and may include a clear polymer material or other material that provides the desired viewing. Multiple viewing windows may be provided at different locations along a length of the support structure1630 (e.g., see viewingwindow38 inFIGS. 27 and 28). Preferably, thewindow1638 is aligned with an open portion of thevoid1685, the materials of the midsole1322 andsupport member1687 between thewindow1638 and thesupport structure1630 must be clear as well in order for viewing to occur. In other embodiments in which the support structure is positioned at a bottom side of the midsole rather than at a top side of the midsole, a window through the outsole alone may provide viewing of the support structure. Other embodiments may include a viewing window from a top side of the support structure, such as through a lasting insole or mast layer of the footwear sole assembly.
• Referring now toFIGS. 49-53, another footwearsole assembly1701 is shown and described.Assembly1701 includes asupport structure1730 having midfoot and hindfootlongitudinal spine portions1732b,1732cand a plurality oflateral supports1734, and amidsole1722. Themidsole1722 includes avoid1785, arecess1781 that defines ashelf1783, and aspine support member1787 positioned in thevoid1785. Amidfoot section1703 of thesupport structure1730 includes alongitudinal spine section1732bhaving a greater cross-sectional area thanspine portion1732cin theheel section1704 thereby providing a shank-like function. Because of the relatively narrow width of themidsole1722 as compared tomidsole1622 shown inFIG. 45, the addition of lateral supports small enough to fit with the relativelywide spine portion1732cwithin that width may not be as useful in providing additional support, shock absorption, and shock attenuation.
• Thespine support member1787 completely fills thevoid1785 and maintains contact with thespine portion1732c. Other embodiments may include a reduced size spine support member or no spine support member at all, wherein thevoid1785 is left completely open for free movement of the spine structure within the void1785 (movement of the spine structure in void1785 being restricted by at least the support of lateral supports1743con shelf1783).
• In the embodiments shown and described with reference toFIGS. 45-53, the hindfoot portion of the support structures may be generally described as being able to move within a void portion in the midsole when a load is applied to the support structure. More specifically, the longitudinal spine portion in the hindfoot section of the footwear sole assembly may be capable of moving within the voided portion or against a compression or shock absorbing member positioned within the void. The same or similar structure may be added in other portions of a footwear sole assembly such as in the forefoot of the assembly if sufficient thickness is provided in the midsole to establish such a void and movement of the support structure within the void or against a material positioned in the void. Using a first material to support ends of the lateral support members and a second material to support at least a portion of the longitudinal spine or the remaining portions of the lateral supports may be particularly useful to meet the demands of shock absorption and shock attenuation while providing desired support in a footwear assembly.
• FIG. 54 illustrates afootwear sole insert1807 that includes asupport structure1830 coupled to abase portion1809. The insert includes forefoot, midfoot andhindfoot sections1802,1803,1804. Thesupport structure1830 includes a portion of the longitudinal member1832 and multiple lateral supports1834 in each of the forefoot, midfoot and hindfoot portions of theinsert1807. Theinsert1807 may be particularly useful when assembling a footwear sole assembly such as the sole assembly shown inFIGS. 55 and 55A. When thebase portion1809 is configured as an outsole member, theinsert1807 may be secured to an under side of anoutsole portion1824, which is in turn coupled to amidsole1822 and further coupled to an upper of a footwear (not shown). Thebase portion1809 may include any desired material with any desired shape, such as, for example, a material having slip resistant properties that is formed in shapes that enhance resistance to the footwear slipping.
• When using molding processes to generate a footwear assembly such asassembly1801, theinsert1807 may first be separately formed by coupling thebase member1809 to thesupport structure1830 using such methods as, for example, molding, heat or sound welding, or adhesives to provide a single insert member. The insert may be placed within a mold cavity and theoutsole1824 andmidsole1822 are molded around theinsert1807 in separate steps. The outsole andinsole members1824,1822 may be separately molded or formed and later coupled to other components of the footwearsole assembly1801 rather than using direct molding on top of theinsert1807.
• Theinsert1807 may have a width that is narrower than a total width of theoutsole1824 as shown inFIG. 55A, or may extend across an entire width of the footwear sole assembly as shown in the embodiment illustrated inFIG. 56A. Theinsert1807 may also have a length that extends along an entire length of the footwear sole assembly and may further extend upward to engage an upper of the footwear if desired (see, for example, the dotted line numbered99 inFIG. 55). Referring toFIGS. 59 and 59A, thefootwear2300 includes anoutsole2324 and asupport structure2330 that could be formed as an insert member, a portion of which extends an entire length of thefootwear2300 and engages the upper2318.
• Theinsert sections1802,1803,1804 may be divided into separate pieces that are individually insertable into different portions of a footwear sole assembly. For example,FIG. 56 illustrates a footwearsole assembly1901 that include forefoot andhindfoot insert sections1902,1904 that are positioned in anoutsole1924 at respective forefoot and hindfoot sections of the assembly. Thebase member1909 may be configured as an outsole member whereinbase member1909 couples thesupport structure1930 against theoutsole1924. Amidsole1922 may be molded or otherwise coupled to theoutsole1924 to complete the footwear sole assembly.
• FIGS. 57 and 58 illustrate footwearsole assemblies2001,2101 that each include insert sections positioned at alternative positions with respect to the outsole.Assembly2001 includes aforefoot section2002 positioned between theoutsole2024 and themidsole2022, and ahindfoot section2004 positioned at a bottom side of theoutsole2024.Assembly2101 includes forefoot andhindfoot sections2102,2104 that are positioned at a top side of theoutsole2124 along an underside of themidsole2122. Other embodiments may include insert segments at other locations within a footwear sole assembly such as on a top side of a midsole or completely embedded within an outsole or insole member.
• Referring again toFIGS. 59 and 59A, thefootwear2300 may be well suited for a welt type molding or forming process in one method, thesupport structure2330 is positioned in a mold cavity with stand-off members (not shown) that hold the support structure vertically above a floor of the mold cavity. The mold cavity is then filled underneath and around the support structure using injection molding, casting, or other methods in which a material such as, for example, a polyurethane foam or a TPU elastomer, fills a portion of the mold cavity to form theoutsole2324. Themidsole2322 is either directly molded on top of thesupport structure2330 andoutsole2324, or is formed separately and then coupled to thesupport structure2330 andoutsole2324. In another method, theoutsole2324 is formed in a mold cavity with a dummy support structure in place to create a recess shaped like the actual support, wherein the dummy support structure is later replaced with theactual support structure2330 before adding the midsole or other layers of thefootwear2300. In a still further embodiment, the support structure is combined with three or more sole layers as shown in the footwearsole assembly2601 shown inFIGS. 62 and 62A.Assembly2601 includes asupport structure2630 positioned between anoutsole2624, afirst midsole2622, and a second midsole2633. The midsole layers2622,2633 (and any other midsole or outsole described herein) may include gels, air pockets, or specialized shock absorbing and shock attenuating materials that are sealed within theassembly2601 to enhance performance of the footwear sole assembly.
• These types of processes may be useful for interchanging support structures with a variety of different designs. For example, themidfoot portion2303 of the support structure may include a longitudinal member and lateral supports configured to provide a shank-like function. Size and shape modifications to the support structure can be accounted for easily when using molding and related methods to form portions of a footwear sole as described above.
• Referring now toFIG. 60, anotherexample footwear2400 is shown including anoutsole2424, alasting insole2422, and asupport structure2430. Thelasting insole2422 may be separately coupled to an upper2418 before being secured to theoutsole2424 using any desired methods such as the molding methods described above. In one example method, the combinedlasting insole2422 and upper2418 may be directly molded or otherwise coupled to theoutsole2424 using, for example, adhesives, cements, or other bonding materials.
• Referring now toFIG. 61, another example footwearsole assembly2501 is shown in which thesupport structure2530 is completely embedded within thebase member2509 so as to provide aninsert2507 in which none of the support structure is exposed. Other embodiments may include exposed portions of the support structure along sides of theinsert2507, but not at top and bottom surfaces of theinsert2507. Theinsert2507 may be combined within anoutsole2524 andmidsole2522 using any of the methods described above.
• Any of the example inserts described above may be configured as a blocker unit that can be trimmed to fit any size footwear desired. When the insert is used as a blocker, end portions of the lateral supports may be removed as part of the trimming process.
• In an additional embodiment illustrated inFIG. 63, a footwearsole assembly2701 includes asupport structure2730 havinglateral supports2734 that extend in a vertically downward direction from thelongitudinal member2732. Thesupport structure2730 is positioned between anoutsole2724 and amidsole2722. The downward sloping lateral supports2734 provide a configuration in which thesupport structure2730 acts as a spring-like member, wherein ends of thelateral members2734 at an outside edge of theassembly2701 maintain a relatively fixed position due to the reduced amount of outsole material between the ground and the lateral support, and thelongitudinal member2732 is vertically movable due to compressibility of the larger amount of outsole material betweenlongitudinal member2732 and the ground beneath theoutsole2724. This type of configuration could also be modified into a blocker style unit in which the lateral members extend out to a further width as shown by the dash lines inFIG. 63, wherein the lateral members are preferably always covered by material of the outsole orinsole2722,2724. With the lateral members at their maximum width, it may be possible to obtain a maximum “spring” effect, although a narrower configuration as shown by the solid lines inFIG. 63 may still provide a desired amount of shock absorption and shock attenuation while providing additional lateral support that may not otherwise be present if thesupport structure2730 were removed from theassembly2701.
• Materials for the spine and ribs of the support structure may include, for example, metals and metal alloys, nylon, polyurethane, polypropylene, or any of a variety of other polymer and synthetic materials. The materials may include fillers such as glass that increase the hardness and reduce flexibility of the structures. In one example, the spine support structure material includes at least about 10% glass, and preferably includes about 30% or more glass.
• The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.

Claims (11)

1-26. (canceled)

27. A method of manufacturing a footwear, the footwear including an upper, a sole, and a spine support structure that includes an elongate spine member and a plurality of transverse supports, the method comprising:

positioning the spine support structure in a mold and positioning the upper adjacent to the mold;

filling the mold with a moldable material to form the sole; and

curing the moldable material to secure the sole and the spine support structure to the upper.

28. The method ofclaim 27, wherein filling the mold with a moldable material includes filling the mold with a first moldable material to form a first portion of the sole, and filling the mold with a second moldable material to form a second portion of the sole.

29. The method ofclaim 27, wherein the footwear further includes a welt member secured to the upper and positioned between the upper and the mold.

30. The method ofclaim 27, wherein the footwear further includes a lasting insole secured to the upper and positioned between the upper and the mold.

31-58. (canceled)

59. A footwear support structure, comprising:

an elongate member extending along a first axis; and

a plurality of laterally extending supports secured to the elongate member, at least a portion of one of the lateral supports extending out of a horizontal plane.

60. A footwear support structure, comprising:

an elongate spine extending along a first axis; and

a plurality of laterally extending support ribs secured to the elongate spine at spaced apart locations along a length of the spine.

61. The support structure ofclaim 60, wherein the spine includes segments along the length of the spine that have different properties.

62. The support structure ofclaim 60, wherein the supports have a width, a height and a depth, and at least one of the width, height or depth varies for supports along a length of the spine.

63. The support structure ofclaim 60, wherein the spine has greater flexibility than the ribs.

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