BACKGROUND OF THE INVENTIONThe present invention relates to footwear, and more particularly, to a sole construction that is adjustable, and related methods of manufacture and use.
Recently emphasis has been placed on footwear that assists in better working the muscles of the wearer, improving the gait of the wearer and burning extra calories by wearing such footwear. Such footwear are generally designed to be worn while the wearer engages in a fitness activity, such as walking, running, or a sport.
Certain manufacturers have refined the soles of footwear to accomplish the above objectives. For example, some manufacturers offer a sole including a curved heel that provides a “rolling” effect, which trains a wearer's body to maintain its natural balance by working the wearer's leg muscles and core. This sole generally includes a wedge that is constructed from a soft, squishy material, and is positioned under the heel of a wearer in a fixed position that is adapted to engage the ground when the heel of the wearer strikes and continues to engage the ground. The lower surface of the wedge includes a large curved portion. With its resilient, compressible curved shape, the wedge apparently simulates uneven terrain typically found in nature, thereby creating a natural instability to which the wearer's muscles respond with intuitive, small movements that compensate for the instability. In some cases, these movements can improve the muscular activity of the wearer's calves, hamstrings, buttocks, lower back and abdominal muscles, and also can reduce stress on hip and knee joints.
While the above wedge shoes can train a wearer's body to maintain its natural balance and can work various muscle groups harder, the shoes take time to become accustomed to, and may be unsuitable when a wearer desires more traditional footwear when traversing uneven terrain, or other terrain that is unsuitable for a easily compressible, low density and/or unstable curved heel. Sometimes, in addition to the aforementioned wedge shoes, a wearer may need to carry a pair of “normal” shoes, that is, a pair of shoes that has a better or more rigid sole, to wear after their fitness activity has ended and the wearer no longer needs or wants to wear the somewhat unstable wedge shoes.
In an unrelated field, there has been a wholly separate trend to provide footwear having portions of the sole that rotate. For example, some cleated footwear include rotatable elements, located under the ball of a wearer's foot, in the forefoot, that are configured to rotate and decrease stress on joints of the legs, such as the ankle and the knee. These rotatable elements include a return feature that automatically rotates the elements back to a default position.
Yet other footwear include heel elements that are selectively rotatable to replace worn out, beveled heel strike areas with new, identical beveled heel strike areas to ensure the wearer experiences a consistent heel strike when engaged in activity. These rotatable heel constructions typically include a set of pins that can be moved laterally away from the axis of rotation of the rotatable heel element to release it and allow it to be rotated so that one beveled heel strike can be replaced with another identical beveled heel strike area. While this construction provides a way to replace worn out portions of footwear, it can sometimes be difficult to operate the pins. Moreover, the mechanism and other features that provide the cushioning within the heel element can be overly complicated, costly and time consuming to assemble.
Accordingly, there remains much room for improvement to provide a footwear construction that includes an adjustable heel that is comfortable, and that is readily interchangeable between a first mode, such as a fitness mode, and a second mode, such as a stability mode, so that the user can quickly and efficiently transition from a fitness activity to other activities where more stability is desired.
SUMMARY OF THE INVENTIONA footwear construction is provided including a sole having an adjustable heel element that is selectively positionable in different orientations to provide different performance characteristics of that heel element, and subsequently of the footwear.
In one embodiment, the adjustable heel element includes a first end and a second end, each having different performance contours adjacent the respective ends. These performance contours optionally can form respective parts of the ground contacting portions of the adjustable heel element.
In another embodiment, the first end can include a first performance contour in the form of a somewhat pronounced curvilinear or arc shape having a rather small radius. The second end can include a second performance contour in the form of a somewhat less pronounced, curvilinear or arc shape having a large radius. Optionally, the curvilinear or other shapes of the contours can include multiple compound curvilinear surfaces and/or flat surfaces.
In yet another embodiment, the first end can include a relatively soft, low durometer cushioning first material that compresses or collapses relatively easily when the first performance contour engages the ground. The second end can be constructed of the same softening material, but optionally can also or alternatively include a second material that is harder or has a greater durometer than the first material. The second material optionally can be in the form of a block or bumper that is positioned adjacent the extremities of the second end.
In still another embodiment, the adjustable heel element can be selectively configurable in one of multiple modes, such as a fitness mode or a stability mode. When the adjustable heel element is configured in the fitness mode, the first end is located rearward of the second end, with the first performance contour oriented so that it engages the ground upon heel strike in a wearer's natural gait cycle. In the fitness mode, a user wearing the footwear experiences a degree of instability and/or impaired movement as the foot begins and/or transitions through the gait cycle, which the user can overcome or compensate with increased muscle recruitment. In turn, this increased muscle recruitment can tone the recruited muscles, which otherwise might not have been used during the cycle, or simply might have been used to a lesser degree.
In still yet another embodiment, when the adjustable heel element is configured in the stability mode, the second end is located rearward of the first end, with the second performance contour generally oriented so that it engages the ground upon heel strike in the natural gait cycle of the wearer. In the stability mode, the second end and second performance contour can provide the user with a feeling of stability, much like a “normal” shoe, particularly upon initial heel strike at the beginning of the gait cycle. This increased stability can make the user feel more confident in their footing, so that they react and use muscles more like they would with a normal shoe.
In a further embodiment, the adjustable heel element includes an adjustment assembly. The adjustment assembly can include an actuator and one or more flexible tabs that join the heel adjustment element with the remainder of the sole or footwear. The actuator can be actuated to enable a user to reorient the first and second ends (or other portions if included) of the adjustable heel element. Optionally, the actuator can be removed from registration with a portion of the heel element so that the adjustable heel element can be rotated and converted from a fitness mode to a stability mode or vice versa.
In yet a further embodiment, the adjustable heel element can be joined with a generally rigid support element that is joined with the remainder of the sole. The support element can extend from the heel toward the arch of the footwear.
In still a further embodiment, the adjustable heel element and the support element can include or be joined with locking elements. These locking elements can be configured to interlock with one another when the adjustable heel element is in at least one of different modes, for example, a fitness mode and a stability mode. The locking elements can provide additional securement to prevent or impair inadvertent reorientation, such as rotation, of the adjustable heel element while the footwear is in use.
In still yet a further embodiment, the adjustable heel element can include a support element and a different adjustment assembly including a biasing element that urges the remainder of the adjustable heel element toward the sole. The biasing element can be in the form of a spring, for example a coil spring, that is compressed under force between an attachment plate and a wall or the rim support element. A fastener can extend from the attachment plate to another portion of the adjustable heel element, for example an anchor element. The spring can push the attachment plate away from the wall, which in turn draws the anchor element toward the remainder of the sole. Because the anchor element attaches to the fastener and the remainder of the adjustable heel element, the remainder of the adjustable heel element also is drawn toward the remainder of the sole element and/or the support element to provide additional securement and to prevent or impair reorientation of the heel element.
The footwear described herein provides a simple and efficient mechanism that enables a wearer to convert the footwear between different modes having different performance characteristics depending on the wearer's preferences. For example, rotation of the adjustable heel element can permit a sole to be converted from a fitness mode when a wearer desires to engage in a particular fitness activity or otherwise tone their muscles, to a stability mode when a wearer desires more stable performance from the footwear, or simply is finished with the fitness activity. Because the adjustable heel element can be adjusted by varying its orientation, the wearer need not carry around two or more pairs of shoes should the wearer desire to engage in a variety of activities.
These and other objects, advantages and features of the invention will be more readily understood and appreciated by reference to the detailed description of the embodiments and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 is a side view of footwear of a current embodiment in a first mode;
FIG. 2 is a bottom view of the footwear being actuated to adjust the footwear from the first mode to a second mode;
FIG. 3 is another side view of the footwear in the second mode;
FIG. 4 is an exploded view of a sole and a heel adjustment element of the footwear;
FIG. 5 is a sectional view of the sole taken along line5-5 inFIG. 1;
FIG. 6 is a second section view of the sole taken along line6-6 ofFIG. 3;
FIG. 7 is a bottom view of the sole;
FIG. 8 is a section view of the sole taken along line8-8 ofFIG. 5;
FIG. 9 is a rear view of the footwear;
FIG. 10 is a section view of the sole taken along line10-10 ofFIG. 5;
FIG. 11 is a section view of the sole taken along line11-11 ofFIG. 5;
FIG. 12 is a section view of the sole taken along line12-12 ofFIG. 5;
FIG. 13 is a section view of the sole taken along line13-13 ofFIG. 5;
FIG. 14 is an exploded view of a sole of a first alternative embodiment of the footwear;
FIG. 15 is a section view of the sole of the first alternative embodiment in a first mode;
FIG. 16 is a section view of the sole of the first alternative embodiment in a second mode;
FIG. 17 is a bottom view of the sole of the first alternative embodiment;
FIG. 18 is a perspective view of a heel adjustment module of the first alternative embodiment being adjusted;
FIG. 19 is a bottom view of the sole of the first alternative embodiment;
FIG. 20 is a section view of the footwear of the first alternative embodiment taken along line20-20 inFIG. 17;
FIG. 21 is a section view of the footwear of the first alternative embodiment taken along line21-21 inFIG. 17; and
FIG. 22 is a section view of the footwear of the first alternative embodiment taken along line22-22 ofFIG. 17.
DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTSI. OverviewA current embodiment of fitness footwear or shoe is shown inFIGS. 1-13 and generally designated10. The fitness footwear can include an upper20 joined with a sole30 which can include anoutsole31 and amidsole35. The sole30 can include an adjustable heel module orelement50 located in the heel and/or arch region of thefootwear10. Theadjustable heel element50 can include anadjustment assembly60 that joins theadjustable heel element50 with theprimary portion32 of the sole30. Theadjustable heel element50 can include afirst end51 and asecond end52. Thefirst end51 can include a first performance contour on its lower portion, for example, the performance contour can be a relatively notable and afirst curve91 or angled portion such that the thickness toward the first end diminishes rather rapidly. The first performance contour can provide a gentle rolling or rocking motion upon heel strike when thefirst end51 is oriented rearwardly relative to thefootwear10.
Thesecond end52 can be more squared-off or angular toward its extremity, and can include a second performance contour. As shown inFIG. 5, the second performance contour can be a different curve92 (or even a flat surface) adjacent the squared-off extremity of thesecond end52. The squared-off extremity can transition to thesecond curve92 and also can include a small curvilinear portion. Thesecond end52 can generally impart a more rigid, and well defined heel strike to the wearer in the wearer's gait cycle as the wearer walks with the footwear.
The footwear can also include anadjustment assembly60 that secures the adjustable heel element to the sole30. The assembly can enable a wearer to rotate theadjustable heel element50 about the axis ofrotation100, end-for-end, so that the first end can be replaced with the second end and vice versa, depending on the desired performance characteristic of the footwear.
For purposes of disclosure, the embodiments herein are described in connection with a fitness footwear. As will be appreciated, the embodiments also are well suited for any other type of footwear including other athletic footwear, sandals, casual footwear, work footwear, outdoor footwear, walking footwear and multi-sport footwear. Further, as used herein, the term “arch region” (or arch portion) refers generally to the portion of the footwear corresponding to the arch of the wearer's foot; the term “forefoot region” (or forefoot portion) refers generally to the portion of the footwear forward of the arch region corresponding to the forefoot (e.g., including the ball and the toes) of a wearer's foot; and the term “heel region” (or heel portion) refers generally to that portion of the footwear rearward of the arch region corresponding to the heel of the wearer's foot. Theforefoot region81,arch region82 andheel region83 are generally identified inFIG. 1, however, it is to be understood that delineation of these regions may vary depending upon the configuration of the footwear.
II. StructureThe components of thefitness footwear10 will now be described in more detail. As shown inFIG. 1, the upper20 can include avamp22,quarters24 and aback stay26. Optionally, a removable footbed (not shown) can be positioned in the upper as desired. The upper20 can include a lower portion that transitions to an allowance that is folded generally inward toward the center of the footwear. The allowance can be fastened to a sole board (not shown) or Strobel stitched to an insole and/or a fabric sock liner (not shown).
The upper can be joined with a sole30. As illustrated inFIGS. 5 and 6, the sole30 can include aprimary portion32 which extends generally through the forefoot, arch andheel regions81,82,83. In the heel region, the sole30 can include a heel adjustment element ormodule50, which will be described in more detail below. The sole30 can also include amidsole35 which can be constructed from a cushioning material, such as ethyl vinyl acetate (EVA) or other suitable cushioning materials. This midsole can be covered by anoutsole31, and in particular can be covered by an outsole first portion37 (FIG. 2) in theforefoot81 and/orarch82 regions. The outsolefirst portion35 can terminate short of theadjustable heel element50. Theoutsole31 and its portions can be manufactured from a relatively hard rubber or other sufficiently durable or wear-resistant material. The bottom of theoutsole31 can include anouter surface36 that forms the wearing surface of theoutsole31 and can be contoured to a desired pattern. Theouter surface36 can be textured to provide traction from the heel to the forefoot if desired, or it can be compartmentalized to include specific tread patterns in certain regions of the foot. For example, as shown inFIG. 2, theoutsole31 can include afirst traction pod34 that is generally disposed under the toes of the wearer wearing thefootwear10. It can also include asecond traction pod33 that is generally disposed under the ball of the foot of the wearer wearing thefootwear10. Of course these different types of pods can be replaced with other conventional tread or lug patterns, depending on the application.
As shown inFIGS. 4-6, the soleprimary portion32 can also be joined with asupport element40. Thesupport element40 can extend within theheel region83 of thefootwear10, and optionally into the arch82 andforefoot regions82 and83. Thesupport element40 can be constructed from a relatively hard, rigid and generally non-deflectable material such as a thermoplastic polyurethane, a composite, a carbon fiber material, a nylon or other polymeric material, metal, or combinations of the foregoing. Thesupport element40 can generally extend across the width of the bottom of thefootwear10 from the lateral side to the medial side, and it can extend rearward from the rearward most portion of theheel region83 forwardly into thearch region82, and optionally into theforefoot region81 in certain applications. Thesupport element40 can be sufficiently rigid to provide a platform to which theadjustable heel element50 can be sturdily and consistently mounted and reoriented relative thereto.
Optionally, as shown inFIG. 7, the support element can include reinforcingridges94, grids, or other structures to increase the rigidity of the support element, for example in the arch region. Of course, this increased rigidity can alternatively or additionally be provided by adding a shank (not shown), or by increasing the thickness of thesupport element40 in the arch region where bulkiness or thickness of the shoe does not detract from its aesthetics.
Thesupport element40 can include anactuator42 that extends adjacent arecess43 further defined by thesupport plate40. Theactuator42 can include a hinge orfolding portion44 about which the remainder of theactuator42, which as shown is in the form of a tab, can move. As shown inFIG. 5, theactuator42 can be manually depressed by a user, without the use of tools, from the configuration shown in solid lines to the configuration shown in phantom lines where the latter configuration allows the adjustable heel element to be rotated. The actuator can be fully depressed to allow rotation of the adjustable heel with optionally about 1 to about 20 pounds, further optionally about 3 to about 10 pounds, and even further optionally about 5 pounds of force applied by a user. Optionally, although not shown, the opposingedges42A and42B can be connected to thesupport element40. The connection of the edges can add rigidity to the tab and can prevent inadvertent movement.
Further optionally, as shown primarily in the embodiment inFIGS. 5-7, theend42C opposite thehinge44 can be attached to and project upwardly toward and join with thesupport element40 via anend connector42D. This configuration can add rigidity to the tab so that theend42C does not move substantially when subjected to rotational forces imparted through theheel element50 and therecesses55 and56. Even further optionally, the tab can include a fastener (not shown) joined between it and the support element to establish and fix the distance between the tab and thesupport element40 so that it generally does not move unless actuated by the user.
Where theend42C is connected to thesupport element40 via anend connector42D as shown inFIG. 5, the soleprimary portion32 can include material (not shown) that extends and optionally engages theunderside42E of theactuator42. With such a construction, therecess43 under theactuator42 can be filled or at least partially filled with the material from which the sole primary portion is constructed or other material if desired. Where the soleprimary portion32 is constructed from polyurethane or some other soft material, the material adjacent the actuator can generally be easily compressed when the actuator is depressed manually by a user. Accordingly, it will not prevent the actuator from being depressed to disengage the adjustable heel element and facilitate rotation of the heel element.
If desired, however, the material under theactuator42 can be profiled or otherwise configured to provide additional resistance to the depression of the actuator by a user. For example, the material can be trimmed, ground or otherwise formed so that it is positioned immediately adjacent or joined with theunderside42E of the actuator, or more densely formed there. With this construction, a user will generally apply more force, for example, about 2 pounds to about 8 pounds of additional force to actuate the actuator so that the adjustable heel element can be rotated. Where less force or no additional force is desired for actuation of the actuator, the material can be scuffed, cut or ground down so that therecess43 is formed adjacent theunderside42E of the actuator, with that material generally not interfering with the depression of the actuator.
The actuator can be configured to register within and engage portions of afirst recess55 located in thefirst end51, as well as asecond recess56 located in thesecond end52 of theadjustable heel element50. When theactuator42 is registered within therespective recesses55 or56, it can operate to prevent movement or rotation of theheel adjustment module50 about theaxis100. Alternatively, theactuator42 can interfit with some tolerance between it and the respective recesses when registered therein. In such a configuration, theadjustable heel element50 and/orsupport plate40 or other components of the footwear can be outfitted with additional locking elements to prevent or impair theadjustable heel element50 from rotating about theaxis100.
As shown inFIG. 11, thesupport plate40 and/or theoutsole31 can include ribs orother contours45 that extend downwardly adjacent theactuator42. Theribs45 can extend a distance from the support plate that is greater than the distance thelocking tab42 extends from the plate. Theseribs45 can prevent inadvertent depression of the actuator into therecess43, which could possibly cause inadvertent rotation or movement of theadjustable heel element50 relative to the sole30. Of course, other locking mechanisms may be used in conjunction with theactuator42 to prevent its depression or actuation. For example, another part of thesupport plate40 could be temporarily lodged behind thetab42 to prevent its inadvertent depression. As another example, theadjustable heel element50 might include a pin (not shown) that registers with theactuator42 to lock it in place in therespective recesses55,56. Other constructions are contemplated to keep the actuator from moving and can be implemented as desired.
As shown inFIGS. 4-7, theadjustable heel element50 can be joined with thesupport plate40 viaflexible tabs62. Thesetabs62 can be in the form of multiple independent tabs as shown inFIG. 4, or can be in the form of a single, continuous annular ring that extends around the axis ofrotation100. Generally, the tabs can be configured in the form of an annular shape to provide unimpaired rotation of theadjustable heel element50 about the axis. Each of thetabs62 includeheads64 distal from thesupport plate40. Theheads64 can project outwardly away from theaxis100 of rotation. Theheads64 can be of sufficient dimension and depth to sufficiently engage theupper plate66 of theadjustable heel element50 as shown inFIGS. 5 and 13. Thehead64 can also include a tapered or curvedinstallation engagement surface63 that can assist in urging the respective tabs to flex or move during an installation operation. For example, as shown inFIG. 4, when theheel adjustment element50 is joined with thesupport plate40, thetabs62 are initially positioned adjacent theaperture67 defined by theupper plate66 of theadjustable heel element50. The installation engagement surfaces63 of the tabs engages the inner most boundary or rim of thataperture67. With further force exerted on theadjustable heel element50, bringing it toward thesupport plate40, the installation engagement surfaces63 urge the tabs toward theaxis100. The tabs flex or bend toward theaxis100 until theinstallation engagement surface63 clears the depth or large dimension or thickness of theplate66, at which point the tabs can snap outward, away from theaxis100, so that thehead64 sufficiently engages the rim about thehole67 of theupper plate66 of the adjustable heel element. The inner rim of the aperture may be of a uniform cross section, or it may be rounded or angled to facilitate entry and guiding of the tabs into the aperture, generally decreasing the amount of force required to install the tabs in the aperture.
Optionally, after theheads64/tabs62 snap into place and engage the rim, theadjustable heel element50 is permanently secured to thesupport plate40, and cannot be removed therefrom without at least partially destroying one or more components of thefootwear10. Further, with the construction of theflexible tabs62 and their interaction with the rim about theaperture67 defined in theupper plate66, after initial assembly and joining of these elements, thehead64 effectively locks in place and engages theupper plate66. Accordingly, theadjustable heel element50 is no longer detachable or removable from thesupport plate40. This added feature can prevent consumers from tampering with theadjustment assembly60 and inadvertently altering it to make the footwear less safe.
Of course, if, in a particular application, it is suitable to have theadjustable heel element50 removable or detachable from thesupport plate40 andfootwear10, theflexible tabs62 can be outfitted with a mechanism that engages theheads64 or other portions of thetabs62 to pull and/or flex them inwardly so that they can be removed from thehole67 defined by theupper plate66, and thereby detach theadjustable heel element50 from the support plate. Where other assemblies are used to attach the heel element to the support plate, those other assemblies optionally can include mechanisms to allow the heel element to be detached from the remainder of the shoe if appropriate for the application.
Further optionally, although theaperture67 is shown associated with theupper plate66, or generally theadjustable heel element50, and the tabs are shown associated with thesupport element40, these features can be reversed, with the tabs associated with the upper plate and heel element, and the aperture defined by the support element.
Thetabs62 can be made flexible by varying their thickness, or by selecting an appropriate material from which they are made. Generally they are configured to flex at their base or at a location distant from thesupport element40. After flexing or bending, thetabs62 can regain their original downwardly extending configuration.
As shown inFIGS. 4,6,7 and12, thesupport plate40 and theadjustable heel element50 can include corresponding interlocking lugs47 and recesses orholes48 which receive the lugs. The cooperation of these elements, also referred to as locking elements, can further impair or prevent rotation of theadjustable heel element50 about theaxis100. The number of locking elements, the depth and height of the recesses and lugs, and the general location of these elements can vary depending on the application. Further, the lugs and recesses can be included on either thesupport element40 or theadjustable heel element50. As shown inFIG. 7, additional locking elements in the form of lockingposts49A that engage correspondingapertures49B can be included in the construction, joined with the support plate49 andadjustable heel element50. Of course, these locking elements, that is, the ports and corresponding holes, can be reversed on therespective support plate40 andheel element50 as well. Optionally, other locking mechanisms also can be used in connection with theadjustable heel element50 to prevent it from rotating as desired.
Further optionally, the surfaces of the respective locking elements, for example thelugs47, therecesses48, theposts49A and postholes49B can project outwardly from the respective surfaces so that they can both prevent unintended movement or rotation of theadjustable heel element50 about theaxis100, but do not prevent rotation of theadjustable heel element50 when subjected to a rotating force intentionally presented by a user also depressing or moving theactuator42 in an effort to rotate the adjustment element. The precise heights and dimensions of the locking elements can be adjusted depending on the desired level of ease in rotating the heel element, or the expected level of twisting action to be exerted on the heel during an intended activity of the wearer.
Theadjustable heel element50 can also include atrough element57 that generally defines agroove58 into which theflexible tabs62 extend when theadjustable heel element50 is joined with theprimary portion32 of the sole30. Thetrough element57 can extend annularly about a portion or all of the axis ofrotation100. Likewise, thegroove58 can extend around a portion or all of theaxis100. Thegroove58 can be of a depth sufficient to accommodate therespective heads64 of the tabs and provide clearance for the installation engagement surfaces63 while theadjustable heel element50 is rotated about theaxis100.
The groove orinternal space58 defined by thetrough element57 generally can be unsealed, so that air can flow freely therefrom to the environment. Accordingly, if water or other debris becomes located in the space, it can be removed by washing the footwear with water which flushes out the space and the corresponding debris.
As shown inFIGS. 5 and 13, thetrough element57 can include an upwardly extendingcenter portion59 that generally extends upwardly from the lower most portion of thetrough element57. Thiscentral portion59 can be in the same shape as the trough and/or configuration of theflexible tabs62. Generally, it is configured so that it does not interfere with the rotation of theadjustable heel element50 about therotation axis100, and in particular, does not interfere with movement of theflexible tabs62 as they rotate and move about theaxis100. Of course, in certain applications, it could be modified to provide some interference with the tabs or other elements to impair or prevent rotation if desired.
As mentioned above, theadjustable heel element50 can include anupper plate66. Thisupper plate66 can be constructed from the same materials as thesupport plate40 or different materials. If desired, theupper plate66 can transition toward thesecond end52 and can include a downwardly extendingwall71 that covers a rearward portion of the adjustable heel element at thesecond end52. Theupper plate66 can be integrally or otherwise joined with thetrough element57. Alternatively, thetrough element57 can be locked in place with a physical or mechanical interlock to the bottom of aupper plate66. Theupper plate66 also can define the respective actuator recesses55 and56 with which theactuator42 registers.
As shown inFIG. 5, theupper plate66 can include a downwardly extendingwall71 at thesecond end52. Thiswall71 can terminate adjacent anoutsole cover74 joined with theadjustable heel element50. Optionally, thewall71 can provide additional rigidity to thesecond end52 of theheel element50.
Although not shown, theadjustable heel element50 may optionally be secured to thesupport plate40 by a fastener. The fastener may be used to supplement theflexible tabs62 and provide further resistance to separation of theadjustable heel element50 from thesupport plate40. The fastener may be positioned concentric with the axis of rotation of theadjustable heel element50 so that theadjustable heel element50 may be rotated about the fastener or theadjustable heel element50 and the fastener may rotate together with respect to thesupport plate40. The fastener may be essentially any structure capable of rotatably interconnecting theadjustable heel element50 with thesupport plate40, such as a rivet, screw or bolt/nut combination. The fastener may extend between any two components with sufficient structural strength. For example, with the embodiment ofFIG. 1, the fastener may extend from thesupport plate40 to thecenter portion59 of thetrough element57. The fastener may be separate component(s) (e.g. a separate bolt and nut) or it may be partially or fully integrated into the existing components. For example, in those embodiments in which the fastener is a bolt/nut combination, a threaded shaft may be integrated into one of thesupport plate40 and thetrough element57 and/or an internally threaded screw boss may be integrated into one of thesupport plate40 and thetrough element57.
With reference toFIGS. 5,6,12 and13, theadjustable heel element50 can include afirst material75 that can provide cushioning to the heel of a wearer. The first material can be polyurethane or any other suitable polymers. Optionally, thefirst material75 can be of a first hardness, for example, a first durometer in the range of optionally35 to40 on the Asker C Scale, further optionally45 to50 on the Asker C Scale. In general, this first material could be somewhat soft or of a low density, and provide a “squishy” or easily compressible effect when loaded that is translated to a wearer when theadjustable heel element50 is in the configuration shown inFIG. 6. Thefirst material75 can extend from the first end partially or fully to the second end, generally filling the space between theupper plate66 throughelement57 and the outsole covering74.
Optionally, a block orbumper72 can be positioned within thesecond end52 or elsewhere in theheel element50. As shown, thebumper72 generally includes front and rearvertical walls77,78. These vertical walls are generally fully encapsulated by thefirst material75. Thebumper72 can be constructed from a second material that is harder than the first material. For example, the second material can be of a durometer of optionally about 60 to 65 on the Asker C Scale, further optionally about 65 to 70 on the Asker C Scale. The second material can be polyurethane or some other suitable polymer. Accordingly, the adjustable heel element can including cushioning constructed from first and second materials, where the first material has a different hardness or durometer than the second material. This can provide a differential effect upon heel strike and through at least an initial portion of the gait of the wearer, depending on whichend51,52 of the adjustable heel element is most rearwardly positioned. Generally, due to the different hardness or durometer materials in different locations within theadjustable heel element50, the adjustable heel element can compress near thefirst end51 differently than the adjustable heel element compresses near the second end. For example, near the first end, the compression can be significant so that the first end provides a notable cushion effect. Near the second end, the compression of the heel element can be subdued and insignificant, for example, less than 1 to 10 mm, so that this end provide some cushion effect, but less than the first end.
Thebumper72 can be of a height so that when theadjustable heel element50 is in the configuration shown inFIG. 5, upon initial heel strike, the bumper will prevent further compression of thesecond end52 within its thickness. Accordingly, the user can experience a feeling of stability upon heel strike of thesecond end52 with the ground. Of course, this is opposed to the wearer's experience when theadjustable heel element50 is oriented as shown inFIG. 6. In this configuration, when thefirst end51 initially strikes the ground, the feeling is a generally squishy, soft feeling as the user rotates the foot forwardly about the initial point of impact along the curvilinear contours.
Optionally, the wearer may experience a “bottoming” or feel the effect of the bumper or block solidifying the second end of the adjustable heel element as the wearer transitions through the gait cycle when the adjustable heel element is configured as shown inFIG. 6. In other cases, the wearer may simply transition over the block through their gait so rapidly that the weight of the wearer is transferred to theforefoot region81 or ball of the foot, and the effect or presence of the bumper is never felt by the wearer.
As illustrated, the current embodiment of thefootwear10 generally is void of any substantial air pockets, sealed air chambers, or air cushions located within theadjustable heel element50. In some cases, these types of air cushions can add somewhat too much instability to the performance of the adjustable heel element when the heel element is in the fitness mode. Of course, in certain applications, such air pockets, sealed air chambers, or air cushions optionally may be added to theadjustable heel element50 to provide such desired additional instability, or simply where it is desired to make theadjustable heel element50 lighter or more springy.
Referring toFIG. 1, thefirst end51 andsecond end52 can include lower surfaces, which can be covered by the outsole covering74. Thefirst end51 can include a first performance contour which can be in the form of its lower most surface or ground engaging surface having a first curvilinear shape. This curvilinear shape can be one or more portions of an arc orcurve91 having a first radius R1. Thesecond end52 can include an arc orcurve92 having a radius R2. The radius R1 can be less than the radius R2. Of course the radii of each of thecurved portions91 and92 can vary, depending on the desired performance characteristic of the footwear. Moreover, thecurvilinear portions91 and92 can include differently curved portions or regions. For example, the bottom surface of theadjustable heel element50 can include multiple compound curvilinear portions that transition into one another from thefirst end51 to thesecond end52.
With thecurves91 and92 in thefirst end51 andsecond end52, respectively, theadjustable heel element50 includes a bottom surface that is continuously curved and void of any flat portions. Of course, as noted below, the bottom surface of theadjustable heel element50 can be modified to include flat portions where desired.
If desired, the bottom of theadjustable heel element50 can include a flat portion. For example, thecurved portion92 at thesecond end52 could be replaced with or include a flat portion to even further provide a slightly different performance characteristic of that end of theadjustable heel element50. This flat portion can transition in to thecurvilinear portion91 at a preselected location and interface. Other configurations for the performance contours can be readily substituted for those illustrated in the current embodiment.
III. Method of Assembly and OperationA method of assembly and a method of operation of thefootwear10 will now be described with reference toFIGS. 1-6. In general, the upper20 can be manufactured using conventional techniques and apparatus. For example, the desired upper material (not shown) can be cut to form the upper20. The multiple elements of the upper, such as thevamp22,quarters24 and back stay26 can be fitted and sewn or glued or otherwise fastened together. Optional waterproof membranes or liners can be secured within the upper via adhesives or stitching. The lower portion of the upper can be Strobel stitched or otherwise lasted or attached to an insole (not shown). The sole30 can be direct attached, glued, fastened or otherwise joined with the lowermost portion of the upper and any insole that is included therewith. The various components of theoutsole31,midsole35,support element40 andadjustable heel element50, including the features of theadjustment assembly60, can be manufactured using injection molding, compression molding or other molding techniques to include the features described in connection with each of these elements above.
Themidsole35 can be joined with theoutsole31 via stitching, gluing, cementing or molding these components together. Likewise, thesupport element40 can be joined with the midsole, and the remainder of theprimary portion32 of the sole30. Optionally, thesupport element40 can be integrally molded within themidsole35 or portion of theoutsole31.
To assemble the adjustable heel element, theupper plate66 can first be molded. Thehole67 can be defined in theplate66. Thetrough element57 can be brought into engagement with the upper plate so that thegroove58 defined by thetrough element57 can be aligned and centered on the hole. While these two components brought adjacent one another, thefirst material75 can be injected or pour molded over these elements. In the same mold, the bumper or block72 can be positioned so that thefirst material75 encapsulates that bumper or block72 within thefirst material75. Thefirst material75 can fill in thecentral portion59 of thetrough element57 and can act to hold thetrough element57 into engagement with theupper plate66. In the molding operation, the performance contours, for example thefirst curve91 andsecond curve92 can be formed. After thefirst material75 is allowed to cure, theadjustable heel element50 can be removed from the mold.
In another operation, the outsole covering74 can be joined with the first material and/orbumper72. Of course alternatively, the covering74 can be included in the mold along with the other components and joined with thefirst material75 in the molding operation. With the heel element assembled, it is readied for being joined with theprimary portion32 of the sole30.
In particular, thehole67 of the heel element can be aligned with the flexible extendingtabs62. The installation engagement surfaces63 can be brought into engagement with the rim of thathole67. With an amount of force ranging from 10 to 150 pounds, or other forces depending on the application, theadjustable heel element50 can be pressed toward thesupport element40. This action can cause theflexible tabs62 to flex inwardly toward the axis orrotation100 and effectively clear the inside of the rim of thehole67. Theinstallation engagement surface63 facilitates this insertion of theflexible tabs62 into thehole67. After theheads64 have cleared the thickness of theupper plate66, the flexible tabs resiliently spring back so that theheads64 lockingly engage thatplate66 and secure the adjustable heel element to thesupport plate40 and theprimary portion32 of the sole30.
Operation of the footwear of the current embodiment, and more particularly, the reorientation of theadjustable heel element50 will now be described with respect toFIGS. 1-6. To rotate the adjustable heel element about the axis ofrotation100, and thereby change from one performance contour to another performance contour, depending on the terrain or desired stability of the wearer, the wearer can depress theactuator42 as shown inFIG. 2. By depressing the actuator42, that actuator disengages from thefirst actuator recess55 as shown inFIG. 5, generally moving upward into a recess defined by thesupport plate40. This action thereby removes the actuator from engagement with theadjustable heel element50. The wearer then grasps the adjustable heel element and exerts a rotating force as shown byarrows102 about the axis ofrotation100. The wearer also exerts a moment about therotational axis100 sufficient to overcome the locking action provided by the lockingelements47 and48 as well as49A,49B. Optionally, the range of torque that can be supplied to overcome these locking features can range from optionally about 10 ft-lbs to about 150 ft-lbs, further optionally about 30 ft-lbs to about 75 ft-lbs, or other torques, depending on the application. The wearer then continues to rotate the adjustable heel element about theaxis100.
In the above operation, the user effectively can adjust theadjustable heel element50 convert between first and second modes, for example a fitness mode and a stability mode. As an example, a wearer can transition from a first mode, such as a stability mode, shown inFIG. 5, where thesecond end52 is positioned rearward of thefirst end51, to a second mode, such as a fitness mode shown inFIG. 6, where thefirst end51 is positioned rearward of the second end. Generally, in moving the respective ends in this manner, thesecond end52 initially is positioned adjacent therearwardmost portion93 of the soleprimary portion32, but after a rotation of the heel element 180 degrees, thefirst end51 is positioned adjacent therearwardmost portion93 of the soleprimary portion32. The operation can be reversed to switch from the fitness mode back to the stability mode and vice versa again.
Optionally, theadjustable heel element50 is rotatable in 180 degree increments about theaxis100 so that either thefirst end51 or thesecond end52 face the rear of the footwear and form the heel strike region of the sole. Of course, if desired, the adjustable heel element can be modified so that it is rotatable in other increments, for example 120 degree increments, in which case the ground contacting surface of the element could be modified to include corresponding performance contours for each increment of rotation. Further optionally, during rotation, the first and second ends of the heel element are swapped along a lengthwise axis of the footwear, which generally extends from the heel region through the forefoot region, so that these ends are substituted for one another during each respective rotation of the heel element.
Where the adjustable heel element only includes two opposing performance contours, the user can rotate the adjustable heel element about 180°. During this action, the user may pull downwardly on theadjustable heel element50, away from thesupport element40, to overcome friction caused by thelugs47 moving across theupper plate66. When theadjustable heel element50 has obtained the position as shown inFIGS. 3 and 6, theactuator42, which again remains in an upwardly extending position as shown inFIG. 5 during the rotation, will resiliently move into theother recess56. Generally, the actuator will audibly snap into that recess which will indicate to the wearer that theadjustable heel element50 has obtained its desired amount of rotation, and it is securely and fixedly positioned relative to thesupport element50. Optionally, the entire adjustment of the heel element can be performed while the footwear is worn by the user.
After the adjustment, the wearer can don the footwear and experience the newly selected performance contour.
IV. First Alternative EmbodimentA first alternative embodiment of the footwear is illustrated inFIGS. 14-22 and generally designated110. Thisfootwear110 and its corresponding sole130 is similar to the embodiment described above with several exceptions. For example, thesupport element140 andadjustment assembly60 and certain components of theadjustable heel element150 differ from the embodiment above.
As shown inFIGS. 14-16 and22, thesupport plate140 is configured to define ahole141 within itsupper surface142 which generally faces the interior of thefootwear110 or upper. This hole can include arim143. Placed atop the rim and generally covering the hole is asupport plate144, which is generally configured in the same shape as thehole141. The support plate can be generally rigid, inflexible and non-deflectable, and can cover the hole and make theupper surface142 of thesupport plate140 generally continuous and flat. Therigid plate144 optionally can be glued, cemented or otherwise fastened down to therim143 or thesupport plate140 so that it is not detachable after thefootwear110 is assembled as described below.
To further increase the rigidity of thesupport plate144, it can be constructed from a slightly more dense or harder material. In one example, thesupport plate140 can be constructed from a first TPU or other polymeric material as described above, while thesupport plate144 can be constructed from a second, more dense or higher durometer TPU or other material. Thesupport plate144 further can be constructed to prevent thefastener164 from being felt by a wearer of the footwear when extreme forces are placed on theadjustable heel element150.
Thesupport plate140 can cover abiasing compartment145 located below it inFIG. 16. Within thebiasing compartment145, a biasingelement162 can be located. Thecompartment145 can be bounded by a downwardly extendingwall182. This downwardly extending wall can be a continuous wall in a circular or cylindrical configuration so that thecompartment145 is of a generally cylindrical or circular configuration to accommodate thespring162. Of course, where the spring is not cylindrical, and is of another configuration, for example, the leaf spring or a coil spring that is generally rectangular, oval or of some other shape, the recess can be of a corresponding geometric shape. Thecompartment145 andsidewall182 can be of a corresponding geometric shape as well.
Returning toFIGS. 16 and 22, thewall182 extends downwardly from the support plate140 a distance and transitions at its opposing end to an inwardly extending rim orflange146. This inwardly extendingflange146 terminates a distance from therotational axis100, and generally forms ahole183 within the bottom of the biasingelement compartment145. The size of thehole183 can vary, but can generally be configured to receive therewithin thecentral portion159, also referred to as an anchor element, of theadjustable heel element150. Thiscentral portion159 can be further joined with or form a portion of thetrough element157. Thetrough element157 can generally extend upwardly from a position adjacent thelower rim146 toward theupper plate166 of theadjustable heel element150. Optionally, the downwardly extendingwall182 andlower rim146 can be concentrically located within thetrough element157, riding on, within or adjacent thetrough element157. The tolerance between the trough element and the downwardly extendingwall145 andrim146 can be tight to prevent any undesirable slop or movement between thesupport plate140 and theadjustable heel element150.
The biasingelement162 can be positioned within the biasingelement compartment145 as illustrated inFIGS. 16 and 22. The biasing element can be in a configuration of a coil spring, but as described above can be substituted for other types of biasing elements depending on the application. The biasingelement162 can be positioned within the biasingelement compartment145 so that it engages thelower rim146 of thesupport element140. In general, almost all of the lower portion of the biasing element rests on thelower rim146. The biasing element also can be configured so that it is slightly larger than or at least the same size as the dimension of thehole183 formed in the bottom of the biasingelement compartment145.
Mounted atop the biasingelement162 can be atransmission member163 which generally can be in the form of a plate which engages the uppermost coils. Theplate163 can be of the same geometric shape as the biasingelement162, or can vary in geometric shape if desired. Theplate163 can be configured in the shape of a washer, with acentral aperture163A through which thefastener146 protrudes. The plate can include, be integral with, or be joined with afastener164. In this construction, as shown inFIGS. 14 and 22, thehead164A can be positioned atop theplate163 preventing it from being drawn through the aperture. Theshaft164B of thefastener164 can extend downwardly from theplate163. Thisshaft164 optionally can be threaded into acorresponding attachment element165, which generally is shown as a nut. Thisattachment element165 can be further joined with the anchor element orcentral portion159 of theadjustable heel element150. With this construction, theplate163 is generally anchored in a fixed orientation relative to thecentral portion159.
Further illustrated inFIG. 22, the biasing element orcoil spring162 can be located between theplate163 and therim146. The biasingelement162 is placed in this position under compression. Accordingly, the biasingelement162 engages both theplate163 and thelower rim146 and pushes these elements away from one another. In turn, this urges theplate163 upward, or generally away from therim146. This force can be transmitted to theanchor element159, thetrough element157 and theupper plate166. This urges the remainder of theadjustable heel element150 upward toward thesupport plate140.
As shown inFIG. 22, the components that are all attached to one another forming aunit188 move upward under the force of the spring of abiasing element162. This, in turn causes theupper plate166 to come into solid engagement with the bottom of thesupport element140. Additionally, the lockingelements147 and148 seat firmly within one another to provide a locking force for theadjustable heel element150 so that it is impaired or prevented from rotating about theaxis100. In addition, this urging of theadjustable heel element150 toward thesupport plate140 further engages theadditional locking tabs149A within lockingrecesses149B (FIGS. 19 and 21) so that they register within one another and act to prevent or impair rotation of theadjustable heel element150 about the axis ofrotation100.
The biasingelement162 can be selected to be of a compressive force of optionally about 5 lbs to about 150 lbs, or some other suitable force depending on the application. These forces can be selected so that most wearers can manually grasp the adjustable heel element, pull downward on the heel element to further compress the biasing element, and slightly separate the adjustable heel element from thesupport plate140, thereby disengaging the lockingelements147,148 and149A/149B so that the wearer can subsequently rotate theadjustable heel element150 about theaxis100.
In operation, the user can adjust theadjustable heel element150 to readily convert between one performance contour and another thereby switching between a first and second modes, for example a fitness mode and a stability mode. As an example, a wearer can transition from a first mode, such as a stability mode, shown inFIG. 15, where thesecond end152 is positioned rearward of thefirst end151, to a second mode, such as a fitness mode shown inFIG. 16, where thefirst end151 is positioned rearward of the second end. To do so, a user grasps theadjustable heel element150, and as shown inFIG. 18, pulls downwardly on that element. The amount of force suitable to pull the adjustable heel element down can be dictated by the force stored in thebiasing element162. After the user overcomes that force of the biasingelement162, theupper plate166 separates slightly from thesupport plate140. In turn, this reduces the registration and general engagement of the locking features147 and148 as well as the engagement and registration of a locking tabs andcorresponding recesses149A and149B.
With the disengagement or de-registration of these elements, a user can then supply a moment and rotate the adjustable heel element about theaxis100. The user can continue rotation until thesecond end152 is swapped for thefirst end151, and thefirst end151 is positioned to face the rear of the footwear generally forming the heel strike area of the footwear. After the rotation has been completed, the user can discontinue application of the force to overcome the compression spring. Accordingly, the compression spring force will then urge theplate163 upward within the biasingelement compartment145 thereby pulling along with it the central portion and theupper plate166 and the remainder of theadjustable heel element150. This in turn, will reengage the lockingelements147 and148 with one another as well as the locking tabs and recesses149A and149B with one another. Accordingly, the adjustable heel element will be satisfactorily repositioned in the configuration shown inFIG. 16.
When in this position or that shown inFIG. 15, it is noted that the force exerted by a wearer downwardly through the sole30 and theadjustable heel element150 urges thesupport plate140 andadjustable heel element150 toward one another. In turn, the lockingelements147 and148 as well as the locking tabs and recesses149A and149B are also maintained or further urged in a registration with one another. This can provide additional locking between the features that resists rotation of theadjustable heel element150 relative to thesupport element140 and the remainder of the sole130.
The above descriptions are those of the preferred embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Any references to claim elements in the singular, for example, using the articles “a,” “an,” “the,” or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.