US20180103727A1 - Footwear construction with heel support assembly - Google Patents

Abstract

An article of footwear having a heel support assembly with a memory foam layer situated internally of a heel counter is provided. The memory foam layer may be laminated to the heel counter, for example, by adhesive or direct attachment. The heel memory foam layer may have a maximum thickness that is sufficient to embrace the heel of the wearer's foot potentially cradling the calcaneus, the retrocalcaneal bursa and the base of the Achilles tendon. The heel support assembly may also include a heel cradle extending around an external portion of the upper and including a lasting allowance. The heel cradle can provide torsional support in the arch region (or waist) of the article of footwear, for example when the heel support assembly is incorporated into an article of footwear with a strobel construction.

Description

BACKGROUND OF THE INVENTION
• The present invention relates to footwear and more particularly to an article of footwear with a heel support assembly.
• Conventional footwear typically includes two primary elements: an upper and a sole. The upper can be formed of a lightweight and flexible material, for example leather or synthetic materials, and can provide ventilation to the wearer's foot. The sole can include multiple layers, for example an insole, a midsole, and an outsole. The insole is sometimes positioned within the upper to provide added comfort to the wearer's sole. The midsole is generally joined to the upper and provides energy absorption, often in the heel strike area. The outsole is generally formed from a wear resistant material and includes tread elements to provide the desired degree of traction for the intended application of the article of footwear.
• Heel support is an important aspect in the design and construction of modern footwear. Insufficient heel support along the upper is known to lead to injuries to the heel and over pronation of the wearer's foot. Heel counters are well known in athletic and other types of footwear, and are typically constructed to provide heel support to an otherwise lightweight and flexible upper. Known heel counters include a curved plastic insert that extends around the heel bone (calcaneus) to cradle each side of the wearer's foot. However, the support provided by heel counters typically comes at a cost, namely discomfort in the heel over extended wear and the lack of a customized fit for differently shaped heels.
• Accordingly, there remains a continued need to provide improved heel support for an article of footwear. In particular, there remains a continued need for an article of footwear having a lightweight system of heel support that provides comfort and stability for a range of differently shaped feet.
SUMMARY OF THE INVENTION
• The present invention provides an article of footwear having a heel support assembly with a memory foam layer situated internally of a heel counter. The heel memory foam layer may have a thickness that is sufficient to embrace the heel of the wearer's foot, potentially cradling the calcaneus, the retrocalcaneal bursa and the base of the Achilles tendon. The heel support assembly may also include a heel cradle extending around an external portion of the upper and including a lasting allowance. The heel cradle may provide torsional support in the arch region (or waist) of the article of footwear, for example when the heel support assembly is incorporated into an article of footwear with a strobel construction.
• In one embodiment, the heel memory foam layer is somewhat dome-shaped having a maximum thickness through a center region and tapering gradually thinner toward its peripheral edge. For example, the heel memory foam layer may have a maximum thickness of approximately 10 mm. The maximum thickness may, however, vary from application to application, for example, in the range of about 7 mm to about 30 mm. The heel memory foam layer may be molded and, after molding, laminated to a plastic heel counter. Alternatively, the heel memory foam layer may be molded directly onto the heel counter. For example, the heel counter may be placed within the heel memory foam layer mold prior to molding of the heel memory foam layer so that they become intimately attached as the heel memory foam cures.
• In one embodiment, the upper also includes a transitional foam layer integrated into the upper above the heel counter. The transitional foam layer may be situated immediately above the heel memory foam layer to provide a smooth transition along the inside of article of footwear. The thickness of the transitional foam layer may be substantially smaller than the thickness of the heel memory foam layer. For example, the transitional memory foam layer may be approximately 3 mm in thickness. This thickness is merely exemplary and the thickness may be in the range of about 1 mm to about 20 mm.
• In one embodiment, the heel support assembly includes an overlay situated over the upper in a region generally corresponding to the heel counter. The overlay may be substantially coextensive with the heel counter. However, it may have a different size and/or shape than the heel counter. For example, the overlay may be somewhat smaller or somewhat larger than the heel counter.
• In one embodiment, the article of footwear has a strobel construction in which the upper is closed by a strobel board. The strobel construction may include a generally flexible strobel board that is joined to the lasting margin of the upper by a butt-seam. The strobel construction may provide an athletic-inspired, low-weight article of footwear.
• In one embodiment, the heel cradle is disposed at the bottom of the upper around the heel region. The heel cradle provides additional support to the heel to help keep the foot in place. The heel cradle may be manufactured from a relatively rigid and resilient material, such as thermoplastic polyurethane. The cradle may extend forwardly to provide additional torsional control. This additional torsional control may be particularly beneficial when incorporated into footwear with more flexible constructions, such as a strobel construction. The cradle may include a lasting allowance that extends under the upper and is secured to the sole. The lasting allowance may be provided only in the arch region (or waist) of the article of footwear.
• The heel cradle may have a shorter section in the rear of the heel. The shorter section may provide improved comfort in some applications by allowing some degree of flexibility in the portion of the heel overlying the retrocalcaneal bursa.
• In one embodiment, the article of footwear includes an insole specifically configured to interact with the heel support assembly. In this embodiment, the insole may be manufactured from a material that is highly resistant to compression set. For example, the insole may be manufactured from cast-mold polyurethane having a compression set of ≤5% after 500,000 compressions and a recovery period of 24 hours.
• The present invention provides an article of footwear with a heel support assembly that simultaneously provides improved comfort and improved support for the heel. The heel memory foam helps to firmly, yet comfortably, lock the wearer's foot into the article of footwear. The various components of the assembly are configured to collectively provide a unique degree of customized fit without compromising support. The heel memory foam layer is intended to conform to the wearer's foot in and around the rear and sides of the heel. The cradle may be provided to give torsional support in the arch region (or waist) of the article of footwear—particularly when the heel support assembly is incorporated into an article of footwear with a strobel construction.
• These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.
• Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components. 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.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a perspective view of a boot incorporating a footwear construction in accordance with an embodiment of the present invention.
• FIG. 2 is an exploded perspective view of the boot ofFIG. 1.
• FIG. 3 is a cross-sectional view of the boot ofFIG. 1.
• FIG. 4 is a bottom perspective view of the upper with the cradle installed.
• FIG. 5 is a close-up cross-sectional view of the heel counter assembly ofFIG. 3.
• FIG. 6 is a perspective view of the heel cradle.
• FIG. 7 is a sectional view similar toFIG. 3 showing the wearer's foot situated in the boot.
• FIG. 8 is an exploded perspective view of an alternative embodiment incorporating an alternative transition foam layer.
DESCRIPTION OF THE CURRENT EMBODIMENT
• Referring now toFIGS. 1 and 2, an article of footwear including a heel support assembly of a current embodiment is illustrated and generally designated10. For purposes of disclosure, the article offootwear10 is illustrated as a work boot. Embodiments of the invention may, however, be incorporated into essentially any style or type of footwear that incorporates a closed heel. For example, embodiments of the invention may be incorporated into essentially any safety shoes, safety boots, work shoes, work boots, athletic shoes, running shoes, sneakers, tennis shoes, hiking shoes, hiking boots, biker boots, boat shoes, deck shoes, dress shoes, military footwear, uniform footwear and sandals with a closed heel.
• Referring again toFIGS. 1 and 2, the article offootwear10 generally includes an upper12 and a sole14. The upper12 may be essentially any footwear upper. The current embodiment is described in the context of a lightweight athletic-inspired upper, the bottom of which is closed by aflexible strobel board15 along a butt seam. The upper12 includes a vamp16 (or toe box), atongue18 and one ormore quarters20. Thevamp16 generally forms the forefoot portion of the upper16 and may be manufactured from any combination of pieces of upper material. Thetongue18 may be joined to thevamp16 and extend rearwardly to underlie thelaces22. As with thevamp16, thetongue18 may be manufactured from any combination of pieces. Thetongue18 may be padded, which in part helps to protect the wearer's foot from thelaces22. The quarter orquarters20 form the heel portion of the upper12 and may be manufactured from any combination of pieces of upper material. The various pieces of the upper12 may be manufactured from any of a wide range of materials, such as leather, synthetic leather, mesh, canvas, textile (e.g. woven, knit, bonded), fabric and molded components.
• The upper12 may include various trim, cushioning and reinforcing elements. For example, a toe cap (not shown) may be provided to reinforce thevamp16. Further, padding may be sandwiched between the layers of the upper12, such as between thevamp16 and aninternal liner24. Reinforcing elements may be affixed to the upper12 to reinforce the portions of the upper12 that receive the laces. The interior of the upper12, such as thevamp16,tongue18, andquarters20, may be covered by theliner24, for example a layer of DriLex, Cambrelle or other lining materials. Theliner24 may be a single layer of material or it may be a combination of materials. For example, theliner24 may include integrated padding throughout or in select regions, such as around the ankle and the foot opening. The construction of the illustrated upper12 is merely exemplary, and the present invention may be incorporated into footwear that includes essentially any upper construction.
• As noted above and shown inFIGS. 1 and 2, the article offootwear10 includes a sole14. For purposes of disclosure, the current embodiment is described in the context of a generally conventional sole, including amidsole26 and anoutsole28. Themidsole26 provides energy absorption and foot support, and theoutsole28 includes a wear surface (not shown) and asidewall30. Greater or fewer elements of the sole14 can be included in other embodiments. For example, some embodiments can include only an outsole, while other embodiments can include an outsole, a midsole, and an insole. Still other embodiments can include a unit sole, in which the midsole and the outsole are combined into a unitary element. The construction of the illustrated sole14 is merely exemplary, and the present invention may be incorporated into footwear that includes essentially any sole construction.
• Referring now toFIG. 3, a heel support assembly in accordance with a current embodiment is illustrated and generally designated32. Theheel support assembly32 includes aheel counter34, a memory foam layer36 (collectively referred to as a heel counter assembly38) and aheel cradle40. Theheel counter assembly38 is positioned between the upper12 and theliner24, and theheel cradle40 is positioned outside of the upper12, extending forwardly toward the wearer's arch. Each such element is discussed below.
• Theheel counter34 of theheel counter assembly38 is shaped to conform to the heel of the article offootwear10 and provide rigid support to an otherwise flexible upper12. As perhaps best shown inFIG. 5, theheel counter34 includes a curved sidewall42 with an arcuatetop edge44 that gradually tapers from a maximum height adjacent the rear of the heel to a minimum height forward of the heel. For example, the curved sidewall42 includes a continuously downwardly curvingtop edge44, terminating at or near the wearer's arch. The curved sidewall42 also includes a concaveinner surface48 and a convexouter surface50 defining a generally uniform thickness therebetween. Theheel counter34 optionally includes abottom flange46 that is turned under and extends beneath the wearer's heel, such that thebottom flange46 is sandwiched between the stroble board15 (or other insole element) and the midsole26 (or other outsole element). Theheel counter34 can be a unitary element, or can be formed from two or more optionally interconnected elements. Theheel counter34 is formed from a thermoplastic in the current embodiment, for example thermoplastic polyurethane, but can be formed from other materials in other embodiments as desired.
• Thememory foam layer36 of theheel counter assembly38 is adapted to provide enhanced comfort for the rear and side portions of the wearer's heel. As used herein, a “memory foam layer” means a slow recovery foam element having a two-dimensional or three-dimensional shape such that, when pressure is applied and released, the slow recovery foam element returns to substantially its original shape. The memory foam layer can include viscoelastic polyurethane foam and low-resilience polyurethane foam for example. Thememory foam layer36 is formed as a sheet-like element in some embodiments, while in the illustrated embodiment thememory foam layer36 can be formed with a three-dimensional shape. For example, a flat or tapered-flatmemory foam layer36 can applied to the interior of theheel counter34, such that thememory foam layer36 assumes a convex curvature and is coextensive with the concaveinner surface48 of the heel counter sidewall42. In other embodiments a pre-shapedmemory foam layer36 is applied to the interior of theheel counter34, being pre-shaped with a convex surface that is coextensive with the concaveinner surface48 of the heel counter sidewall42. Thememory foam layer36 is laminated to the concaveinner surface48 of the heel counter sidewall42 by adhesive in some embodiments, while in other embodiments thememory foam layer36 is molded directly to the concaveinner surface48 of theheel counter34 so that they become intimately attached as the memory foam cures.
• The thickness of thememory foam layer36 can be selected to provide optimized support to the rear and side portions of the wearer's heel. As used herein, the “thickness” of thememory foam layer36 includes the distance between substantially opposing major surfaces of thememory foam layer36. Thememory foam layer36 may have a maximum thickness that is sufficient to embrace the heel of the wearer's foot potentially cradling the calcaneus, the retrocalcaneal bursa and the base of the Achilles tendon. For example, thememory foam layer36 may have a maximum thickness of approximately 10 mm. The maximum thickness may, however, vary from application to application, for example, in the range of about 7 mm to about 30 mm. In addition, thememory foam layer36 can maintain a substantially constant thickness along its height in some embodiments. For example, the thickness at the rearward-most portion of the memory foam layer36 (in the heel-toe direction) can be relatively constant. More particularly, the thickness can be least 7 mm, further optionally about 10 mm. In other embodiments, thememory foam layer36 includes a thickness that varies along its height. For example, and as shown inFIG. 5, the maximum thickness of thememory foam layer36 can occur midway between the upper and lower edges of the memory foam layer. In this example, the maximum thickness is at least 7 mm, further optionally about 10 mm. The thickness of thememory foam layer36 transitions or tapers to a reduced thickness at its periphery, terminating at a thickness less than the maximum thickness, for example 1 mm to 3 mm, inclusive. Thememory foam layer36 can assume other thicknesses in other embodiments.
• As noted above, thememory foam layer36 is situated internally of theheel counter34 closest to the wearer's heel to form theheel counter assembly38. The periphery of thememory foam layer36 can be shaped according to the intended embodiment. In one embodiment, the heel memory foam layer is somewhat dome-shaped having maximum thickness through a center region and tapering gradually thinner toward its peripheral edge. In another embodiment, thememory foam layer36 can include a rearwardly-chamfered or rearwardly-beveledupper portion52 that generally follows the contour of the heel counterupper edge44. In still other embodiments, thememory foam layer36 can include a flatupper portion52 that generally follows the contour of the heel counterupper edge44 and a flat bottom edge54 that straddles the wearer's heel. Theheel counter assembly38 is positioned between the upper12 and theliner24 in the present embodiment, but can be positioned to directly engage the wearer's foot in other embodiments.
• Theheel cradle40 is shaped to provide external heel support to the upper while also aiding in the removal of the article offootwear10. As perhaps best shown inFIG. 4, theheel cradle40 is generally u-shaped and extends around an exterior portion of the upper immediately above and adjacent to the sole14. That is, theheel cradle40 extends forwardly into the arch region (or waist) of the article offootwear10 to provide additional torsional control. This additional torsional control may be particularly beneficial when incorporated into footwear with more flexible constructions, such as a strobel construction. Theheel cradle40 includes amedial portion56, alateral portion58, and anintermediate portion therebetween60. The medial andlateral portions56,58 are spaced apart from each other by the width of theintermediate portion60 and generally mirror each other. The medial andlateral portions56,58 define a height greater than a height defined by theintermediate portion60, such that theintermediate portion60 represents a dip in the rear profile of theheel cradle40. In addition the medial andlateral portions56,58 each include a lasting allowance in the form of one ormore projections62 that extend under the upper12 and are secured to the sole14. In other words, the lasting allowance of themedial portion56 extends toward the lasting allowance of thelateral portion58. Theintermediate portion60 includes a thickness, protruding from the rear of the upper, to provide ashelf64. Theshelf64 is conveniently placed to provide an area for removing the article offootwear10 with downward pressure. Consequently, the heel cradle is generally rigid, being formed for example from thermoplastic polyurethane, but can be formed from other materials in other embodiments as desired. In addition, the shorterintermediate portion60 can provide improved comfort in some applications by allowing some degree of flexibility in the portion of the heel overlying the retrocalcaneal bursa.
• Theheel support assembly32 is described above as including a heel counter assembly38 (heel counter34 and memory foam layer36) and aheel cradle40, but can include greater or fewer elements that provide support to the heel area of the upper12. For example, theheel support assembly32 can include only theheel counter assembly38 in some embodiments. In other embodiments, theheel support assembly32 can include anoverlay66 that extends around the sides and back of the heel portion of the upper12, being layered between the upper12 and theheel cradle40. Thisoverlay66 is generally depicted inFIG. 1. Theoverlay66 is formed from the same material as the upper10 in the present embodiment (e.g., leather), but can be formed from a material different from that of the upper10 in other embodiments as desired. For example, theoverlay66 can be formed from synthetic leather, nylon, or other materials in other embodiments as desired. Theoverlay66 may be substantially coextensive with theheel counter34. However, it may have a different size and/or shape than theheel counter34. For example, theoverlay66 may be somewhat smaller or somewhat larger than theheel counter34.
• Referring again toFIGS. 3, 7 and 8, the upper10 includes a transitionalmemory foam layer68 integrated into the ankle region of the upper12 immediately above theheel counter34. The transitionalmemory foam layer68 is formed from a memory foam material, optionally the same memory foam material than the heelmemory foam layer36. In other embodiments thetransitional foam layer68 is formed from a different (non-memory) foam material. Thetransitional foam layer68 is situated immediately above the heelmemory foam layer36 to provide a smooth transition along the inside of article offootwear10. Thetransitional foam layer68 may be tapered to increase in thickness as it approaches theheel counter34. As shown inFIG. 8 for example, thetransitional foam layer68 may transition from a thickness of about 1 mm at the top to a thickness of about 3 mm at the bottom adjacent to the top of theheel counter34. The maximum thickness of the transitionalmemory foam layer68 is generally smaller than the maximum thickness of the heelmemory foam layer36. For example, the transitionalmemory foam layer68 maximum thickness is approximately 3 mm in one embodiment, while the maximum thickness of the heelmemory foam layer36 is approximately 10 mm in this embodiment. In this respect, the ratio of the heelmemory foam layer36 maximum thickness to the transitionalmemory foam layer68 maximum thickness is at least 3:1, further optionally at least 5:1, and still further optionally at least 10:1. This maximum thickness of the transitionalmemory foam layer68 is merely exemplary and the thickness may be in the range of about 1 mm to about 20 mm. As shown inFIGS. 3, 7 and 8, the upper edge of the52 of the heelmemory foam layer36 can also include a thickness equal to the thickness of the transitionalmemory foam layer68 where they meet to provide a flush interface.
• The article offootwear10 can also include aninsole70 specifically configured to interact with theheel support assembly32. Theinsole70 can be manufactured from a material that is highly resistant to compression set. For example, theinsole70 can be manufactured from a material having a compression set of ≤5% after 500,000 compressions and a recovery period of 24 hours. Example insole materials include cast-mold polyurethane, pour molded polyurethane, and expanded thermoplastic polyurethane, available under the name Infinergy from BASF.
• To reiterate, the article offootwear10 of the current embodiment includes aheel support assembly34 with amemory foam layer36 incorporated into theheel counter34. Thememory foam layer36 may be laminated to the interior of theheel counter34 and may have a thickness in the range of 7 mm to 30 mm. The upper12 may include atransitional foam layer68 that is disposed above theheel counter34 to assist in fitting a wearer's foot into the interior of the article offootwear10. Thetransitional foam layer68 may be configured to provide a gradual entry into thememory foam36 of theheel counter34. Thetransitional foam layer68 may be tapered to increase in thickness as it approaches theheel counter34, generally shown inFIG. 8 for example. Further by example, thetransitional foam layer68 may transition from a thickness of about 1 mm at the top to a thickness of about 3 mm at the bottom adjacent to the top of theheel counter34. Theheel support assembly32 may also include anoptionally leather overlay66 and aheel cradle40 that contributes to the unique overall characteristics of theassembly32. Thecradle40 of the illustrated embodiment includes alasting allowance62 in the arch or waist region of the article offootwear10 that helps to reinforce the heel region of the article offootwear10 and to provide a degree of torsional control through the heel and arch regions. The article offootwear10 may have a strobel construction and thecradle40 may be configured to add heel and torsional support that would not otherwise be available with a conventional strobel construction.
• An article of footwear incorporating a heel support assembly in accordance with a current embodiment can be formed according to the following steps, discussed individually below: a) joining a memory foam layer to a heel counter to form a heel counter assembly; b) securing the heel counter assembly to a heel portion of an upper; c) joining an overlay to the heel portion of the upper; d) positioning a heel cradle having a lasting allowance over a base of the upper; and e) securing a sole to the upper, such that the lasting allowance is disposed between the upper and the sole. While the foregoing manufacturing steps are recited in connection with the illustrated embodiments, the manufacturing steps can vary from application to application as desired, such that greater or fewer method steps can be used in connection with other embodiments.
• Joining a memory foam layer to a heel counter includes fixedly attaching the memory foam layer to the concave interior surface of the heel counter. This step can include, for example, laminating the memory foam layer to the heel counter by adhesive. Also by example, this step can include molding the memory foam layer directly to the heel counter. Still further by example, this step can include positioning an intermediate adhesive layer between the heel counter and the memory foam layer, such that that the memory foam layer is indirectly attached to the heel counter. The memory foam layer is fixed with respect to the heel counter in these examples, such that that the memory foam layer cannot be removed without damaging the integrity of the memory foam layer. As noted above, the memory foam layer can be a flat foam sheet. For example, a flat memory foam layer can be applied to the interior of the heel counter, such that the memory foam layer assumes a convex mating surface that bonds with the concave inner surface of the heel counter sidewall. Alternatively, the memory foam layer can be molded with a three-dimensional contour. For example, a pre-shaped memory foam layer can be applied to the interior of the heel counter, being pre-shaped with a convex mating surface that is coextensive with the concave inner surface of the heel counter.
• Securing the heel counter assembly to a heel portion of an upper includes gluing the heel counter assembly to the upper in the current embodiment. For example, the heel counter assembly can be glued between a portion of the upper and a liner. In this position, the upper can be strobel lasted such that the upper is closed by a strobel board, thereby providing flexibility in the upper, while the heel counter assembly is securely positioned therein. Joining an overlay about the heel portion of the upper includes attaching the overlay to the exterior of the upper, for example using an adhesive. The overlay can be substantially coextensive with the heel counter or can have a different size and/or shape than the heel counter. In addition, the overlay is formed from the same material as the upper in the current embodiment, but can be formed from a material different from that of the upper in other embodiments as desired. For example, the overlay can be formed from synthetic leather, nylon, or other materials.
• The steps of positioning a heel cradle over a base of the upper and securing the sole to the upper provide an article of footwear having a reinforced heel. The heel cradle is rigid in the current embodiment, being molded from thermoplastic polyurethane having u-shaped construction that extends around the heel region of the upper. The heel cradle is also molded to have a shortened intermediate portion that provides a shelf to aid the wearer in removing the article of footwear with downward pressure. The sole can be secured to the upper according to any desired technique, for example by gluing a midsole to the strobel board. Optional further manufacturing steps can include positioning an insole within the upper and over the strobel board, the insole being specifically configured to interact with the heel support assembly. The insole can be manufactured from a material that is highly resistant to compression set. For example, the insole may be manufactured from a material having a compression set of ≤5% after 500,000 compressions and a recovery period of 24 hours. Suitable insole materials include cast-mold polyurethane, pour-molded polyurethane, and expanded thermoplastic polyurethane, for example.
• Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. Further, the terms “medial,” “lateral” and “longitudinal” are used in the manner commonly used in connection with footwear. For example, when used in referring to a side of the shoe, the term “medial” refers to the inward side (that is, the side facing the other shoe) and “lateral” refers to the outward side. When used in referring to a direction, the term “longitudinal direction” refers to a direction generally extending along the length of the shoe between toe and heel, and the term “lateral direction” refers to a direction generally extending across the width of the shoe between the medial and lateral sides of the shoe. The use of directional terms should not be interpreted to limit the invention to any specific orientation. As used above, the term “arch region” (or arch or midfoot) refers generally to the portion of the footwear or sole assembly corresponding to the arch or midfoot of the wearer's foot; the term “forefoot region” (or forefoot) refers generally to the portion of the footwear forward of the arch region corresponding to the forefoot (for example, including the ball and the toes) of a wearer's foot; and the term “heel region” (or heel) refers generally to that portion of the footwear rearward of the arch region corresponding to the heel of the wearer's foot.
• The above description is that of current 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. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference 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.

Claims (21)

1. An article of footwear comprising:

a sole:

an upper joined to the sole, the upper include a heel counter assembly disposed in the heel region of the upper, the heel counter assembly including a heel counter and a memory foam layer, the memory foam layer having a maximum thickness of at least 7 mm, the upper further including a transition foam layer disposed above the heel counter assembly having a maximum thickness less than the maximum thickness of the memory foam layer; and

a heel cradle extending around the heel region of the upper into the arch region of the upper.

2. The article of footwear ofclaim 1 wherein the heel cradle includes a lasting allowance disposed between and secured to the upper and the sole.

3. The heel support assembly ofclaim 1 wherein the memory foam layer is laminated to the heel counter.

4. The heel support assembly ofclaim 1 wherein the memory foam layer is molded to the heel counter.

5. The heel support assembly ofclaim 1 further including an overlay extending laterally around the upper, the overlay being substantially coextensive with the heel counter.

6. The article of footwear ofclaim 1 wherein the upper includes a strobel construction.

7. The heel support assembly ofclaim 1 wherein the heel cradle includes a medial portion, a lateral portion, and an intermediate portion therebetween, the intermediate portion having a reduced height relative to the medial and lateral portions of the heel cradle.

8. The heel support assembly ofclaim 1 wherein the transition foam layer includes a maximum thickness of less than or equal to 3 mm.

9. The heel support assembly ofclaim 1 wherein the memory foam layer includes a tapered peripheral edge.

10. The heel support assembly ofclaim 9 wherein the thickness of the tapered peripheral edge of the memory foam layer is generally equal to the thickness of the transition foam layer.

11. A heel support assembly for an article of footwear including an upper and a sole, the heel support assembly comprising:

a heel counter assembly including:

a heel counter disposed adjacent to a heel portion of the upper of the article of footwear, and

a memory foam layer positioned internally of the heel counter, the memory foam layer being substantially coextensive with the heel counter; and

a u-shaped heel cradle extending around an exterior portion of the upper and including a medial portion and a lateral portion each having a lasting allowance extending inwardly between the upper and the sole.

12. The heel support assembly ofclaim 11 further including an overlay substantially encompassing the heel counter assembly along the exterior portion of the upper.

13. The heel support assembly ofclaim 11 wherein the memory foam layer includes a tapered peripheral edge.

14. The heel support assembly ofclaim 11 wherein the memory foam layer is laminated to the heel counter.

15. The heel support assembly ofclaim 11 wherein the memory foam layer is molded to the heel counter.

16. A method of manufacturing an article of footwear comprising:

joining a memory foam layer to a heel counter to form a heel counter assembly;

securing the heel counter assembly to a heel portion of an upper;

positioning a u-shaped heel cradle over a base of the upper, the heel cradle including a medial portion, a lateral portion, and an intermediate portion therebetween; and

securing a sole to the upper, the medial and lateral portions each including a lasting allowance disposed between the sole and the upper.

17. The method ofclaim 16 wherein joining the memory foam layer to the heel counter includes laminating the memory foam layer to the heel counter.

18. The method ofclaim 16 wherein joining the memory foam layer to the heel counter includes molding the memory foam layer to the heel counter.

19. The method ofclaim 16 wherein securing the heel counter assembly to the heel portion of the upper includes gluing the heel counter assembly to the upper.

20. The method ofclaim 16 further including positioning an overlay around a heel portion of the upper, the overlay being substantially coextensive with the heel counter assembly.

21. (canceled)

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