US20240324718A1 - Hinged footwear sole structure for foot entry and method of manufacturing - Google Patents

Abstract

A sole structure for an article of footwear comprises a unitary midsole having a first portion and a second portion rearward of the first portion. A bottom surface of the unitary midsole defines a groove extending from a medial side to a lateral side of the unitary midsole, and a top surface of the unitary midsole defines a slit disposed over the groove and extending from the medial side to the lateral side. The unitary midsole forms a living hinge at the groove and the slit, with the living hinge connecting the first portion to the second portion so that the first portion and the second portion are selectively pivotable relative to one another at the living hinge between a first orientation and a second orientation. The groove is wider in the first orientation than in the second orientation, and the slit is wider in the second orientation.

Description

CROSS-REFERENCE TO RELATED APPLICATION
• This application is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 17/879,934, filed Aug. 3, 2022, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 16/798,999, filed Feb. 24, 2020, now U.S. Pat. No. 11,439,197, issued Sep. 13, 2022, which is a divisional of and claims the benefit of priority to U.S. application Ser. No. 15/792,059, filed Oct. 24, 2017, now U.S. Pat. No. 10,602,802, issued Mar. 31, 2020, which claims the benefit of priority to U.S. Provisional Application No. 62/413,037, filed Oct. 26, 2016, each of which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
• The present teachings generally include a sole structure for an article of footwear, an article of footwear, and a method of manufacturing an article of footwear.
BACKGROUND
• Traditionally, placing footwear on a foot often requires the use of one or both hands to stretch the ankle opening of a footwear upper, and hold the rear portion during foot insertion. The fit of the upper is then adjusted following foot insertion, such as by tying laces.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG.1 is a schematic illustration in perspective view of a lateral side of an embodiment of an article of footwear in a use position.
• FIG.2 is a schematic illustration in perspective view of the lateral side of the article of footwear ofFIG.1 in an access position.
• FIG.3 is a schematic illustration in fragmentary perspective view of the bottom of the midsole of the article of footwear ofFIG.1 in the use position.
• FIG.4 is a schematic illustration in perspective view of a lateral side of another embodiment of an article of footwear in a use position.
• FIG.5 is a schematic illustration in perspective view of a medial side of the article of footwear ofFIG.4.
• FIG.6 is a schematic illustration in fragmentary side view of the lateral side of a midsole of the article of footwear ofFIG.4 in the use position showing a living hinge.
• FIG.7 is a schematic illustration in fragmentary side view of the lateral side of the midsole ofFIG.6 when the article of footwear ofFIG.4 is in an access position.
• FIG.8 is a schematic illustration in perspective view of the lateral side of the article of footwear ofFIG.4 in an access position.
• FIG.9 is a schematic illustration in perspective view of a bottom of the midsole of the article of footwear ofFIG.4 in the access position.
• FIG.10 is a schematic illustration in fragmentary perspective view of the article of footwear ofFIG.4 in the access position.
• FIG.11 is a schematic illustration in perspective view of a lateral side of another embodiment of an article of footwear in a use position.
• FIG.12 is a schematic illustration in perspective view of the lateral side of the article of footwear ofFIG.11 in an access position.
• FIG.13 is a schematic illustration in fragmentary side view of the lateral side of the article of footwear ofFIG.11 in the use position.
• FIG.14 is a schematic illustration in fragmentary side view of the lateral side of the article of footwear ofFIG.11 in the use position.
• FIG.15 is a schematic illustration in perspective view of a medial side of another embodiment of an article of footwear in a use position.
• FIG.16 is a schematic illustration in perspective view of the medial side of the article of footwear ofFIG.15 in an intermediate position.
• FIG.17 is a schematic illustration in perspective view of the medial side of the article of footwear ofFIG.15 in an access position.
• FIG.18 is a schematic illustration in side view of a lateral side of another embodiment of an article of footwear in a use position.
• FIG.19 is a schematic illustration in perspective view of a medial side of the article of footwear ofFIG.18.
• FIG.20 is a schematic illustration in plan view of the article of footwear ofFIG.18.
• FIG.21 is a schematic illustration in side view of the medial side of the article of footwear ofFIG.18 in an access position.
• FIG.22 is a schematic illustration in side view of the lateral side of the article of footwear ofFIG.18 in the access position.
• FIG.23 is a schematic illustration in fragmentary side view of the lateral side of the midsole of the article of footwear ofFIG.4 in the use position with an alternative embodiment of a living hinge.
• FIG.24 is a schematic illustration in fragmentary side view of the lateral side of the midsole of the article of footwear ofFIG.4 in the use position with an alternative embodiment of a living hinge.
• FIG.25 is a schematic illustration in fragmentary side view of the lateral side of the midsole of the article of footwear ofFIG.4 in the use position with an alternative embodiment of a living hinge.
DESCRIPTION
• A sole structure for an article of footwear enables hands-free placement of the article of footwear on a foot. The sole structure comprises a unitary midsole having a first portion and a second portion rearward of the first portion. A bottom surface of the unitary midsole defines a groove extending from a medial side to a lateral side of the unitary midsole. A top surface of the unitary midsole defines a slit disposed over the groove and extending from the medial side to the lateral side. The unitary midsole forms a living hinge at the groove and the slit, with the living hinge connecting the first portion to the second portion so that the first portion and the second portion are selectively pivotable relative to one another at the living hinge between a first orientation and a second orientation. The groove is wider in the first orientation than in the second orientation, and the slit is wider in the second orientation than in the first orientation.
• In one or more embodiments, the slit is closed and the groove is open in the first orientation, and the slit is open and the groove is closed in the second orientation. Additionally, in one or more embodiments, the slit includes a main portion, a front branch, and a rear branch, such as in a Y-formation. The front branch extends downward from the top surface of the unitary midsole toward the groove and has a distal end spaced above the groove. The front branch extends from the distal end of the main portion into the first portion and terminates above the bottom surface. The rear branch extends from the distal end of the main portion into the second portion and terminates above the bottom surface. In such an embodiment, the unitary midsole may have a front wall and a rear wall in the bottom surface at the groove, the front branch of the slit may extend above the front wall, and the rear branch of the slit may extend above the rear wall.
• In one or more embodiments, the first portion of the unitary midsole includes a forefoot region and a midfoot region, the second portion of the unitary midsole includes a heel region. The bottom surface of the unitary midsole in the heel region has a main portion and a rearmost portion extending from and disposed at an obtuse angle to the main portion. The main portion of the bottom surface extends along a horizontal plane in the first orientation, and the rearmost portion of the bottom surface extends along the horizontal plane in the second orientation.
• In one or more embodiments, the top surface of the unitary midsole in the second portion has a main portion and a rearmost portion extending from and disposed at an obtuse angle to the main portion of the top surface so that the second portion of the unitary midsole has a ridge between the rearmost portion of the bottom surface and the rearmost portion of the top surface.
• Within the scope of the present teachings, an article of footwear comprises a sole structure having a front sole portion, a rear sole portion, and a living hinge extending transversely across the sole structure from a medial side to a lateral side of the sole structure and connecting the front sole portion to the rear sole portion. The article of footwear further comprises a divided footwear upper including a front upper portion and a separate rear upper portion. The front upper portion is fixed to the front sole portion and defines at least the forefoot region of the footwear upper, and the rear upper portion is fixed to the rear sole portion and defines the heel region of the footwear upper. The front sole portion and the rear sole portion are selectively pivotable relative to one another at the living hinge between a use position and an access position. In the use position, the front upper portion and the rear upper portion together define a foot-receiving cavity and an ankle opening, and the rear upper portion overlaps the front upper portion at a medial side of the sole structure and at a lateral side of the sole structure. In the access position, the front upper portion and the rear upper portion are spaced apart from one another so that the ankle opening is larger than in the use position. Accordingly, the article of footwear with the divided upper portion may enable hands-free foot entry in the access position, while the overlapping front and rear upper portions provide lateral stability to the upper in the use position.
• In one or more embodiments, the rear upper portion includes an elastic biasing member that extends along a medial side of the article of footwear and a lateral side of the article of footwear and is secured to the article of footwear forward of the living hinge. Stated differently, the rear upper portion itself is the elastic biasing member. Alternatively, in one or more embodiments, the elastic biasing member may be separate from the rear upper portion, and extends along a medial side of the article of footwear and a lateral side of the article of footwear and around a rear periphery of the rear upper portion, and is secured to the article of footwear forward of the living hinge.
• In one or more embodiments of the article of footwear, the front upper portion includes a heel footbed. A rear periphery of the heel footbed is surrounded by the rear upper portion and overlays the rear sole portion in the use position, and the heel footbed is disposed further away from the rear upper portion when the front sole portion and the rear sole portion are in the access position than when in the use position. The interfitting of the heel footbed of the front upper portion with the rear upper portion in the use position helps further stabilize the divided upper when in the use position.
• Alternatively, a heel footbed can be an integral part of the front sole portion. For example, in one or more embodiments of the article of footwear, the front sole portion includes a heel footbed, a rear periphery of the heel footbed is surrounded by the rear upper portion and overlays the rear sole portion in the use position. The heel footbed is disposed further away from the rear upper portion when the front sole portion and the rear sole portion are in the access position than when in the use position.
• In one or more embodiments of the article of footwear, the rear upper portion includes a compliant protrusion that protrudes forward into the foot-receiving cavity above the heel footbed when the front sole portion and the rear sole portion are in the use position. The compliant protrusion further stabilizes the divided upper in the use position as it provides at least some resistance to the heel footbed moving past the compliant protrusion out of the foot-receiving cavity. Additionally, the compliant protrusion may enable the upper to securely fit to a wider range of ankle girths.
• In one or more embodiments of the article of footwear, the front sole portion, the rear sole portion, and the living hinge are coplanar in the use position, and the sole structure is lifted at the living hinge in the access position relative to the use position so that the rear sole portion inclines from a rear end of the rear sole portion to the living hinge, and the front sole portion inclines from a forward end of the front sole portion to the living hinge. In the access position, the front sole portion and the opening of the foot receiving cavity of the front upper portion are thus angled upward for easy foot insertion, such as with the foot entering toes first at a downward and forward angle.
• In one or more embodiments of the article of footwear, the article of footwear further comprises a cinching system for tightening the upper in the use position. The cinching system includes at least one cable extending at least partially over the front upper portion and secured to the rear sole portion at one of the medial side or the lateral side of the sole structure, and a pulley secured to the front sole portion at the same one of the medial side or the lateral side of the sole structure. The cable is relatively slack when the front sole portion and the rear sole portion are in the access position, and is relatively taut when the front sole portion and the rear sole portion are in the use position. The cinching system automatically tightens as the sole structure moves to the use position from the access position.
• In one or more embodiments of the article of footwear, the at least one cable has a first end secured to the rear sole portion at the medial side of the sole structure, and a second end secured to the rear sole portion at the lateral side of the sole structure. The pulley is a first pulley secured to the front sole portion at the medial side of the sole structure. The at least one cable extends around the first pulley between the first end of the at least one cable and the second end of the at least one cable. The cinching system further comprises a second pulley secured to the front sole portion at the lateral side of the sole structure. The at least one cable extends around the second pulley between the first end of the at least one cable and the second end of the at least one cable.
• In one or more embodiments of the article of footwear, the front upper portion includes a heel footbed, and a rear periphery of the heel footbed is surrounded by the rear upper portion and overlays the rear sole portion in the use position. The heel footbed is disposed further away from the rear upper portion when the front sole portion and the rear sole portion are in the access position than when in the use position. The article of footwear further comprises a strap having a fixed end secured to the heel footbed and a free end extending through an aperture in the rear upper portion. The strap has a length configured so that the strap is slack when the sole structure is in the access position, and the front upper portion is pivoted toward the use position when the strap is pulled taut by the free end.
• In one or more embodiments of the article of footwear, the sole structure is a unitary midsole, a bottom surface of the unitary midsole defines a groove extending from the medial side to the lateral side of the sole structure, and a top surface of the unitary midsole defines a slit disposed over the groove and extending from the medial side to the lateral side. The unitary midsole forms the living hinge at the groove and the slit, with the groove wider in the first orientation than in the second orientation, and with the slit wider in the second orientation than in the first orientation.
• Within the scope of the present teachings, an article of footwear comprises a midsole having a front midsole portion, a rear midsole portion, and a living hinge extending transversely across the midsole from a medial side of the midsole to a lateral side of the midsole and connecting the front midsole portion to the rear midsole portion. The article of footwear includes a divided footwear upper including a front upper portion and a separate rear upper portion. The front upper portion is fixed to the front midsole portion and defines at least a forefoot region of the footwear upper, and the rear upper portion is fixed to the rear midsole portion and defines a heel region of the footwear upper. The front midsole portion and the rear midsole portion are selectively pivotable relative to one another at the living hinge between a use position and an access position. The midsole is lifted at the living hinge in the access position relative to the use position so that the rear midsole portion inclines from a rear end of the rear midsole portion to the living hinge, and the front midsole portion inclines from a forward end of the front midsole portion to the living hinge. A bottom surface of the midsole in the heel region has a main portion and a rearmost portion extending from and disposed at an obtuse angle to the main portion. The main portion of the bottom surface rests on a horizontal ground surface in the use position, and the rearmost portion of the bottom surface rests on the horizontal ground surface in the access position. Accordingly, the level nature of the rearmost portion of the bottom surface of the midsole provides stability when the midsole rests on the rearmost portion of the bottom surface in the access position prior to foot entry.
• In one or more embodiments of the article of footwear, the top surface of the rear midsole portion has a main portion and a rearmost portion extending from and disposed at an obtuse angle to the main portion so that the rear midsole portion has a ridge between the rearmost portion of the bottom surface and the rearmost portion of the top surface.
• In one or more embodiments of the article of footwear, the rear upper portion includes an elastic biasing member that extends along a medial side of the article of footwear and a lateral side of the article of footwear and is secured to the article of footwear forward of the living hinge. In such embodiments, the rear upper portion serves also as the elastic biasing member. Alternatively, an elastic biasing member may be separate from the rear upper portion, and may extend around a rear periphery of the rear upper portion and along a medial side of the article of footwear and a lateral side of the article of footwear, and may be secured to the article of footwear forward of the living hinge and extend.
• A method of manufacturing footwear such as the articles of footwear described herein comprises forming a midsole having a front midsole portion, a rear midsole portion, and a living hinge that extends transversely across the midsole from a medial side of the midsole to a lateral side of the midsole and connects the front midsole portion and the rear midsole portion. In one or more embodiments, forming the midsole includes molding the midsole by one of compression molding or injection molding. Molding the midsole may include molding a bottom surface of the midsole with a groove extending from a medial side of the midsole to a lateral side of the midsole, the groove at least partially establishing the living hinge. As such, the living hinge is integral with the front and rear midsole portions as a one-piece, molded component. Forming the midsole with the living hinge by molding is simpler and may be less time consuming than manufacturing sole structures with hinges that are comprised of multiple interconnected and separately formed components.
• In one or more embodiments of the method of manufacturing footwear, molding the midsole includes molding a bottom surface of the rear midsole portion to have a main portion and a rearmost portion extending from and disposed at an obtuse angle to the main portion. Accordingly, the rearmost portion on which the footwear rests in the access position may be efficiently molded into the midsole rather than provided by cutting the midsole in a separate step after forming the midsole.
• In one or more embodiments of the method of manufacturing footwear, molding the unitary midsole includes molding a top surface of the midsole with a slit that extends from the medial side of the midsole to the lateral side of the midsole above the groove, the slit partially establishing the living hinge. Molding the top surface of the midsole with the slit is contemporaneous with molding the bottom surface of the midsole with the groove.
• In one or more embodiments of the method of manufacturing footwear, the method may comprise providing a slit in a top surface of the midsole by hot knife cutting or laser cutting, with the slit extending from the medial side of the midsole to the lateral side of the midsole and disposed over the groove. The hot knifing cutting or laser cutting is carried out subsequent to molding of the unitary midsole.
• In one or more embodiments of the method of manufacturing footwear, the method comprises providing a groove in a bottom surface of the unitary midsole by hot knife cutting or laser cutting. The groove extends from a medial side of the unitary midsole to a lateral side of the unitary midsole. The hot knifing cutting or laser cutting is carried out subsequent to molding of the unitary midsole.
• In one or more embodiments of the method of manufacturing footwear, the method further comprises securing a front upper portion to the front midsole portion, and securing a rear upper portion to the rear midsole portion. The rear upper portion is divided from the front upper portion.
• In one or more embodiments of the method of manufacturing footwear, the method further comprises securing an elastic biasing member to the article of footwear forward of the living hinge so that the elastic biasing member extends along a medial aide and a lateral side of the article of footwear and around a rear periphery of the rear upper portion.
• In one or more embodiments of the method of manufacturing footwear, the method further comprises attaching a strap to a heel footbed of the front upper portion, and extending a free end of the strap through an aperture in the rear upper portion.
• In one or more embodiments of the method of manufacturing footwear, the method further comprises securing a pulley to the front midsole portion at one of the medial side of the midsole or the lateral side of the midsole, and securing at least one cable to the rear midsole portion at said one of the medial side of the midsole or the lateral side of the midsole. The at least one cable extends around the pulley and at least partially over the front upper portion. The at least one cable and the pulley are arranged so that the upper is automatically tightened when the midsole pivots to the use position from the access position.
• The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the modes for carrying out the present teachings when taken in connection with the accompanying drawings.
• Referring to the drawings, wherein like reference numbers refer to like components throughout the views,FIGS.1-3 show an embodiment of an article of footwear10 (also referred to herein as footwear10) that includes asole structure12 with a unitary midsole14 that includes a livinghinge16. As used herein, a “living hinge” is flexible hinge that is integral with two adjacent portions of a component that it hingedly connects and, in some embodiments, is made from the same material as the adjacent portions of the component. The article offootwear10 also includes a divided footwear upper18. As discussed herein, these and other features of the article offootwear10 enable an access position of the footwear (such as shown inFIG.2) that affords easy, hands-free foot entry into the article offootwear10, which adopts a use position (such as shown inFIG.1) after foot entry, also in a hands-free manner. The footwear herein is depicted as leisure shoes and athletic shoes, but the present teachings also include an article of footwear that is a dress shoe, a work shoe, a sandal, a slipper, a boot, or any other category of footwear.
• As indicated inFIG.1, thefootwear10 may be divided into three general regions: aforefoot region20, amidfoot region22, and aheel region24 which are also the forefoot region, the midfoot region, and the heel region, respectively, of the midsole14 and the upper18. Thefootwear10 also includes alateral side26 and a medial side28 (best shown inFIG.3) opposite to thelateral side26. Theforefoot region20 generally includes portions of the article offootwear10 corresponding with the toes and the joints connecting the metatarsals with the phalanges. Themidfoot region22 generally includes portions of the article offootwear10 corresponding with the arch area of the foot, and theheel region24 corresponds with rear portions of the foot, including the calcaneus bone. Thelateral side26 andmedial side28 extend through each offorefoot region20, themidfoot region22, and theheel region24 and correspond with opposite sides of the article offootwear10. Theforefoot region20, themidfoot region22, theheel region24, thelateral side26 and themedial side28 are not intended to demarcate precise areas offootwear10, but are instead intended to represent general areas offootwear10 to aid in the following discussion.
• The unitary midsole14 is depicted as a single, one-piece midsole, including the livinghinge16, but in other embodiments could be multiple components integrated as a unit. The midsole14 may be integrated with outsole components as a unisole. For example, the outsole components may be traction elements formed from a wear-resistant rubber material that may be textured to impart traction and/or may include traction elements such as cleats secured to abottom surface34 of the midsole14. The midsole14 may be formed from a compressible polymer foam element (e.g., a polyurethane or ethylvinylacetate foam) that attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. In further configurations, the midsole14 may incorporate fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot.
• The unitary midsole14 has a first portion30 and a second portion32 rearward of the first portion30. The first portion30 is also referred to as a front sole portion or a front midsole portion30, and the rear portion32 is also referred to as a rear sole portion or a rear midsole portion32. The front midsole portion30 of the unitary midsole14 includes theforefoot region20 and themidfoot region22 of the midsole14, and the rear midsole portion32 of the unitary midsole14 includes theheel region24. In order to establish a livinghinge16 in the unitary midsole14, abottom surface34 of the unitary midsole14 defines agroove36 extending from themedial side28 to thelateral side26, as best shown inFIG.3. The unitary midsole14 has atop surface38 opposite to thebottom surface34. Thebottom surface34 generally serves as the ground contact surface during wear of the article offootwear10. Thetop surface38 generally faces away from thebottom surface34, and may be referred to as a foot-facing surface as it generally faces the foot supported above it. Thetop surface38 defines aslit40 disposed over thegroove36 but not extending to the groove, and extending from themedial side28 to thelateral side26.
• The unitary midsole14 forms the livinghinge16 at thegroove36 and theslit40, with the livinghinge16 connecting the first portion30 to the second portion32 and extending transversely across the midsole14 from themedial side28 to thelateral side26. The first portion30 and the second portion32 are selectively pivotable relative to one another at the livinghinge16. For example,FIG.1 shows thefootwear10 in a first orientation, also referred to as a use position, andFIG.2 shows thefootwear10 in a second orientation, also referred to as an access position. The first portion30 and the second portion32 are pivotable relative to one another at the livinghinge16 between the first orientation and the second orientation. Thegroove36 is wider in the first orientation than in the second orientation, and theslit40 is wider in the second orientation than in the first orientation. Because the livinghinge16 is an integral portion of the one-piece midsole and seamlessly connects the first portion and the second portion, rather than being one or more additional separate components positioned between and securing two discrete front and rear midsole components, the unitary midsole14 may be lighter and easier to manufacture than other hinged sole structures.
• As illustrated inFIG.1, in the use position, the front midsole portion30, the livinghinge16, and the rear midsole portion32 are generally coplanar in a plane parallel to the plane shown in phantom representing the ground surface GS. As indicated inFIG.2, the unitary midsole14 is lifted at the livinghinge16 in the access position relative to the use position (FIG.1) so that the rear midsole portion32 inclines from arear end42 of the rear midsole portion32 to the livinghinge16, and the front midsole portion30 inclines from aforward end44 of the front midsole portion30 to the livinghinge16.
• To facilitate pivoting of thefootwear10 at the livinghinge16 and hands-free foot entry, thefootwear10 includes a divided footwear upper18. The upper18 includes a frontupper portion18A and a separate rearupper portion18B. The upper18 is referred to as divided because the frontupper portion18A and the rearupper portion18B are separate, discreet upper components that are not physically connected to one another. The frontupper portion18A is fixed to the front midsole portion30 and defines at least theforefoot region20 of the footwear upper18. In the embodiment shown, the frontupper portion18A also defines themidfoot region22. The rearupper portion18B is fixed to the rear midsole portion32 and defines theheel region24 of the footwear upper. The livinghinge16 is at the divide between the frontupper portion18A and the rearupper portion18B.
• Additionally, the frontupper portion18A may include aheel footbed46 extending rearward from the remainder of the frontupper portion18A. Arear periphery48 of theheel footbed46 is surrounded by the rearupper portion18B and overlays the rear midsole portion32 in the use position shown inFIG.1. Thetop surface38 at the rear midsole portion32 may be slightly recessed to receive theheel footbed46 which has a width less than the width between the two side walls of the rearupper portion18B. Theheel footbed46 is within the foot-receivingcavity45 formed by theupper portions18A,18B in the use position. In the access position ofFIG.2, theheel footbed46 is exposed above the rear midsole portion32, and disposed further away from the rearupper portion18B than when in the use position. In the embodiment shown, theheel footbed46 may be an integral portion of the frontupper portion18A. In other embodiments, theheel footbed46 may be an integral portion of the front midsole portion30. In still other embodiments, there may be noheel footbed46 that extends from the frontupper portion18A. Instead, each of the front and rear midsole portions30,32 would have discrete footbed portions.
• In the use position, the frontupper portion18A and the rearupper portion18B are generally contiguous as aforward edge50 of the rearupper portion18B contacts or is at least substantially adjacent to arear edge52 of the frontupper portion18A at both themedial side28 and thelateral side26. The frontupper portion18A and the rearupper portion18B define anankle opening43 that leads into a foot-receivingcavity45 in which a wearer's foot is supported and secured during use of thefootwear10. In the use position, the size of theankle opening43 is determined by afront collar portion19A and arear collar portion19B of the contiguousupper portions18A,18B. Thefootwear10 has atongue21 and alacing system23. Thelacing system23 may be adjusted to vary the size of theankle opening43 in the use position. However, due to the ability of thefootwear10 to be selectively pivoted to the access position, and to remain in the access position until use is desired, thelacing system23 may be initially adjusted to a desired tightness to obtain a desired fit in the use position, and then left at the initially set tightness during subsequent cycles of placement of thefootwear10 on the foot for use and removal of thefootwear10 from the foot.
• In the access position ofFIG.2, the frontupper portion18A and the rearupper portion18B are discontinuous with theforward edge50 and therearward edge52 significantly spaced apart from one another. In the access position, thefront collar portion19A and therear collar portion19B are separated due to the discontinuity of theupper portions18A,18B, widening the ankle opening substantially. In fact, due to the incline of the frontupper portion18A presented in the access position with the rearupper portion18B disposed entirely below the entry angle for the frontupper portion18A, a foot can slide forward into the foot-receivingcavity45 at the frontupper portion18A with the toes entering at a downward and forward trajectory, using theheel footbed46 as a guide, and without a need to stretch, open, shift, or otherwise displace any portion of thefootwear10. When the foot is inserted into the frontupper portion18A and weight is placed on the front midsole portion30, the front midsole portion30 is urged to return to the use position, and the rear midsole portion32 also returns to the use position causing the rearupper portion18B to surround a rear portion of the foot, capturing the foot within the foot-receivingcavity45.
• The rearupper portion18B may include a compliant protrusion53 (best shown inFIG.2) that protrudes forward into the foot-receivingcavity45 above theheel footbed46 when the front midsole portion30 and the rear midsole portion32 are in the use position ofFIG.1. Theprotrusion53 may be, for example, a bulge of foam padding at the inner periphery of the rearupper portion18B just under therear collar portion19B. Theprotrusion53 can be configured to help trap theheel footbed46 below theprotrusion53, and also provides enough compliance to permit thefootbed46 to move past theprotrusion53 when moving to the access position, and so that the rearupper portion18B comfortably secures to ankles of different girths.
• An elastic biasingmember54 extends along themedial side28 and thelateral side26 of the article offootwear10 and around arear periphery56 of the rearupper portion18B. Theelastic biasing member54 can be any resiliently stretchable material, such as rubber or elastic nylon. Theelastic biasing member54 is secured to the front midsole portion30 forward of the livinghinge16. Theelastic biasing member54 is shown at thelateral side26 inFIG.1, and at themedial side28 inFIG.3. Theclastic biasing member54 loops around therear periphery56 of the rearupper portion18B. The front midsole portion30 hasrecesses55 that are openings of a transverse channel in the front midsole portion30 at thelateral side26 and themedial side28, and the elastic biasingmember54 may extend through the channel and may be a continuous loop. Alternatively, the elastic biasingmember54 may have opposite ends that secure to themedial side28 and thelateral side26 of the front midsole portion30, respectively. In still other embodiments, the clastic biasingmember54 can be secured to article offootwear10 between the front midsole portion30 and the frontupper portion18A. For example, the elastic biasingmember54 can be stitched to the frontupper portion18A at a lower region of the frontupper portion18A that is then secured to theupper surface38 of the front midsole portion30. As another alternative, the elastic biasingmember54 could pass under thebottom surface34 of the front midsole portion30 (and under any outsole or outsole elements that may be secured thereto). In each alternative, the clastic biasingmember54 secures to the article offootwear10 forward of the livinghinge16 at an anchor location that causes a portion of the elastic biasingmember54 that is in tension to cross over or close to the livinghinge16 so that the livinghinge16 is a bi-stable living hinge (i.e., stable in both the use position and the access position). Theelastic biasing member54 is of a length such that it is in tension when in the use position in order to keep theupper portions18A,18B contiguous during wear, and is also in tension when thefootwear10 is in the access position ofFIG.2, in order to maintain the footwear in the access position, ready for foot entry. The tension of the elastic biasingmember54 is overcome when a foot loads thefootwear10, so that the clastic biasingmember54 is stretched during a transition from the access position to the use position.
• The article offootwear10 is configured to stably balance on a horizontal surface and remain in the access position awaiting foot entry. More specifically, thebottom surface34 of the unitary midsole14 in theheel region24 has amain portion60 and arearmost portion62 extending from and disposed at an obtuse angle A1 to themain portion60 so that themain portion60 of thebottom surface34 extends along a horizontal plane in the first orientation (i.e., the use position), and therearmost portion62 of thebottom surface34 extends along the horizontal plane in the second orientation (i.e., the access position). For example, the obtuse angle A1 may be the same as angle A of thegroove36 in the use position. Assuming themain portion60 is level in the use position, then when the groove is closed in the access position, therearmost portion62 will be level. The horizontal plane GS is indicated in phantom inFIGS.1 and2 and represents a horizontal ground surface. Accordingly, the article offootwear10 rests on themain portion60 in the use position, and rests on therearmost portion62 in the access position.
• The article offootwear10 is also configured to facilitate hands-free removal. With reference toFIG.3, thetop surface38 of the second portion32 of the unitary midsole14 has amain portion64 and arearmost portion66 extending from and disposed at an obtuse angle A2 to themain portion64 so that the second portion32 has a ridge68 (seeFIG.1 orFIG.3) between therearmost portion62 of thebottom surface34 and therearmost portion66 of thetop surface38. Therearmost portion66 extending to theridge68 protrudes sufficiently to allow an opposite foot to place a downward load thereon, causing the midsole14 to pivot at thehinge16, moving thefootwear10 to the access position, which also serves as a removal position that enables hands-free withdrawal of the foot from the foot-receivingcavity45.
• FIGS.4-10 depict another embodiment of an article offootwear110 within the scope of the present teachings. The article offootwear110 has many of the same features as the article offootwear10, some of which are indicated with like reference numbers. The description of the corresponding features of the article offootwear10 applies equally to the article offootwear110. For example, the article offootwear10 has asole structure112 with amidsole114 that is depicted as a unitary, one-piece midsole, including the livinghinge16, but in other embodiments could be multiple components integrated as a single unit.
• Theunitary midsole114 has afirst portion130 and asecond portion132 rearward of thefirst portion130. Thefirst portion130 is also referred to as a front sole portion or afront midsole portion130, and therear portion132 is also referred to as a rear sole portion or arear midsole portion132. Thefront midsole portion130 of theunitary midsole114 includes theforefoot region20 and themidfoot region22 of themidsole114, and therear midsole portion132 of theunitary midsole114 includes theheel region24. In order to establish aliving hinge116 in the unitary midsole14, abottom surface134 of the unitary midsole14 defines agroove136 extending from themedial side28 to thelateral side26. Theunitary midsole114 has atop surface138 opposite thebottom surface134. Thebottom surface134 generally serves as the ground contact surface during wear of the article offootwear110. Thetop surface138 generally faces away from thebottom surface134, and may be referred to as a foot-facing surface as it generally faces the foot supported above it. Thetop surface138 defines aslit140 disposed over thegroove136 and extending from themedial side28 to thelateral side26.
• The livinghinge116 that is alike in all aspects to midsole14 with livinghinge16 except that theslit40 of the midsole14 is replaced with a morecomplex slit140. With reference toFIGS.6 and7, theslit140 includes amain portion140A extending downward from thetop surface138 of themidsole114 toward thegroove136 and having adistal end141 spaced above the groove136 (i.e., stopping short of and not extending all of the way to the groove136). Theslit140 has afront branch140B extending from thedistal end141 of themain portion140A into thefront midsole portion130 and terminating above the bottom surface134 (i.e., stopping short of and not extending all of the way to the bottom surface134). Theslit140 also has arear branch140C extending from thedistal end141 of themain portion140A into therear midsole portion132 and terminating above the bottom surface134 (i.e., stopping short of and not extending all of the way to the bottom surface134).
• As is evident inFIG.6, theunitary midsole114 has afront wall135 and arear wall137 in thebottom surface134 at thegroove136. Thefront branch140B of theslit140 extends above thefront wall135, and therear branch140C of theslit140 extends above therear wall137. In the embodiment shown, thewalls147A,147B of themidsole114 at thefront branch140B are parallel to thefront wall135, and thewalls147C,147D of themidsole114 at therear branch140C are parallel to therear wall137 when themidsole114 is in the use position ofFIG.6. Thebranches140B,140C of theslit140 need not be parallel with thewalls135,137 at thegroove136 in other embodiments, but are configured in all embodiments so that thebranches140B,140C relieve stress of themidsole114 at themain portion140A of theslit140.
• The livinghinge116 connects thefirst portion130 and thesecond portion132 so that thefirst portion130 and thesecond portion132 are selectively pivotable relative to one another at the living hinge between the first orientation (the use position) ofFIGS.4-6 and a second orientation (the access position) ofFIGS.7-10. As is evident inFIGS.6-7, thegroove136 is wider in the first orientation than in the second orientation, and theslit140 is wider in the second orientation than in the first orientation.
• Thewalls141A,141B of themidsole114 at themain portion140A may be in contact when thefootwear110 is in the use position. Thewalls147A,147B of thefront branch140B may be in contact with one another when thefootwear110 is in the use position. Thewalls147C,147D of therear branch140C may be in contact when thefootwear110 is in the use position. Thebranches140B,140C thus provide added surface area at thewalls147A-147D over which compressive forces may be borne. Thebranches140B,140C also allow theslit140 to open from the Y-shape ofFIG.6 to the W shape ofFIG.7. As is evident inFIG.7, stress at theliving hinge116 is distributed over two valleys V1 and V2 (which are the distal ends of thebranches140B,140C) and the material between the valleys V1 and V2, rather than concentrated at a single valley as would be the case with a simple straight slit (e.g., at the end ofslit40 inFIG.1). Thecomplex slit140 thus relieves stress at theliving hinge116.
• Other example embodiments of living hinges with complex slits that may be used in themidsole114 ofFIG.4 in lieu of theslit140 are illustrated inFIGS.23-25.FIG.23 shows aliving hinge516 established by agroove536 in thebottom surface134 of themidsole114 and acomplex slit540 extending from thetop surface138 of themidsole114 and disposed over thegroove536. Thebottom surface134 of the midsole at thegroove536 has a roundedportion539 under theslit540 rather than a V-shaped portion as with thegroove136. Theslit540 includes amain portion540A, afront branch540B extending from the distal end of themain portion140A into thefront midsole portion130 and terminating above thebottom surface134 of the midsole114 (i.e., stopping short of and not extending all of the way to the bottom surface134). Theslit540 also has arear branch540C extending from the distal end of themain portion540A into therear midsole portion132 and terminating above thebottom surface134 of the midsole114 (i.e., stopping short of and not extending all of the way to the bottom surface134). Thebranches540B,540C are nonlinear, extending downwardly at a gradually changing slope. Therounded portion539 and the nonlinear, slopedbranches540B,540C encourage bending and stress distribution in the region of theliving hinge516 below thebranches540B,540C and above thegroove536.
• FIG.24 shows aliving hinge616 established by thegroove136 in thebottom surface134 of themidsole114 and acomplex slit640 extending from thetop surface138 of themidsole114 and disposed over thegroove636. Thebottom surface134 of themidsole114 at thegroove136 has a V-shape as inFIG.4. Theslit640 includes amain portion640A, afront branch640B extending from the distal end of themain portion640A into thefront midsole portion130 and terminating above thebottom surface134 of the midsole114 (i.e., stopping short of and not extending all of the way to the bottom surface134). Theslit640 also has arear branch640C extending from the distal end of themain portion640A into therear midsole portion132 and terminating above thebottom surface134 of the midsole114 (i.e., stopping short of and not extending all of the way to the bottom surface134). Thebranches640B,640C are nonlinear, extending first horizontally and then downwardly at an angle from the horizontal portion. Thenonlinear branches640B,640C encourage bending and stress distribution in the region of theliving hinge616 below thebranches640B,640C and above thegroove636.
• FIG.25 shows aliving hinge716 established by agroove736 in thebottom surface134 of themidsole114 and acomplex slit740 extending from thetop surface138 of themidsole114 and disposed over thegroove736. Thebottom surface134 of themidsole114 at thegroove736 has straight front and rear walls and a flattenedapex739 between the walls. Theslit740 includes amain portion740A, afront branch740B extending from the distal end of themain portion740A into thefront midsole portion130 and terminating above thebottom surface134 of the midsole114 (i.e., stopping short of and not extending all of the way to the bottom surface134). Theslit740 also has arear branch740C extending from the distal end of themain portion740A into therear midsole portion132 and terminating above thebottom surface134 of the midsole114 (i.e., stopping short of and not extending all of the way to the bottom surface134). Thebranches740B,740C are nonlinear, extending first horizontally and then downwardly at an angle from the horizontal portion. Thenonlinear branches740B,740C encourage bending and stress distribution in the region of theliving hinge716 below thebranches740B,740C and above thegroove736. The flattenedapex739 helps prevent stress concentrations above thegroove736.
• As illustrated inFIGS.4-6, in the use position, thefront midsole portion130, the livinghinge116, and therear midsole portion132 are generally coplanar in a plane parallel to the plane representing the ground surface GS (shown in phantom inFIG.4). Theunitary midsole114 is lifted at theliving hinge116 in the access position (FIGS.7-10) relative to the use position (FIGS.4-6) so that therear midsole portion132 inclines from arear end142 of therear midsole portion132 to theliving hinge116, and thefront midsole portion130 inclines from aforward end144 of thefront midsole portion130 to theliving hinge116, as best illustrated inFIG.8.
• To facilitate pivoting of the article offootwear110 at theliving hinge116, the article offootwear110 has a divided footwear upper118 with a frontupper portion118A and a rearupper portion118B. The frontupper portion118A and the rearupper portion118B are configured differently than frontupper portion18A and rearupper portion18B in that the rearupper portion118B overlaps the frontupper portion118A at themedial side28 and at thelateral side26 of thefootwear110 when the article offootwear110 is in the use position, rather than simply abutting at edges asupper portions18A,18B abut atedges50,52. The frontupper portion118A has aheel footbed146 best shown inFIG.10. Theheel footbed146 may be an integral portion of the frontupper portion118A. In other embodiments, theheel footbed146 may be an integral portion of thefront midsole portion130. Arear periphery148 of theheel footbed146 is surrounded by the rearupper portion118B and overlays therear midsole portion132 in the use position shown inFIG.4. Theheel footbed146 is within the foot-receivingcavity145 formed by theupper portions118A,118B in the use position. Thetop surface138 of therear midsole portion132 may be slightly recessed to receive theheel footbed146 which has a width less than the width between the twoside walls117A,117B of the rearupper portion118B. In the access position ofFIGS.8-10, theheel footbed146 is exposed above therear midsole portion132, and disposed further away from the rearupper portion118B than when in the use position.
• The frontupper portion118A has a rear portion159 that extends upward and around therear periphery148 of theheel footbed146 from the lateral side26 (seeFIG.8) to the medial side28 (seeFIG.10). The rear portion159 has alateral wall159A, amedial wall159B, and a rear wall159C connecting thelateral wall159A and themedial wall159B so that thewalls159A,159B,159C form a continuous inner heel cup. The rear portion159 is disposed laterally inward of the medial and lateral sides of the rearupper portion118B when the article offootwear110 is in the use position. More specifically, as shown inFIG.4, alateral wall117A of the rearupper portion118B is laterally outward of and adjacent to thelateral wall159A of the rear portion159 of the frontupper portion118A in the use position. Amedial wall117B of the rearupper portion118B is laterally outward of and adjacent to themedial wall159B of the rear portion159 of the frontupper portion118A in the use position. As used herein, a component is laterally outward of another component if it is further from a longitudinal axis of the footwear in a transverse direction of the footwear (i.e., along the width of the footwear). The footwear upper118 thus has a double wall thickness at theheel portion24 due to the overlapping frontupper portion118A and rearupper portion118B. The double wall thickness lends lateral stability to theheel region24 of the upper118 in the use position.
• The rearupper portion118B includes acompliant protrusion153 best shown inFIGS.4,8 and10 that protrudes forward into the foot-receivingcavity145 above theheel footbed146 when thefront midsole portion130 and therear midsole portion132 are in the use position. Theprotrusion153 may be, for example, foam padding at the inner periphery of the rearupper portion118B. Theprotrusion153 can be configured to be disposed above theheel footbed146 in the use position to help trap theheel footbed146 below theprotrusion153, but also provides enough compliance both to permit thefootbed146 to move past theprotrusion153 when moving to the access position, and so that the rearupper portion118B comfortably secures to ankles of different girths.
• The frontupper portion118A and the rearupper portion118B define theankle opening143 that leads into the foot-receivingcavity145 in which a wearer's foot is supported and secured during use of thefootwear110. In the use position, the size of theankle opening143 is determined by thewalls159A,159B,117A,117B of the overlappingupper portions118A,118B. Thefootwear110 has atongue121 and alacing system123. Thelacing system123 may be adjusted to vary the size of theankle opening143 in the use position. However, due to the ability of thefootwear110 to be selectively pivoted to the access position, and to remain in the access position until use is desired, thelacing system123 may be initially adjusted to a desired tightness to obtain a desired fit in the use position, and then left at the initial tightness setting during subsequent removals of thefootwear110 from the foot and placement of thefootwear110 on the foot.
• In the access position, the frontupper portion118A and the rearupper portion118B do not overlap, and thewalls159A,159B are separated from (i.e., not adjacent to) thewalls117A,117B, widening the ankle opening substantially. In fact, due to the incline of the frontupper portion118A presented in the access position, a foot can slide forward into the foot-receivingcavity145 at the frontupper portion118A with the toes entering at a downward and forward trajectory using theheel footbed146 as a guide, and without a need to stretch, open, shift, or otherwise displace any portion of thefootwear110, because the rearupper portion118B is disposed entirely below the entry angle for the frontupper portion118A. When the foot is inserted into the frontupper portion118A and weight is placed on thefront midsole portion130, thefront midsole portion130 is urged to return to the use position, causing theliving hinge116 to pivot back to the use position, and the rearupper portion118B to surround a rear portion of the foot, capturing the foot within the foot-receivingcavity145.
• Anelastic biasing member154 is secured at themedial side28 of thefront midsole portion130 and at thelateral side26 of thefront midsole portion130 and extends around arear periphery156 of the rearupper portion118B. Theelastic biasing member154 can be any resiliently stretchable material, such as rubber or elastic nylon. Theelastic biasing member154 may loop around therear periphery156 of the rearupper portion118B and is secured to both themedial side28 and thelateral side26 of thefront midsole portion130, or theelastic biasing member154 may have a medial side component and a separate lateral side component. Theelastic biasing member154 may have ends that secure to thefront midsole portion130 inrecesses155 at the opposite sides, or therecesses155 may be openings of a transverse channel in thefront midsole portion130 that opens at thelateral side26 and themedial side28, and theelastic biasing member154 may be a continuous loop that extends through the channel. In still other embodiments, theelastic biasing member154 can be secured to article offootwear110 between thefront midsole portion130 and the frontupper portion118A. For example, theelastic biasing member154 can be stitched to the frontupper portion118A at a lower region of the frontupper portion118A that is then secured to theupper surface138 of thefront midsole portion130. As another alternative, theclastic biasing member154 could pass under thebottom surface134 of the front midsole portion130 (and under any outsole or outsole elements that may be secured thereto). In each alternative, theelastic biasing member154 secures to thefootwear110 forward of theliving hinge116 at an anchor location that causes a portion of theelastic biasing member154 that is in tension to cross over or close to theliving hinge116 so that theliving hinge116 is a bi-stable living hinge (i.e., stable in both the use position and the access position). Theelastic biasing member154 is of a length such that it is in tension when in the use position in order to keep theupper portions118A,118B contiguous during wear, and is also in tension when thefootwear10 is in the access position ofFIG.8, in order to maintain thefootwear110 in the access position, ready for foot entry.
• The article offootwear110 is configured to stably balance on a horizontal surface and remain in the access position awaiting foot entry. More specifically, with reference toFIG.9, thebottom surface134 of theunitary midsole114 in theheel region24 has amain portion160 and arearmost portion162 extending from and disposed at an obtuse angle A1 to themain portion160 so that themain portion160 of thebottom surface134 extends along a horizontal plane in the first orientation (i.e., the use position, seeFIG.4), and therearmost portion162 of thebottom surface134 extends along the horizontal plane in the second orientation (i.e., the access position, seeFIG.8). The horizontal plane GS is indicated in phantom inFIGS.4 and8 and represents a horizontal ground surface. Accordingly, the article offootwear110 rests on themain portion160 in the use position, and rests on therearmost portion162 in the access position. The angle A1 may be the same as the angle between the walls of thegroove136 when thegroove136 is in the use position so that therearmost portion162 is level when the groove closes (i.e., such as in the access position)
• The article offootwear110 is also configured to facilitate hands-free removal. Thetop surface138 of thesecond portion132 of theunitary midsole114 has a main portion164 (seeFIGS.5 and7) and arearmost portion166 extending from and disposed at an obtuse angle A2 to themain portion164 so that thesecond portion132 has aridge168 between therearmost portion162 of thebottom surface134 and therearmost portion166 of thetop surface138. Therearmost portion166 extending to theridge168 protrudes sufficiently to allow an opposite foot to place a downward load thereon, causing themidsole114 to pivot at theliving hinge116 to move thefootwear110 to the access position. The access position also serves as a removal position that enables hands-free withdrawal of the foot from the foot-receivingcavity145.
• FIGS.11-14 depict another embodiment of an article offootwear210 within the scope of the present teachings. The article offootwear210 has many of the same features as the articles offootwear10 and110, some of which features are indicated with like reference numbers. The description of the corresponding features of the articles offootwear10 and110 applies equally to the article offootwear210. For example, the article offootwear210 includes themidsole114 with theliving hinge116, with thebottom surface134 with therearmost portion162 that provides stability for thefootwear210 resting in the access position, and thetop surface138 with therearmost portion166 that enable thefootwear210 to be removed in a hands-free manner.
• The article offootwear210 includes a divided footwear upper218 with a frontupper portion218A and a rearupper portion218B. The frontupper portion218A functions the same as and has the same features as frontupper portion118A, except that it is a laceless style. The rearupper portion218B functions the same as and has the same features as the rearupper portion118B except thatwalls117A,117B and theelastic biasing member154 are replaced withwalls217A,217B that establish therear periphery256 of the rearupper portion118B and are secured to the lateral andmedial sides26,28 of thefront midsole portion130. Similarly as discussed with respect toelastic midsole portion154, thewalls217A,217B can be secured to thefootwear210 anywhere forward of theliving hinge116 such that portions in tension cross over or close to theliving hinge116 along the lateral and medial sides of the article offootwear210. For example, thewalls217A,217B can be stitched to the frontupper portion218A at a lower region of the frontupper portion218A that is then secured to theupper surface138 of thefront midsole portion130. As another alternative, thewalls217A,217B could pass under thebottom surface134 of the front midsole portion130 (and under any outsole or outsole elements that may be secured thereto). Thewalls217A,217B can be part of a continuous loop that passes through a channel in thefront midsole portion130 that opens at the medial and lateral sides. Thewalls217A,217B are of an elastic material, such as a stretchable nylon so that thewalls217A,217B also serve as the elastic biasing member. The rearupper portion218B thus includes the elastic biasing member.
• The rearupper portion218B overlaps the frontupper portion218A in the use position ofFIG.11 as thewalls217A,217B are disposed laterally outward oflateral side wall259A and amedial side wall259B, respectively, of the frontupper portion218A when the article offootwear210 is in the use position. Arear periphery148 of theheel footbed146 is surrounded by the rearupper portion218B and overlays therear midsole portion132 in the use position shown inFIG.11. As best shown inFIGS.13-14, therear midsole portion132 has arear lip167 that extends upward and rearward of theheel footbed146 and supports the rearupper portion218B. Theheel footbed146 is within the foot-receivingcavity245 formed by theupper portions218A,218B in the use position. In the access position ofFIG.12, theheel footbed146 is exposed above therear midsole portion132, and is disposed further away from the rearupper portion218B than when in the use position. An ankle opening in the access position is thus larger than theankle opening243 formed by theupper portions218A,218B in the use position.
• FIGS.15-17 show another embodiment of an article offootwear310 within the scope of the present teachings. The article offootwear310 has many of the same features as the articles offootwear10,110, and210, some of which are indicated with like reference numbers. The description of the corresponding features of the articles offootwear10,110,210 applies equally to the article offootwear310. For example, the article offootwear310 includes asole structure312 with aliving hinge316. Thesole structure312 includes a midsole314 and anoutsole315 secured to a bottom surface of the midsole314. Theoutsole315 is a full-length outsole with aforefoot region20, amidfoot region22, and aheel region24. The midsole314 has aslit340 that extends to theoutsole315. Theslit340 divides the midsole314 into afront midsole portion330, also referred to as a front sole portion, and arear midsole portion332, also referred to as a rear sole portion. Thefront midsole portion330 and therear midsole portion332 can be formed as one-piece with a slit molded in or cut after molding, or themidsole portions330,332 can be separately molded. In the use position, thefront midsole portion330, therear midsole portion332, and theliving hinge316 are substantially coplanar in a plane parallel to the horizontal ground surface GS. Theoutsole315 has a bottom surface with arearmost portion362 on which thefootwear310 rests and that provides stability for thefootwear310 resting in the access position ofFIG.17. In the access position ofFIG.17, thesole structure312 is lifted at theliving hinge316 relative to the use position ofFIG.15 so that the rearsole portion332 inclines from arear end342 to theliving hinge316, and the frontsole portion330 inclines from aforward end344 to theliving hinge316, as shown inFIG.17.FIG.16 is a position between the use position ofFIG.15 and the access position ofFIG.17. In the access position, theslit340 opens, and theoutsole315 functions as aliving hinge316 below theopen slit340.
• The article offootwear310 includes a divided footwear upper318A,318B with a frontupper portion318A and a rearupper portion318B. The frontupper portion318A functions the same as and has the same features as frontupper portion118A. The rearupper portion318B functions the same as and has the same features as the rearupper portion118B. In the use position, the front and rearupper portions318A,318B overlap at theheel region24. More specifically, side walls359 (one shown inFIG.16) of the rear portion of the frontupper portion318A overlap with side walls317 (one shown) of the rearupper portion318B.
• The frontupper portion318A overlaps the rearupper portion318B in the use position ofFIG.15 as the side walls317 (one visible in the side view shown) are disposed laterally outward ofside walls359 of a rear portion of the frontupper portion318A when the article offootwear310 is in the use position. Arear periphery348 of theheel footbed346 extending rearward from the frontupper portion318A is surrounded by the rearupper portion318B and overlays therear midsole portion332 in the use position shown inFIG.15. In the access position ofFIG.17, theheel footbed346 is exposed above therear midsole portion332, and disposed further away from the rearupper portion318B than when in the use position. The rearupper portion318B may have a protrusion353 (seeFIG.15) that extends into the foot-receivingcavity345 and is disposed above theheel footbed346 in the access position, similar toprotrusion153. Anankle opening343 in the access position is thus larger than the ankle opening formed by theupper portions318A,318B in the use position. Access to the foot-receivingcavity345 is thus easier in the access position, as discussed with respect tofootwear110.
• There is no elastic biasing member secured to thefront midsole portion330 in the article offootwear310. Instead, thefootwear310 includes astrap380. Thestrap380 has a fixedend382 secured to theheel footbed346 and afree end384 extending through anaperture386 in the rearupper portion318B. Thestrap380 has a length configured so that thestrap380 is slack when the midsole314 is in the access position ofFIG.17, and the frontupper portion318A pivots toward the use position when thestrap380 is pulled taut by thefree end384. Thestrap380 may be pulled taut by the weight of a foot entering the frontupper portion318A in the access position, returning thefootwear310 to the use position. Thestrap380 may also be manually pulled to return thefootwear310 to the use position. Thestrap380 also prevents over-extension of theliving hinge316 by limiting the maximum pivot of themidsole portions330,332 relative to one another to an orientation in which thestrap380 becomes taut.
• FIGS.18-22 show another embodiment of an article offootwear410. The article offootwear410 includes theunitary midsole114 with all of the features and functions as described with respect toFIGS.4-10, including thegroove136 and theslit140 at which themidsole114 forms theliving hinge116, or any of the alternative living hinge configurations described herein. The article offootwear410 also includes a divided upper418 with a frontupper portion418A and a rearupper portion418B. The frontupper portion418A includes arear portion459 with lateral and medial walls459A,459B, respectively (seeFIG.21), and the rearupper portion418B has lateral andmedial walls417A,417B that overlap with the walls459A,459B when theheel footbed446 extending rearward from the frontupper portion418A overlies therear midsole portion132 and thefootwear410 is in the use position ofFIGS.18-20, similarly as described with respect towalls117A,117B,159A,159B ofFIG.4. Anelastic biasing member454 that functions identically as biasingmember154 is secured to the medial and lateral sides of thefront midsole portion130 of theunitary midsole114 in the same manner as biasingmember154, and may extend transversely through themidsole114 as described with respect to biasingmember154 or may have any of the other configurations described with respect to biasingmember154.
• The frontupper portion418A and the rearupper portion418B define the ankle opening443 (seeFIG.18), that leads into the foot-receivingcavity445 in which a wearer's foot is supported and secured during use of thefootwear410. In the use position, the size of theankle opening443 is determined by thewalls459A,459B,417A,417B of the overlappingupper portions418A,418B. In the access position, theupper portions418A,418B are separated, with the rearupper portion418B below theheel footbed446, and theankle opening443 is widened relative to the size of theankle opening443 in the use position.
• The article offootwear410 includes acinching system490 for tightening the footwear upper418 in the use position. Thecinching system490 is shown and described with respect to the article offootwear410, but could also be used on any of the articles of footwear within the scope of the present teachings, such as articles offootwear10,110,210, and310. Thecinching system490 includes at least onecable492 extending at least partially over the frontupper portion418A and secured to therear midsole portion132 at one of thelateral side26 or themedial side28 of theunitary midsole114. The at least onecable492 may be a cord, a wire, a string, a strand, a lace, or another elongated tensile element.
• Thepulley494 is secured to thefront midsole portion130 at the same side at which thecable492 is secured. In the embodiment shown, there are twopulleys494, one on each of the lateral side and themedial side26,28. Asingle cable492 passes througheyelets495 and over the top of the frontupper portion418A between the twosides26,28. In an alternative embodiment, there are twocables492, one secured to each side and each anchored at a respective eyelet or elsewhere.
• As shown inFIG.19, thecable492 extends along themedial side28 and has aportion496A that passes througheyelet495. Thecable492 also has anend497A secured to themedial side28 of therear midsole portion132. Thecable492 extends along thelateral side26 and has aportion496B that passes through aneyelet495. Thecable492 also has anend497B secured to thelateral side26 of therear midsole portion132. Thecable492 extends around thefirst pulley494 between theportion496A of thefirst cable492 and thesecond end497A of thefirst cable492. Thesecond pulley494 is secured to thelateral side26 of thefront midsole portion418A. Thecable492 extends around thesecond pulley494 between theportion496B of thecable492 and theend497B of thecable492. Due to the positioning of the first end, the pulley, and the second end on each of the sides, thecable492 is relatively slack when thefront midsole portion130 and therear midsole portion132 are in the access position, and is relatively taut when thefront midsole portion130 and therear midsole portion132 are in the use position. Accordingly, when thefootwear410 returns to the use position from the access position (such as when the weight of a foot enters the foot-receivingcavity445 in the frontupper portion418A), thefootwear410 returns to the use position, and thecinching system490 is automatically tightened, pulling the frontupper portion418A snugly against the foot.
• A method of manufacturing footwear such as thefootwear10,110,210,310, and/or410 disclosed herein comprises forming a midsole having a front midsole portion, a rear midsole portion, and a living hinge extending transversely across the midsole from amedial side28 of the midsole to alateral side26 of the midsole and connecting the front midsole portion and the rear midsole portion. For example, with respect tounitary midsole114, forming theunitary midsole114 may include molding theunitary midsole114 such as by one of compression molding or injection molding. Molding theunitary midsole114 may include molding abottom surface34 of theunitary midsole114 with agroove136 extending from amedial side28 of the unitary midsole to alateral side26 of theunitary midsole114. Molding thebottom surface34 of theunitary midsole114 may also include molding the bottom surface of therear midsole portion132 with amain portion160 and arearmost portion162 extending from and disposed at an obtuse angle A1 to themain portion160.
• Molding theunitary midsole114 may include molding atop surface138 of theunitary midsole114 with aslit140, or with any of the other configurations ofslits40,540,640,740 disclosed herein. The method may include molding both thegroove136 and the slit140 (or slit40,540,640,740) in the same mold contemporaneously, without any secondary processing steps needed to provide thegroove136 and theslit140. For example, if the mold is configured with a mold cavity corresponding to an intermediate position of themidsole114 in which thegroove136 is partly closed and theslit140 is partly open, both can be molded contemporaneously.
• Alternatively, instead of molding thegroove136 and/or theslit140, the method of manufacturing footwear such asfootwear110 may instead include providing thegroove136 in thebottom surface34 of theunitary midsole114 by hot knife cutting or laser cutting, either of which would occur after molding theunitary midsole114. Thegroove136 extends from themedial side28 of theunitary midsole114 to thelateral side26 of theunitary midsole114. The method may further comprise providing aslit140 in atop surface38 of theunitary midsole114 by hot knife cutting or laser cutting. Theslit140 as provided extends from themedial side28 of the unitary midsole to thelateral side26 of the unitary midsole and is disposed over thegroove136.
• Still further, the method may include attaching an outsole to bottom surfaces of segmented front and rear midsole portions, with the outsole at least partially forming the living hinge. For example, in one embodiment, the front and rear midsole portions are segmented (i.e., not physically connected to one another), either because they are molded or otherwise formed separately, or because a formed midsole is cut or otherwise separated into portions. The outsole is secured to bottom surfaces of the segmented front and rear midsole portions. The separation between the front and rear midsole portions thereby forms a slit, while the outsole connects the front and rear midsole portions and flexes under the slit as a living hinge, as shown and described with respect tomidsole portions330,332 andoutsole315 ofFIGS.15-17.
• In yet another embodiment, themidsole114 can be provided with the groove, such asgroove136 by molding, and an outsole such asoutsole315 can be secured to abottom surface134 of themidsole114, including the portion of thebottom surface134 in thegroove136. In such an embodiment, the outsole lines the groove and portions of the outsole secured in the groove close together against one another when the groove closes.
• After the midsole is formed, the method includes securing a front upper portion such as frontupper portion118A to the front midsole portion, such asfront midsole portion130, and securing a rear upper portion such as rearupper portion118B to the rear midsole portion such asrear midsole portion132, with the rear upper portion divided from the front upper portion, such as described with respect to each of the embodiments offootwear10,110,210,310,410. The upper portions, such asupper portions118A,118B may be secured to the respective midsole portions, such asmidsole portions130,132, by thermal bonding, radio frequency welding, adhesive, stitching, or otherwise.
• After the upper portions are secured to the midsole portions, the method includes securing anelastic biasing member54 or154 to thefootwear10 or110 forward of the livinghinge16 or116, such as at thefront midsole portion30 or130 at themedial side28 of theunitary midsole14 or114 and at thelateral side26 of theunitary midsole14 or114 so that theelastic biasing member154 extends around arear periphery56 or156 of the rearupper portion18B or118B and along medial and lateral sides of the article offootwear10 or110. Alternatively, the rear upper portion itself may serve as an clastic biasing member, and may secure forward of the living hinge, such as rearupper portion218B secures forward of livinghinge116 inFIG.12. Alternatively or in addition to securing an elastic biasing member as described, the method may include attaching astrap380 to aheel footbed346 of the frontupper portion318A as described with respect to the article offootwear310. The method may also include extending afree end384 of thestrap380 through anaperture386 in the rearupper portion318B.
• With respect to the article offootwear410, the method further comprises securing apulley494 to thefront midsole portion130 at one of themedial side28 or thelateral side26, and securing at least onecable492 to therear midsole portion132 at the same one of themedial side28 or thelateral side26 of theunitary midsole114 so that the cable extends around the pulley at and at least partially over the front upper portion. The at least one cable may be a cable, a lace, or another elongated tensile element.
• “A”, “an”, “the”, “at least one”, and “one or more” are used interchangeably to indicate that at least one of the items is present. A plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., of quantities or conditions) in this specification, unless otherwise indicated expressly or clearly in view of the context, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. In addition, a disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range. All references referred to are incorporated herein in their entirety.
• The terms “comprising”, “including”, and “having” are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Orders of steps, processes, and operations may be altered when possible, and additional or alternative steps may be employed. As used in this specification, the term “or” includes any one and all combinations of the associated listed items. The term “any of” is understood to include any possible combination of referenced items, including “any one of” the referenced items. The term “any of” is understood to include any possible combination of referenced claims of the appended claims, including “any one of” the referenced claims.
• Those having ordinary skill in the art will recognize that terms such as “above”, “below”, “upward”, “downward”, “top”, “bottom”, etc., may be used descriptively relative to the figures, without representing limitations on the scope of the invention, as defined by the claims.
• While several modes for carrying out the many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not as limiting.

Claims (18)

1. An article of footwear comprising:

a midsole having a first portion and a second portion, the second portion rearward of the first portion;

a footbed; and

an upper, the upper comprising a front upper portion and a rear upper portion;

wherein the second portion of the midsole is coupled to the rear upper portion;

wherein the footbed is coupled to the front upper portion;

wherein the footbed is configured to pivot relative to the second portion of the midsole between a first orientation and a second orientation, wherein at least a portion of the footbed is spaced further from the second portion of the midsole in the second orientation than in the first orientation; and

wherein, in the first orientation, the portion of the footbed is positioned underneath a protrusion coupled to an inner surface of the rear upper portion, the protrusion configured to secure the footbed in the first orientation.

2. The article of footwear ofclaim 1, wherein the protrusion is a compliant protrusion.

3. The article of footwear ofclaim 2, wherein the compliant protrusion is comprised of a foam material.

4. The article of footwear ofclaim 2, wherein:

the rear upper portion has a rear collar portion; and

the protrusion is disposed at an inner periphery of the rear upper portion under the rear collar portion.

5. The article of footwear ofclaim 1, wherein a rear periphery of the footbed is surrounded by the rear upper portion in the first orientation.

6. The article of footwear ofclaim 1, wherein an upper surface of the second portion of the midsole is recessed to receive the footbed in the first orientation.

7. An article of footwear comprising:

a sole portion;

a footbed; and

an upper, the upper comprising an upper forward portion and an upper heel portion;

wherein the sole portion is coupled to the upper heel portion;

wherein the footbed is coupled to the upper forward portion;

wherein the footbed and upper forward portion are configured to pivot relative to the sole portion between an open position, in which a rear edge of the footbed is not in contact with the sole portion, and a closed position, in which the rear edge of the footbed is in contact with the sole portion; and

wherein, in the closed position, the rear edge of the footbed is positioned underneath a protrusion coupled to an inner surface of the upper heel portion, the protrusion configured to secure the upper forward portion and the footbed in the closed position.

8. The article of footwear ofclaim 7, wherein the protrusion is a compliant protrusion.

9. The article of footwear ofclaim 8, wherein the protrusion is comprised of a foam material.

10. The article of footwear ofclaim 7, wherein:

the upper heel portion has a rear collar portion; and

the protrusion is disposed at an inner periphery of the upper heel portion under the rear collar portion.

11. The article of footwear ofclaim 7, wherein the rear edge of the footbed is surrounded by the upper heel portion in the closed position.

12. The article of footwear ofclaim 7, wherein an upper surface of the sole portion is recessed to receive the footbed in the closed position.

13. An article of footwear comprising:

a sole portion;

a footbed; and

an upper, the upper comprising an upper forward portion and an upper heel portion;

wherein the sole portion is coupled to the upper heel portion;

wherein the footbed is coupled to the upper forward portion;

wherein the footbed and upper forward portion are configured to pivot relative to the sole portion between a first orientation and a second orientation;

wherein, in the first orientation, at least a portion of a lower surface of the footbed is in contact with an upper surface of the sole portion;

wherein, in the second orientation, the at least a portion of the lower surface of the footbed is not in contact with the upper surface of the sole portion; and

wherein, in the second orientation, a portion of the footbed is positioned underneath a protrusion coupled to an inner surface of the upper heel portion, the protrusion configured to secure the footbed in the first orientation.

14. The article of footwear ofclaim 13, wherein the protrusion is a compliant protrusion.

15. The article of footwear ofclaim 14, wherein the compliant protrusion is comprised of a foam material.

16. The article of footwear ofclaim 14, wherein:

the upper heel portion has a rear collar portion; and

the protrusion is disposed at an inner periphery of the upper heel portion under the rear collar portion.

17. The article of footwear ofclaim 13, wherein a rear periphery of the footbed is surrounded by the upper heel portion in the first orientation.

18. The article of footwear ofclaim 13, wherein an upper surface of the sole portion is recessed to receive the footbed in the first orientation.

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