Shoe Last and Sole and Method of Manufacture

Abstract

A shoe last and shoe sole are provided, an underside of the shoe last comprising a forefoot cavity and a heel cavity, the shoe sole comprising a forefoot pad and a heel pad. The forefoot cavity is adapted to receive the forefoot pad. The heel cavity is adapted to receive the heel pad. A method of centering the sole on the shoe last comprises the steps of providing the shoe last and shoe sole; providing a shoe upper; positioning the shoe last in the shoe upper; using the forefoot pad and heel pad, centering the shoe last on the sole such that an upper portion of the upper heel pad nests within the heel cavity and an upper portion of the forward heel pad nests within the forefoot cavity; attaching the shoe upper to the sole; and removing the shoe last from the shoe upper.

Claims

1. A method of centering a shoe sole on a shoe last, the method comprising the steps of: providing a shoe last, the shoe last comprising a front portion and a heel portion, an underside of the shoe last comprising forefoot and heel cavities; providing a shoe sole comprising a forefoot pad and heel pad; providing a shoe upper; positioning the shoe last in the shoe upper; using the forefoot pad and heel pad, centering the shoe last on the shoe sole such that an upper portion of the upper heel pad nests within the heel cavity and an upper portion of the forward heel pad nests within the forefoot cavity; attaching the shoe upper to the shoe sole; and removing the shoe last from the shoe upper.

2. The method of claim 1, the shoe sole comprising a forefoot recess and a heel recess, wherein, the forefoot pad partially nests within the forefoot recess and the heel pad partially nests within the heel recess.

3. The method of claim 1, the forefoot cavity and forefoot pad each comprising oval configurations.

4. The method of claim 1, the heel cavity and heel pad each comprising oval configurations.

5. The method of claim 1, the shoe upper comprising a footbed fabric.

6. The method of claim 1, the forefoot cavity and the heel cavity each being interior to an outside perimeter of the shoe last.

7. A shoe last and shoe sole, in combination: the shoe last comprising: a front portion and a heel portion; an underside of the shoe last comprising a forefoot cavity and a heel cavity; the shoe sole comprising: a forefoot pad; a heel pad; wherein, the forefoot cavity is adapted to receive an upper portion of the forefoot pad; and the heel cavity is adapted to receive an upper portion of the heel pad.

8. The shoe last and shoe sole of claim 7, the shoe sole comprising a forefoot recess and a heel recess, wherein, the forefoot pad partially nests within the forefoot recess and the heel pad partially nests within the heel recess.

9. The shoe last and shoe sole of claim 7, the forefoot cavity and forefoot pad each comprising oval configurations.

10. The shoe last and shoe sole of claim 7, the heel cavity and heel pad each comprising oval configurations.

11. The shoe last and shoe sole of claim 7, the forefoot cavity and the heel cavity each being interior to an outside perimeter of the shoe last.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] FIG. 1 is a left side perspective view of a shoe last of the present invention in accordance with a preferred embodiment.

[0031] FIG. 2 is a perspective upper view of a shoe sole of the present invention in accordance with a preferred embodiment.

[0032] FIG. 3 is a lower perspective view of the shoe last of FIG. 1.

[0033] FIG. 4 depicts perspective views of cushions incorporated within shoes formed with the shoe last and sole of FIGS. 1 and 2.

[0034] FIG. 5 depicts the shoe last and sole of FIGS. 1 and 2, showing the cushions of FIG. 4. inserted within recesses of the sole generally aligned with the shoe last cavities.

[0035] FIG. 6 depicts the cushions of FIG. 4 and an arch support, the lower heel cushion inserted within the heel recess of the sole.

[0036] FIG. 7 is a perspective bottom view of the shoe sole of FIG. 2.

[0037] FIG. 8 is a conceptual cutaway side view of an assembled article of footwear with the last still in position within a shoe upper.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0038] Referring to FIGS. 1-3, there is shown the shoe last 12 and shoe sole 26 in accordance with a preferred embodiment. As used herein, the terms “a” or “an” shall mean one or more than one. The term “plurality” shall mean two or more than two. The term “another” is defined as a second or more. The terms “including” and/or “having” are open ended (e.g., comprising). The term “or” as used herein is to be interpreted as inclusive or meaning any one or any combination. Therefore, “A, B or C” means “any of the following: A; B; C; A and B; A and C; B and C; A, B and C”. An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive.

[0039] Reference throughout this document to “one embodiment,” “certain embodiments,” “an embodiment,” or similar term means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of such phrases in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner on one or more embodiments without limitation. The detailed description illustrates by way of example, not by way of limitation, the principles of the invention. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives, and uses of the invention, including what is presently believed to be the best mode of carrying out the invention.

[0040] Referring to the figures, the shoe last 12 of the preferred embodiment generally comprises a front portion 14 and a heel portion 16. The heel portion 16 is pivotally associated at 18 with the front portion 14 in the customary manner. An underside of the last 12 comprises forefoot and heel cavities 20, 22. In some embodiments, the front portion 14 comprises a protective toe strip 68 on the underside of the shoe last 12. The shoe last 12 of the preferred embodiment is adapted for use with the specially configured sole 26 and foot pad arrangement 24, 28, 34.

[0041] The shoe last 12 forefoot cavity 20 is adapted to receive an upper portion of a forefoot pad 24 (FIG. 4). The heel cavity 22 is adapted to receive an upper portion of an upper heel pad 28. Although these cavities 20, 22 are adapted to receive the respective pads 24, 28, in use, in the preferred embodiment, a footbed fabric 72 integrated within a shoe upper 70 will be positioned between the shoe last 12 and the sole 26. Therefore, it is to be understood in this disclosure that when it is said that the cavities 20, 22 are adapted to receive the respective pads 24, 28, this description also describes the cavities 20, 22 receiving the pads 24, 28 as covered by the footbed fabric 72.

[0042] The forefoot pad 24 of the preferred embodiment is positioned within a forefoot recess 30 of the sole member (“sole” or “shoe sole”) 26. The upper heel pad 28 and a lower heel pad 34 are positioned within a heel recess 32 of the sole 26. As used herein, the terms “upper” (except when referring the shoe upper 70 itself), “lower”, “forward”, “rearward”, “front”, “rear”, “top”, “underside”, and “bottom” and similar terms are used to describe spatial relationships between components of the last, sole, footwear and/or between a component of the last, sole, and/or footwear and the ground. Such terms are relative to footwear positioned in an upright orientation on a ground surface. “Ground” includes interior floors and exterior surfaces such as streets, sidewalks, soil, etc.

[0043] The shoe last 12 can be formed of an appropriate solid material such as wood, metal, or plastic. In the preferred embodiment, the shoe last 12 is formed from polycarbonate material. The last 12 is utilized with conventional and commercially available footwear-making equipment and will consistently produce footwear well adapted for a variety of activities. The last 12 of the present invention is adapted for limited production runs as well as mass-production runs for a variety of footwear types. The footwear includes shoes, boots and so on. Examples of footwear include casual shoes, recreational shoes, athletic shoes, outdoor shoes and dress shoes. Further examples of footwear include cowboy boots, western boots, riding boots, outdoor boots, hiking boots and work boots. Additional examples of footwear include specialty footwear such as military boots.

[0044] In the preferred embodiment, there are two heel pads 28, 34, the upper heel pad 28 and lower heel pad 34. However, there need not be two pads 28, 34. Rather, a single heel pad may be used, for example, comprising the combined dimensions of the upper heel pad 28 and lower heel pad 34. In the preferred embodiment, the upper heel pad 28 and lower heel pad 34 each comprise an oval outside configuration when viewed in plan view. Thus, the upper heel pad 28 and lower heel pad 34 each have a greater length than width. In the preferred embodiment, the upper heel pad 28 and lower heel pad 34 have the same length and width dimensions. As best shown in FIG. 4, the lower heel pad 34 of the preferred embodiment comprises a depth that is greater at a heel pad rearward portion 40 than at a heel pad forward portion 42. In the preferred embodiment, the lower heel pad 34 has a thickness of approximately 12 mm at the heel pad rearward portion 40 and 7 mm at the heel pad forward portion 42. The upper heel pad 28 has a thickness of approximately 12 mm. Thus, the combined thickness of the two heel pads 28, 34 is approximately 24 mm at the rear and 19 mm at the front. In the preferred embodiment, the overall length of each of the upper heel pad 28 and lower heel pad 34 is approximately 66 mm. The overall width of both the upper heel pad 28 and lower heel pad 34 is approximately 43 mm. However, the length and widths of the upper heel pad 28 and lower heel pad 34 need not be confined to these dimensions. Rather, the upper heel pad 28 and lower heel pad 34 can comprise greater or lesser widths, thicknesses, and lengths. Additionally, although the heal pads 28, 34 when combined have a different combined height at the front and rear, the heal pads 28, 34 can have the same identical heights at the front and rear. In some embodiments, the depth of the heel recess 32 (discussed in more detail below) may vary between the front and back which, would re-create the forward slope of the combined heel pads 28, 34.

[0045] In the preferred embodiment, the forefoot pad 24 comprises an oval outside configuration when viewed in plan view. Thus, the forefoot pad 24 has a greater length than width. In the preferred embodiment, the overall length of forefoot pad 24 is approximately 116 mm. The overall forefoot pad 24 is approximately 74 mm. The forefoot pad 24 of the preferred embodiment has a thickness of approximately 6 mm. However, the length, width, and thickness of the forefoot pad 24 need not be confined to these dimensions. Rather, the forefoot pad 24 can comprise a greater or lesser length, width, and/or thickness.

[0046] As shown, for example, in FIGS. 2 and 7, the sole 26 comprises an upper surface 54, a lower surface 56, a heel 50, the heel recess 32, and the forefoot recess 30. The sole 26 of the preferred embodiment is formed from rubber, thermoplastic rubber (TRP), Acrylonitrile Butadiene Styrene (ABS), Polyvinyl chloride (PVC), polyurethane, or other suitable natural or manmade materials well known in the art. In the preferred embodiment, the sole 26 is formed by injection molding. However, the sole 26 can be formed by other conventional process known in the art.

[0047] The heel recess 32 of the sole 26 comprises an opening in the upper surface 54 corresponding to the heel 50 such that the heel 50 is partially hollow. The heel recess 32 comprises a depth that is greater at a heel recess rearward portion 44 than at a heel recess forward portion 46. In the preferred embodiment, the depth of the heel recess 32 at the heel recess forward portion 46 is approximately 47 mm and 22 mm at the heel recess forward portion 46. An upper surface 48 of the heel recess 32 (the bottom of the heel recess 32) is preferably approximately parallel-planar with a lower outside surface 52 of the heel 50. A heel recess perimeter 62 is partially defined by a series of posts 60. The heel recess perimeter 62 comprises a generally oval configuration. Thus, the perimeter 62 has a greater length than width. In the preferred embodiment, the heel recess 32 perimeter 62 has slightly larger length and width dimensions than those of the upper heel pad 28 and lower heel pad 34.

[0048] The forefoot recess 30 of the sole 26 comprises an opening in the upper surface 54. The forefoot recess 30 comprises a depth. In the preferred embodiment, the depth of the forefoot recess 30 is approximately 2 mm. The forefoot recess 30 has an oval outside configuration when viewed in plan view. Thus, the forefoot recess 30 has a greater length than width. In the preferred embodiment, the forefoot recess 30 has slightly larger length and width dimensions than those of the forefoot pad 24.

[0049] In the preferred embodiment, portions of the forefoot pad 24 and the upper heel pad 28 are above the upper surface 54 of the shoe sole 26. As discussed herein, this positioning permits portions of the pads 24, 28 to nest within the respective cavities 20, 22 of the shoe last 12.

[0050] Referring, for example, to FIGS. 5 & 6, optionally, the sole 26 comprises an arch support recess 58 adapted to receive an arch support 64. In the preferred embodiment, the arch support 64, when nesting within the arch support recess 58 is flush with the upper surface 54. In the preferred embodiment, the arch support 64 and arch support recess 58 each comprise an expanded “X” configuration. A forward most end of the “X” is wider than a rearward portion. Flex slots 66 or “V” shaped cutouts are positioned in the crotch of the rearward portion of the arch support 64. These slots 66 permit lateral flexion of the sole 26.

[0051] Regarding the shoe last 12, the heel cavity 22 of the preferred embodiment comprises an oval outside configuration when viewed in plan view. Thus, the heel cavity 22 comprises a greater overall length than overall width. The overall length of the heel cavity 22 is slightly larger than the overall length of the upper heel pad 28. Similarly, the overall width of the heel cavity 22 is slightly larger than the overall width of the upper heel pad 28. The heel cavity 22 has a depth that permits the upper portion of the upper heel pad 28 to nest within the heel cavity 22. In the preferred embodiment, the depth of the heel cavity 22 is approximately 2 mm. However, the depth of the heel cavity 22 need not be 2 mm. Rather, the depth of the heel cavity 22 can be more or less than 2 mm. For example, the depth of the heel cavity 22 can range from 1 mm to 17 mm or more. The heel cavity 22 of the preferred embodiment has an overall length of approximately 69 mm and an overall width of approximately 47 mm. However, these dimensions may vary depending on a number of factors, including, for example, shoe size.

[0052] The forefoot cavity 20 of the preferred embodiment comprises an oval outside configuration when viewed in plan view. Thus, the forefoot cavity 20 comprises a greater overall length than overall width. The overall length of the forefoot cavity 20 is slightly larger than the overall length of the forefoot pad 24. Similarly, the overall width of the forefoot cavity 20 is slightly larger than the overall width of the forefoot pad 28. The heel cavity 22 has a depth that permits the upper portion of the upper heel pad 28 to nest within the forefoot cavity 20. In the preferred embodiment, the depth of the forefoot cavity 20 is approximately 2 mm. However, the depth of the forefoot cavity 20 need not be 2 mm. Rather, the depth of the forefoot cavity 20 can be more or less than 2 mm. For example, the depth of the forefoot cavity 20 can range from 1 mm to 17 mms or more. The heel cavity 22 of the preferred embodiment has an overall length of approximately 120 mm and an overall width of approximately 77 mm. However, these dimensions may vary depending on such factors as those discussed above.

[0053] Referring to FIGS. 4-6, in the preferred embodiment, the forefoot pad 24 and upper heel pad 28 contain balls 36 or spheres. The balls 36 are solid and are made of a resilient material such as thermoplastic rubber (TPR), polyurethane (PU), polyethylene or ethylene-vinyl acetate rubber (EVA). In embodiments not containing balls 36, the forefoot pad 24, and heel pads 34, 28 may be formed from TPR, PU, EVA, ABS, foam, polystyrene, or other suitable material providing a cushioning properties. The balls 36 in the forefoot pad 24 are smaller than the balls in the upper heel pad 28. In some embodiments, actual size of the balls 23 depends on the sole 26 size which is a function of shoe size (with larger sole 26 sizes having larger balls 36 than smaller sole 26 sizes). For example, the balls 36 in the forefoot pad 24 can be 4-12 mm in diameter, while the balls 36 in the upper heel pad 28 can be 8-18 mm in diameter. In the embodiments shown in FIGS. 4-6, the balls 36 in the forefoot pad 24 are approximately 3 mm in diameter and the balls 36 in the upper heel pad 28 are approximately 15 mm. The balls 36 may be separated from one another or connected to one another at edges or by a pin or rod (not shown).

[0054] The balls 36 (or parts of balls) are encased in a flexible resilient matrix material 38. The matrix material 38 fills the spaces between the balls 36 thereby preventing the balls 36 from moving with respect to one another. In preferred embodiments, the tops and bottoms of the balls 36 are visible at the respective top and bottom surfaces of the forefoot and upper heal pads 24, 28. This allows the resiliency of the balls 36 to be utilized when foot pressure is applied. The matrix material 38 is made of a flexible and resilient material such as polyurethane.

[0055] In use, the forefoot pad 24 is inserted within the forefoot recess 30. The lower heel pad 34 and upper heal pad 28 are inserted within the heel recess 32 with the lower heel pad 34 below the upper heel pad 28, the heel pad rearward portion 40 being closer to the rear of the sole 26 than the heel pad forward portion 42. The shoe last 26 is positioned in a shoe upper 70. Then, using the forefoot and heel pads 24, 28 the sole 26 and the shoe last 26 are centered such that the upper portion of the upper heel pad 28 nests within the heel cavity 22 and the upper portion of the forward heel pad 24 nests within the forefoot cavity 20. The shoe upper 70 is then attached to the sole 26 either mechanically such as with nails, threads, or other conventional coupling device or adhesively, such as with glue or cement. The shoe last 12 is then removed from the upper 70.

[0056] The method of the preferred embodiment comprises the steps of providing a shoe last 12, the shoe last 12 comprising a front portion 14 and a heel portion 16, the heel portion 16 being pivotally associated with the front portion 14; an underside of the shoe last 12 comprising forefoot and heel cavities 20, 22; providing a sole 26 comprising heel and forefoot recesses 32, 30, the heel recess 32 being adapted to receive one or more heel pads 34, 28, the forefoot recess 30 being adapted to receive one or more forefoot pads 24; providing a shoe upper 70; positioning the shoe last 26 in the shoe upper 70; using the forefoot and heel pads 24, 28 centering the sole 26 and the shoe last 26 such that the upper portion of the upper heel pad 28 nests within the heel cavity 22 and the upper portion of the forward heel pad 24 nests within the forefoot cavity 20; attaching the shoe upper 70 to the sole 26; removing the shoe last 12 from the shoe upper 70.

[0057] In preferred embodiments, the shoe upper 70 comprises a footbed fabric 72. In such embodiments, respective portions of the footbed fabric 72 are pressed by the respective forefoot and heel pads 24, 28 into the respective forefoot and heel cavities 20, 22.

[0058] In other embodiments, the heel recess 32 comprises a sloped bottom 48.

[0059] In other embodiments, the heel recess 32 comprises vertical posts 60 defining a perimeter.

[0060] In other embodiments the heel pad 28 comprises balls 36.

[0061] In other embodiments the forefoot pad 24 comprises balls 36.

[0062] In other embodiments the balls 36 are surrounded by a matrix material 38.

[0063] In other embodiments, the sole comprises an arch support 64.

[0064] In other embodiments, the arch support 64 comprises an “X” configuration.

[0065] In other embodiments, the arch support 64 is positioned in an arch support recess 58.

[0066] While there has been illustrated and described what is, at present, considered to be a preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made, and equivalents may be substituted for elements thereof without departing from the true scope of the invention. Therefore, it is intended that this invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out the invention, but that the invention will include all embodiments falling within the scope of this disclosure.