Rotatable sole assembly

Abstract

We disclose herein a rotatable sole assembly for a shoe which comprises a first plate (305), a second plate (320); and a coating layer (330) between the first and second plates. The coating layer (330) is configured to rotate one of the first and second plates with respect to the other of the first and second plates. The sole assembly is designed to reduce ACL injuries as well as the incidence of other lower leg injuries related to high torque forces.

Claims

1. A rotatable sole assembly for a shoe, the sole assembly comprising: a first plate; a second plate; and a coating layer between the first and second plates; wherein the coating layer is configured to rotate one of the first and second plates with respect to the other of the first and second plates, and wherein the rotatable sole assembly further comprises an elastic material holding the first and second plates to control a rotation of the sole assembly.

2. A sole assembly according to claim 1, being a midsole assembly which is coupled to a front end portion of the shoe and an outer sole portion of the shoe.

3. A sole assembly according to claim 1, wherein: the coating layer comprises a lubricant material, wherein the lubricant material comprises graphite powder; or the coating layer is formed from the first and second plates; or the first and second plates comprises a material comprising polyethylene terephthalate.

4. A sole assembly according to claim 1, further comprising: a first slab coupled to the first plate; and a second slab coupled to the second plate, wherein the first and second slabs are formed on sides of the first and second plates which are opposite to the sides of the first and second plates on which the coating layer is formed.

5. A sole assembly according to claim 4, wherein the first and second slabs comprise a material comprising EthylVinylAcetate (EVA).

6. A sole assembly according to claim 4, wherein the first and second plates each comprise a hole, further comprising: a grommet which fits through the hole of each of the first and second plates, wherein the grommet is attached to the plates and slabs using an adhesive material comprising cyanoacrylate; and the grommet is a plastic grommet.

7. A sole assembly according to claim 4, wherein the elastic material is formed surrounding a perimeter of the plates and slabs, wherein: the elastic material is configured to generate a force which permits each rotatable plate and slab to return to a centrally biased position, wherein the elastic material comprises an elastic modulus which is controlled to generate the force; and the elastic material is attached to the plates and slabs using an adhesive material comprising cyanoacrylate.

8. A sole assembly according to claim 1, wherein: the first plate comprises a concave shape; and the second plate comprises a convex shape; and the sole assembly is coupled to the shoe and to an outer sole of the shoe by an adhesive material; and the sole assembly is configured to rotate at an angle of about 10 to 25 about a longitudinal axis of the sole assembly.

9. A rotatable shoe comprising: a body portion; the sole assembly according to claim 1; and an outer sole; wherein the sole assembly is coupled to a front end portion of the body portion and the sole assembly is coupled to the outer sole, wherein the sole assembly is configured to reduce a torque applied to the front end portion of the body portion of the shoe.

10. A method of manufacturing a rotatable sole assembly for a shoe, the method comprising: providing a first plate; providing a second plate; providing a coating layer between the first and second plates so that one of the first and second plates rotates with respect to the other of the first and second plates; and providing the rotatable sole assembly with an elastic material holding the first and second plates, to control a rotation of the sole assembly.

11. A method according to claim 10, wherein: the sole assembly is a midsole assembly which is coupled to a front end portion of the shoe and an outer sole portion of the shoe; and the coating layer comprises a lubricant material comprising graphite powder; or further comprising deforming the coating layer from the first and second plates.

12. A method according to claim 10, further comprising: providing a first slab on the first plate; and providing a second slab on the second plate, wherein the first and second slabs are provided on sides of the first and second plates which are opposite to the sides of the first and second plates on which the coating layer is formed; wherein the first and second slabs comprise a material comprising EthylVinylAcetate (EVA).

13. A method according to claim 12, further comprising providing a grommet which fits through a hole of the first and second plates, further comprising attaching the grommet to the plates and slabs using an adhesive material comprising cyanoacrylate.

14. A method according to claim 12, further comprising attaching the sole assembly to the shoe and to an outer sole of the shoe by an adhesive material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present disclosure will be understood more fully from the detailed description that follows and from the accompanying drawings, which however, should not be taken to limit the invention to the specific embodiments shown, but are for explanation and understanding only.

(2) FIG. 1 illustrates a shoe in which a midsole assembly is installed;

(3) FIG. 2 illustrates a plate of the shoe assembly;

(4) FIG. 3 illustrates a breakdown view of the construction of the midsole assembly;

(5) FIG. 4 illustrates an arrangement in which the first plate, the first slab and a grommet are assembled together;

(6) FIG. 5 illustrates the sole assembly in pieces showing (left to right) an upper (first) slab, a grommet, a plastic plate (the second plate), a lower (second) slab and a piece of the original outsole, which will be adhered to retain the original tread surface;

(7) FIG. 6 illustrates an elastic material used in the sole assembly;

(8) FIG. 7 illustrates a side view of the sole assembly having chamfered slabs;

(9) FIG. 8 illustrates an assembled midsole accordingly to an embodiment of the present invention;

(10) FIG. 9 illustrates an idealised representation of the vertical force trace of a typical human gait;

(11) FIG. 10 illustrates experimental results showing 4 graphs in which the top left graph represents a vertical force in a first step with the sole assembly being rotated; the top right graph represents a vertical force in a second step in which the sole assembly does not rotate; the bottom left graph represents a torsional force in a first step with the sole assembly being rotated; the bottom right graph represents a torsional force in a second step in which the sole assembly does not rotate;

(12) FIG. 11 illustrates 4 graphs representing vertical and torque forces for two consecutive steps using three different sole assemblies;

(13) FIG. 12 illustrates the comparison of torque forces in three different shoes which is shown in the bottom left graph of FIG. 11; and

(14) FIG. 13 (a) to FIG. 13 (c) show a shoe featuring the sole assembly comprising an elastic material pictured during laboratory testing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(15) The rotation (tare) Torc mechanism is a midsole component or midsole assembly that can be incorporated into many types of footwear at the time of manufacture. It allows for rotation of the foot relative to the floor whilst still maintaining frictional contact, and buffering the transfer of potentially painful or damaging torque forces to the lower leg of the wearer.

(16) Installation of the mechanism does not alter the weight or feel of the footwear, and adds nothing to the thickness of the host shoe. Generally, the rotation mechanism (or the midsole assembly) is adhered in place on the forepart of the host shoe, with the original outsole (which is sliced off the midsole when it was removed from the host shoe) stuck to the bottom of the mechanism to maintain its slip resistance properties. It allows the wearer to rotate the forepart of their shoe relative to the ground without either compromising slip resistance or transferring potentially damaging torque forces through the leg. It would be appreciated that certain commercial applications can involve fitting the mechanism to a shoe at the time of manufacture, or in some pre-planned manner shortly after construction of the main body of the footwear. The manufacturer wanting to incorporate the mechanism into their footwear can also set aside a piece of outsole material for the purpose, rather than cutting such from a host shoe.

(17) FIG. 1 illustrates such a shoe in which a midsole assembly (or the rotation mechanism) is installed. The shoe has a body portion 105 and an outer sole 115 which is cut away from the body portion 105. In one example, the cut away outer sole 115 corresponds to a front end portion of the body portion 105, A wearer toe is generally fitted in the front end portion of the body portion 105. The shoe also includes a midsole assembly 110 fitted between the body portion 105 and the outer sole 115. The midsole assembly 110 is generally attached to the body portion 105 and the outer sole 115 using an adhesive material (glue), for example, cyanoacrylate or superglue.

(18) We will now describe various parts used for the construction of the shoe assembly. At the heart of the midsole assembly (Torc mechanism) are two plates, for example, plastic plates, shaped to follow the outline of the forepart of a midsole. Such a plate 205 is shown in FIG. 2. FIG. 3 illustrates a breakdown view of the construction of the midsole assembly. The midsole assembly includes two plates 305, 320. Each plate 305, 320 is adhered to a slab 310, 325 of a typical midsole material, in this case, EthylVinylAcetate (EVA). In embodiments, the two plates 305, 320 rotate against one another, lubricated with a coating of a suitable lubricant 330, for example, graphite powder. The upper plate (or the first plate) 305 in this embodiment is substantially (slightly) concave, and the lower plate (the second plate) 320 is substantially (slightly) convex. This ensures that the plates nest together neatly and that they follow the contour of the outsole of the host shoe (or the shoe having the body portion described in FIG. 1). It would be appreciated that different footwear types will have different sole profiles, so may accordingly use different plate contours. Each plate 305, 320 includes a hole 335 at a central region. The sole assembly includes a grommet 315 which is generally fitted through the holes 335 of the plates 305, 320. The grommet 315 is generally a plastic grommet.

(19) FIG. 4 illustrates an arrangement in which the first plate 415, the first slab 405 and a grommet 425 are assembled together. The coating layer 420 is also provided in this assembly. The coating layer 420 helps to rotate the plates with respect to one another.

(20) In this embodiment, the grommet 425 is adhered to the plastic plate 415 and the first slab 405 using an adhesive material, for example, cyanoacrylate or superglue.

(21) FIG. 5 illustrates the sole assembly in pieces showing (left to right) an upper (first) slab 505, a grommet 515, a plastic plate (or the second plate) 520, a lower (second) slab 525 and a piece of an outsole 530, this outsole piece can be specially manufactured for application to the mechanism which will be adhered to retain the original tread surface.

(22) In embodiments, once the graphite lubricant has been applied to each plastic plate, the two halves of the sole assembly (Torc mechanism) are mated together ready to be bound by a bumper of strong elastic of the sort for example used for aerobic training. Such an elastic material 600 is shown in FIG. 6.

(23) FIG. 7 illustrates a side view of the sole assembly having chamfered slabs. In this embodiment, the first upper slab 720 has an edge 715 which is closest to the first plate 730. Similarly, the second lower slab 705 has an edge 710 which is closest to the second plate 725. The edges 710, 715 closest to the plates 725, 730 of both the first slab (EVA) 720 at the top of the assembly and the second slab (EVA) 705 at the bottom of the assembly are cut with a chamfer. The lower edge 715 of the first upper (blue) EVA 720 is chamfered inwards, and the upper edge 710 of the lower (second) EVA 705 is also chamfered inwards. Thus when placed together the chamfered edges 710, 715 form a groove in the middle of the perimeter of the midsole assembly (mechanism). The elastic bumper or material (not shown in FIG. 7) is then cut to shape, adhered to the assembly at one end, wrapped tightly around it under tension before being adhered at the other end.

(24) FIG. 8 illustrates an assembled midsole assembly accordingly to an embodiment of the present invention. The end result is that the assembly is encapsulated by an elastic material (elastic bumper) 810, which holds the top section and the bottom section (second section) 805 together whilst still permitting (and controlling) their rotation relative to one another. This then forms the complete midsole assembly or the rotation mechanism, ready to be fitted to the host footwear.

(25) It would be appreciated that, in one embodiment, the elastic material (rand) that runs around the perimeter of the slabs is stretched around the two slab (EVA) sections so that it encloses them, making a sealed unit. In one example, a relatively weaker grade of aerobic elastic material can be used, to create a rotational unit with a reduced torque resistance. This should allow the sole mechanism to engage easily. It would be appreciated that different grades of aerobic elastic material can also be used.

(26) In one example, super glue (cyanoacrylate) can be used as an adhesive to adhere both the elastic material (rand) to the EVA sections and also to adhere the EVA sections to the plastic plates and the rest of the sole assembly. However, other types of adhesive materials can also be used and thus the invention is not restricted to the use of super glue. For example, 6090 type adhesive can be used for adhering the whole rotating unit to the sole of the shoe.

(27) We now describe a series of test or experimental results achieved for the sole assembly installed in a shoe as described herein before.

(28) Testing

(29) To measure torque forces, a force platform has been used, this is able to measure dynamic torque forces transmitted from the footwear and directly relates to the torque forces in the lower leg.

(30) Pedatron

(31) The Pedatron is a walking simulator that recreates the forces of an average human gait using a combination of dead mass, pneumatics and prosthetic foot forms. The forces are not only in vertical loading but also horizontal forces and torque.

(32) A feature of the Pedatron is the ability to rotate the floor by an exact angle between each stride, thus creating rotational torque in the leg as per a human subject making a change in direction. This rotational angle remains the same for any footwear; the footwear is forced to rotate until friction between the shoe sole and the floor surface is overcome and the shoe slips (torsional slip).

(33) This flooring surface can be replaced with a force platform. This is normally done for calibration reasons but in this case, gives a very practical way of determining the torsional forces during the rotational of the floor. These forces will be dependent on the ability of the footwear to resist torsion through shear forces building up in the sole unit and the tread/sole materials ability to grip the surface. Typically as the floor rotates, torsional forces build to a peak at which point the sole is no longer able to grip, friction is overcome and torsional slip occurs.

(34) Interpretation of Force Platform Data

(35) We will now describe how the data gathered by the force platform relates to human gait and the operation of the Pedatron.

(36) The force platform has 4 triaxial sensors capable of measuring force in all three axes. These measurements can be combined by the software to give torsional values. For simplicity, measurements here are moments about the vertical axis.

(37) As the machine walks, the vertical force graph can be captured. As the machine gait is carefully controlled and repeatable, the vertical force graphs can be used to accurately superimpose the results from different footwear. This means that when traces from vertical force recordings are viewed together, the key points from the gait cycle align, allowing for the graphs to be superimposed and the forces compared.

(38) FIG. 9 illustrates an idealised representation of the vertical force trace of a typical human gait. It is annotated with the key physical features of gait. In this example, the user does not wear a shoe having the rotatable sole assembly described above. As can be seen in FIG. 9, the magnitude of the vertical force is relatively high at the first region 905 of the graph where the heel of the user strikes the floor. The vertical force reduces in the subsequent section 910 when the toe of the user moves towards the floor. As soon as the toe strikes the floor (the toe pushing off action) the vertical force increases again as seen in the final section 915 of the graph.

(39) FIG. 10 illustrates experimental results showing 4 graphs in which the top left graph represents a vertical force in a first step with the sole assembly being rotated; the top right graph represents a vertical force in a second step in which the sole assembly does not rotate; the bottom left graph represents a torsional force in a first step with the sole assembly being rotated; the bottom right graph represents a torsional force in a second step in which the sole assembly does not rotate. FIG. 10 illustrates a typical trace/graph covering two full steps by the pedatron. The floor has been programmed to rotate about 15 degrees at every other step. The rotation is triggered shortly after the heel strike, during roll through and toe off.

(40) In FIG. 10, the upper two traces or graphs 1020 and 1030 show the vertical forces of two consecutive steps. Graph 1020 represents the vertical forces for the first step and graph 1030 represents the vertical forces for the second step. In FIG. 10, the lower traces or graphs 1010, 1040 are the torsional forces about the vertical axis. The bottom left trace or graph 1010 shows the floor rotating inducing additional torsion. In the second step, the bottom right graph 1040, the floor is not rotating and so shows low torsional forces. It will be noted that the spikes are produced as a result of the heel strike on the machine and is a mechanical noise.

(41) Force Plate Assessment

(42) Force platform assessments have been carried out to measure torque (about the vertical axis) values when the shoes were tested in the Pedatron, with the default surface of the manufacturer force plate providing the test surface. The surface of the force plate has a mean British Pendulum Slip Value of 46, making it a suitably generic test surface.

(43) The Pedatron has been fitted with a SACH artificial foot (right) of appropriate size, and set to walk for 10 steps. The rotation was left on, so that on every second step the floor indexed underneath the toe/forepart of the footwear, causing the activation of the shoe mechanism.

(44) Tri-axial force data has been gathered and processed by the software and plotted on a graph. The torque trace/graph was then identified, and viewed in isolation.

(45) In each case, a right shoe of each type has been tested. Each shoe was fitted to a SACH foot of suitable size, and set to undergo 10 steps in the Pedatron. The rotation of the test surface has been left on, so that on every alternate step a twisting motion has been applied to the sole of the footwear via this movement.

(46) Three types of sample have been assessed in this way:

(47) 1. A non-modified shoe. This shoe provides the donor chassis that the shoe mechanism was built into. The footwear has an EVA midsole with a TR outsole.

(48) 2. A modified shoe with a blue rand (a first elastic material). The blue rand is the weaker of the two elastics that have been used.

(49) 3. A modified shoe with beige rand (a second elastic material). The beige rand is the most powerful elastic used so far. In other words, the elastic modulus of the second elastic material (beige rand) is higher than the elastic modulus of the first elastic material (blue rand).

(50) FIG. 11 illustrates 4 graphs representing vertical and torque forces in which the top two graphs show vertical forces and the bottom two graphs show torque forces for two consecutive steps using three different sole assemblies. FIG. 12 illustrates the comparison of torque forces in three different shoes which is shown in the bottom left graph of FIG. 11. As can be seen in FIG. 12, the vertical traces almost exactly align showing that vertical forces are very nearly identical for the three shoes. This is also a good indicator the gait of the Pedatron is consistent.

(51) In FIG. 11, the lower trace 1110 show the torsional forces about the vertical axis. The left hand trace is during a step where the floor is rotating, the right hand lower trace (graph) 1120 is where the floor is static. As can be seen the traces for each shoe when the floor is turning are very different, each shoe is transmitting the torsional force in different amounts.

(52) Turning now to FIG. 12, graph 1205 represents the torque force variation of the un-modified shoe or footwear, graph 1210 represents the torque force variation of the shoe having the second elastic material (beige rand) and graph 1215 represents the torque force variation of the shoe having the first elastic material (blue rand). Approximate peak torque values read from the graphs are shown in the following table:

(53) TABLE-US-00001 Force plate default surface PV = 46 Un-modified footwear 16 Nm Footwear with beige rand 10 Nm (the second elastic material) Footwear with blue rand (the 9 Nm first elastic material)

(54) It is therefore apparent that the torque force is reduced when the elastic material is used. It is also apparent that the torque force is in a relationship with the elastic modulus of the elastic material, i.e. the torque force increases with the increase of the elastic modulus of the elastic material.

(55) FIG. 13 (a) to FIG. 13 (c) show a shoe featuring the sole assembly comprising the beige elastic (the second elastic). In FIG. 13 (a), the shoe is positioned as the test surface is twisting anti-clockwise underneath it. In FIG. 13 (b), the shoe is positioned as the test surface is twisted anti-clockwise underneath it. In FIG. 13 (c), the shoe is positioned as the force platform begins to be rotated clockwise underneath the shoe.

(56) Biomedical studies show that with forces of approximately 36 Nm, the probability of ligamentous damage of the knee including complete or partial ACL rupture is about 60%. Avulsion fractures occur at lower torques of about 30 Nm (30% probability). 17 Nm of torque is sufficient to create a turning moment that will twist the knee, even under a load of twice bodyweight. The proposed sole assembly is designed to reduce the overall torque experienced in the knee of an athlete or service personnel, and to ultimately avoid high levels that could cause or exacerbate injury.

(57) Studded/cleated footwear and where sole patterns designed to give good performance on loose surfaces, dramatically reduce torsional slip greatly increasing the risk of ACL injury.

(58) With the use of this proposed sole assembly torsional forces are buffered and rise gradually, not suddenly. There are clear inferences about improved sports performance. For example, golf swing; energy return when kicking a football; avoiding scuffs and ground damage on golf courses.

(59) Torques reduction is in the order of 45% in these tests even when tested with a not particularly grippy surface on our force plate.

(60) The system lends itself to a cassette construction which allows for customisation and replacability between left and right, for making footwear for people convalescing after hip injuries or for footwear aimed at performance sport or for handed sports like golf.

(61) Torsional body movements require slip to occur reducing traction. This design means that traction is actually improved with the sole never actually breaking free and having to slip on the surface.

(62) Although the invention has been described in terms of preferred embodiments as set forth above, it should be understood that these embodiments are illustrative only and that the claims are not limited to those embodiments. Those skilled in the art will be able to make modifications and alternatives in view of the disclosure which are contemplated as falling within the scope of the appended claims. Each feature disclosed or illustrated in the present specification may be incorporated in the invention, whether alone or in any appropriate combination with any other feature disclosed or illustrated herein.