Article of footwear

Abstract

An article of footwear, such as a high heeled shoe, has a resilient midsole layer having a thickness of at least about 5 mm which is formed in a lattice arrangement for providing comfort to the wearer.

Claims

1. An article of footwear having a sole and an upper, the sole having a forepart and a heel end, the sole comprising an outsole and an insole and a cushioning midsole layer between the insole and the outsole, in which the cushioning midsole layer is provided at least in the forepart of the sole and comprises a resilient material, with an array of hollow cells being provided in the resilient material, the array of hollow cells extending in two orthogonal directions, the cushioning midsole layer having a thickness of at least 5 mm, in which the midsole layer includes a shaped cushion element embedded in the hollow cells of the cushioning midsole layer in the forepart of the sole, in which the heel end of the sole is raised by between 50 mm and 150 mm relative to the forepart of the sole, and in which the shaped cushion element is provided between the insole and the outsole so that the outsole prevents the shaped cushion element from contacting the ground.

2. The article of footwear as claimed in claim 1, in which the cushioning midsole layer has a thickness of between at least 10 mm, and up to 50 mm.

3. The article of footwear as claimed in claim 1, in which the cushioning midsole layer has a thickness of at least 25 mm.

4. The article of footwear as claimed in claim 3, in which the cushioning midsole layer has a thickness of between 30 and 40 mm.

5. The article of footwear as claimed in claim 1, in which the cushioning midsole layer extends across substantially the entire forepart region of the sole.

6. The article of footwear as claimed in claim 1, in which the cushioning midsole layer extends across substantially the entire area of the sole.

7. The article of footwear as claimed in claim 1, in which the midsole is arranged to deform up to 20% in thickness during use.

8. The article of footwear as claimed in claim 1, in which the cushioning midsole layer is arranged to have a resilience which varies over the area thereof.

9. The article of footwear as claimed in claim 1, in which the sole comprises a substantially rigid lateral outer layer for maintaining the shape of the shoe in use.

10. The article of footwear as claimed in claim 1, in which the shaped cushion element has a substantially toroid shape.

11. The article of footwear as claimed in claim 1, in which the insole has a central forepart region, and the insole comprises a thin cushioning layer, at least in the central forepart region of the insole.

12. The article of footwear as claimed in claim 1, in which the upper has an inside surface, and at least a portion of the inside surface of the upper is provided with a thin cushioning layer.

13. The article of footwear as claimed in claim 1, in which the cushioning midsole layer is formed of a gel or rubber material.

14. The article of footwear as claimed in claim 1, in which the array of hollow cells is provided between upright walls of the resilient material.

15. The article of footwear as claimed in claim 1, in which the resilient material is formed in a lattice arrangement, with the array of hollow cells being provided in the resilient material forming the lattice arrangement.

16. The article of footwear as claimed in claim 15, in which the lattice arrangement forms diamond or square shaped cells or a honeycomb formation.

Description

(1) FIG. 1 is a perspective view of a shoe according to one embodiment of the invention, showing the structure of the midsole;

(2) FIG. 2 is a cross-sectional side view of the midsole of FIG. 1; and

(3) FIG. 3 is a perspective view of the sole of the shoe of FIG. 1 with the parts separated.

(4) Referring to FIG. 1, a shoe 2 comprises a sole 4 and an upper 6. The sole comprises an outsole 8, an insole 10 and a midsole layer 12 between the outsole and the insole. The outsole 8 may be of standard construction, and is commonly made of a suitable hardwearing material as is known in the art for contact with the ground during use of the shoe, such as a rubber material. The insole 10 may also be of standard construction, and is commonly made from a relatively thin soft covering for contact with the wearer's foot or sock, such as leather or artificial leather or other fabric, sometimes including a thin compressible element. The upper 6 is also of a standard type, commonly made of leather or a leather substitute material in the required shape according to the aesthetic design of the shoe, and in order to hold the shoe onto the wearer's foot. In this example the upper is shown in the style of a simple ladies court shoe, but it could also be in any other design for example being formed of straps such as in the case of a sandal.

(5) The heel end 14 of the sole is raised off the ground relative to the forepart 16 of the sole by a heel element 18. The heel element is of standard type, generally being a thin or tapering element providing support across the heel area of the sole and extending therefrom in the case of a stiletto type shoe as shown in the figures. The heel element could also be in other forms such as a broader element or a wedge-shaped element which supports the sole additionally in the arch area 24, according to the style of the shoe. The sole and heel may alternatively be made as one component for a more sturdy shoe.

(6) Referring also to FIG. 2 and FIG. 3, the midsole layer 12 is formed of a resilient material having a lattice formation, with an array of hollow cells 20 between upright walls 22. In this example the lattice forms diamond or square shaped cells, but it is envisaged that other shapes such as a honeycomb formation may also be suitable. In this example the cells are in the region of one centimeter in width, but could be smaller or larger than this depending upon the material used and/or the resilience required. Alternatively the midsole layer may be formed of a solid gel or rubber material.

(7) The material is such that the midsole layer 12 may be somewhat compressed bearing the weight of a person's foot during wear, so as to provide a cushioning effect. For example, the midsole may compress in the upright direction by between about 10% and 20% when in use. The midsole layer in this example extends across substantially the entire area of the sole from the forepart end 16 to the heel end 14. In other examples, the midsole layer may be present in the forepart only of the sole, supporting the ball of the foot and the toe area, and may taper off towards the arch area 24 of the sole.

(8) The thickness of the layer may be substantially consistent or may vary over the area of the sole. For example, it may be thicker in the forepart area for providing additional cushioning to the ball of the foot, or it may be thicker in the heel area to provide additional heel height. The layer thickness may thus vary over the area of the sole, for reasons of comfort and/or of the style of the shoe, since the midsole layer will provide the appearance of a platform sole in the finished shoe if sufficiently thick. In this example, the layer is thicker in the heel area 14 and forefoot area 16, and thinner in the arch area 24 since the arch area of the foot tends to bear less weight and so requires less cushioning.

(9) Furthermore it is envisaged that the midsole may be provided as a bespoke element made to suit measurements taken from the user's foot. For example, the thickness or resilience of the midsole layer may vary over the area of the sole depending upon the shape or pressure distribution measured. One method of manufacturing such a midsole would be by 3D printing.

(10) In the forefoot area of the midsole layer 12, a shaped spring element 26, here substantially in the shape of a torus, may be embedded in the lattice towards the lower or outsole surface of the layer. The torus element is also formed of a resilient material. The torus element may provide additional support and resistance to deformation in the area of the ball of the foot where the greatest pressure is exerted by the wearer's foot in use of the shoe. The torus shape has also been found to provide advantages in comfort and support in terms of distributing the weight over the ball of the foot. However, the element may be a different shape such as a substantially circular or oval shape, or may be more deformable or springy depending upon requirements.

(11) The midsole layer 12 (which is shown in FIG. 1 and FIG. 2) is shaped so as to fit snugly in an outer casing 28 for the sole (the outer casing 28 is shown in FIG. 3) which covers at least the sides and preferably also forms the outsole covering the base of the midsole layer 12. The casing 28 thus has a base 30 surrounded by an upright side wall 32. At least the side wall 32 may be relatively rigid, substantially to prevent deformation of the outer shape of the shoe in use. This preserves the appearance of the shoe during wear. The heel element 18 may be attached to the underneath of the casing. The rigid parts of the sole such as the casing side wall 32 are preferably formed of a strong and light material which can be formed into a thin layer, for example graphene.

(12) The insole 10 may be more rigid at the periphery thereof, and may have a cut out in the central region (not shown), which may include a further cushioning layer, for example of foam material such as memory foam. The inner surface of the upper may also comprise such a layer to provide further comfort and snugness of fit.