Midsole with incorporated orthotic support

Abstract

A midsole of footwear with an incorporated orthotic support. The midsole includes a soft and flexible member and a more rigid orthotic support. The orthotic support includes a heel cup and an arch support portion that extends forwardly from the heel cup. Embodiments produce the midsole by positioning the orthotic insert between an upper portion of the footwear and an outsole. Then, soft and flexible material is injected into the space surrounding the orthotic. The soft and flexible material subsequently cures forming the multi-part unitary midsole.

Claims

1. A method of producing a midsole of an article of footwear having a heel portion, the method comprising: holding an orthotic in a fixed position between an upper portion of the article and an outsole, the orthotic having a rearfoot portion within the heel portion of the article, the rearfoot portion including a heel cup, and the orthotic having a forward portion extending forwardly from the rearfoot portion and having curvature, wherein the heel cup includes an upper cup surface, the upper cup surface of the heel cup having a low point and perimeter walls that extend upward from the low point, the perimeter walls including a rear wall, a forward wall, and one or more of a medial wall or a lateral wall, the one or more of the medial wall or the lateral wall extending from the rear wall to the forward wall; injecting a material that flows into a space between the upper portion and outsole, surrounding the orthotic; and curing the material to form a midsole member.

2. The method of claim 1 wherein: the orthotic has hollow space within the orthotic that allows for the material to flow through the orthotic.

3. The method of claim 1 wherein: holding the orthotic in the fixed position comprises holding the orthotic in place by support structures extending from the bottom of the upper portion or by support structures extending from an upper surface of the outsole.

4. The method of claim 1 further comprising: holding a rigid support member in place below the orthotic.

5. The method of claim 1 wherein: the orthotic is shaped to provide longitudinal and torsional rigidity.

6. The method of claim 1 further comprising: adjusting a material reaction rate to form varying thickness along a transverse plane of the article.

7. The method of claim 1 wherein: the orthotic is shaped to provide longitudinal and torsional rigidity.

8. The method of claim 1 wherein holding the orthotic in the fixed position between the upper portion of the article and the outsole includes holding the orthotic in the fixed position between the upper portion of the article and the outsole before injecting any material around the orthotic.

9. A method of producing a midsole of an article of footwear having a heel portion, the method comprising: holding an orthotic in a fixed position between an upper surface and a lower surface, the orthotic having a rearfoot portion within the heel portion of the article, the rearfoot portion including a heel cup, and the orthotic having a forward portion extending forwardly from the rearfoot portion and having curvature, wherein the heel cup includes an upper cup surface, the upper cup surface of the heel cup having a low point and perimeter walls that extend upward from the low point, the perimeter walls including a rear wall, a forward wall, and one or more of a medial wall or a lateral wall, the one or more of the medial wall or the lateral wall extending from the rear wall to the forward wall; injecting a material that flows into a space between the upper and lower surface, surrounding the orthotic; and curing the material to form a midsole member.

10. The method of claim 9 wherein: the orthotic has hollow space within the orthotic allowing for the material to pass through the orthotic.

11. The method of claim 9 wherein: holding the orthotic in the fixed position comprises holding the orthotic in place by support structures extending from a top of the lower surface or extending from a bottom of the upper surface.

12. The method of claim 9 wherein: thickness of the orthotic and thickness of the midsole member vary along a transverse plane of the article.

13. The method of claim 9 further comprising: holding a rigid support member in place below the orthotic.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Preferred and alternative examples of the present invention are described in detail below with reference to the following drawings:

(2) FIG. 1 shows a side view of an embodiment of a midsole.

(3) FIG. 2 shows an exploded view of the orthotic insert, soft and flexible material, upper portion of the footwear, and outsole.

(4) FIG. 3 shows a top view of the orthotic, including hollow space, and the flexible material.

(5) FIG. 4 shows an embodiment of a method of production.

(6) FIG. 5 shows a midsole encapsulating both an orthotic and a shank.

DETAILED DESCRIPTION

(7) In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details. In other instances, well known structures and manufacturing techniques associated with footwear and orthotic devices may not be shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments.

(8) Unless the context requires otherwise, throughout the specification and claims that follow, the word comprise and variations thereof, such as, comprises and comprising are to be construed in an open, inclusive sense, that is as including, but not limited to.

(9) Unless otherwise stated, the following terms shall refer to the stated descriptions. The length of the footwear shall refer to an axis extending from the heel portion of the footwear through the toe portion of the footwear. The width of the footwear shall refer to an axis approximately perpendicular to the length axis and approximately parallel to the bottom surface of the footwear. The thickness of the footwear shall refer to an axis perpendicular to the length and width of the footwear.

(10) FIG. 1 depicts a side view cross section of an embodiment of a footwear midsole. The figure depicts an orthotic insert 1 surrounded by soft and flexible material 2. The heel cup 10 is shown in the rear of the footwear. The arch support portion 11 is shown extending forward from the rear portion. One embodiment of the curvature of the arch support portion 11 is shown in FIG. 1. However, the arch support portion of the orthotic could be formed using many different curvatures to support different types and/or shapes of feet or alleviate different foot ailments.

(11) FIG. 1 also depicts an embodiment of a possible length of an orthotic support. FIG. 1 depicts the orthotic insert terminating after the arch support. This configuration allows for increased flexibility of the midsole member in the forward portions of the footwear. Other embodiments may include different lengths to provide support to other areas of the foot.

(12) FIG. 1 also depicts an embodiment of the invention with varying thickness of the midsole. The forward portion of the midsole is depicted as having less cross-sectional thickness than the rearfoot or middle portions of the midsole. A thinner forward portion of the midsole may provide greater flexibility. Higher flexibility is desirable in applications including athletic shoes. Other embodiments may vary thickness differently than depicted in FIG. 1. The thickness variation may be based on intended application of the footwear or other design parameters.

(13) The thickness of the orthotic insert may also be varied. The thickness variation of the orthotic insert may be varied in conjunction with or independently of the thickness variation of the flexible material. FIG. 1 depicts varying the thickness of both the orthotic insert and flexible material. The orthotic insert 1 is illustrated to have a tapered thickness as it extends to the front of the footwear. The flexible material 2 has greater thickness in the heel portion of the footwear. Other embodiments of the invention may use thickness variation of the components to provide support in different areas of the footwear.

(14) Varying the thickness of the midsole members allows for the characteristics of the midsole to be designed for specific areas of a foot. One embodiment of the invention may include a thicker section of the arch support portion of the orthotic insert. This thicker section may provide support to a specific area of the foot to correct for a foot ailment. Another embodiment may include thicker flexible material in the rearfoot portion of the midsole to provide great shock absorption. The thickness of both members may be varied in different portions of the footwear to tailor the characteristics of the footwear to an intended purpose, a specific foot, a specific foot ailment, or other design parameters.

(15) The characteristics of the midsole may be varied in other ways. An embodiment of the invention may include an orthotic insert composed of multiple materials with different rigidities. Other embodiments may use an orthotic insert material to provide a rigidity based on the intended use of the footwear. Embodiments may also vary the shape of the orthotic insert. One embodiment may reduce the width of the orthotic insert to provide greater torsional flexibility. Other preferred embodiments vary the thickness of the flexible material 2 above the orthotic 1. More cushion above the orthotic 1 can be used for a comfort application, while slightly less material above the orthotic or a firmer flexible material 2 above the orthotic may be used for a more performance-oriented application, for example.

(16) Some embodiments of the invention may design the rigidity, thickness, material selection, shape, and other parameters based on the foot of a specific user. A user may have their foot measured by one or more of several methods such as a scan, dynamic pressure assessment, or plaster mold. These measurements may then be analyzed and used to create a footwear with support designed for a specific foot. Other embodiments may vary the characteristics of the midsole based on a specific foot ailment, shape, or other paramter. An example may include a midsole with an orthotic insert shaped to prevent overpronation of a foot. Still further embodiments may vary the design parameters of the footwear based on intended use. One embodiment may include a footwear designed for use as a work boot including a high degree of thickness of the midsole to provide support and shock absorption. Still further embodiments may design footwear based upon the analysis of the gait of an individual.

(17) FIG. 2 depicts an exploded view of the sole assembly of the footwear. This figure shows the orthotic insert 1 separately from a midsole member 20 composed of soft and flexible material 2. The figure also shows an outsole member 21 and upper portion 22.

(18) FIG. 3 depicts a top view of an embodiment of a midsole of a footwear. This figure illustrates the shape of the orthotic 1 and soft and flexible material 2. FIG. 3 depicts an embodiment of hollow spaces 40 passing through the thickness of the orthotic insert. Other embodiments may use a different number of hollow spaces, different shaped spaces, spaces differently oriented, or other variations. Some embodiments may include the soft and flexible material of the midsole passing through these hollow spaces 40. The material passing through the hollow space in the orthotic insert may help to hold the insert in place.

(19) FIG. 4 depicts a view of a configuration that may be used to produce the footwear. The figure depicts an upper portion of the footwear 22, an orthotic 1, and an outsole 21. The outsole is the portion of the footwear that contacts the ground. FIG. 4 depicts an embodiment that holds the orthotic 1 in place a distance from the top surface of the outsole. This embodiment positions the orthotic using structures 30 extending from the top surface of the outsole. In this embodiment, the upper portion of the footwear is positioned such that the orthotic is between the outsole and upper portion. One embodiment of the invention includes injecting a flowing material into the space that surrounds the orthotic insert that is positioned between the outsole and upper portion. This material subsequently cures creating a midsole of the footwear with an incorporated, embedded orthotic. Other embodiments may include using structures extending from the bottom surface of the upper portion or extending from an outside structure to secure the orthotic in position.

(20) FIG. 4 depicts an orthotic insert with heel cup in the rearfoot portion of the footwear. FIG. 4 also depicts an orthotic with a curvature that supports the arch of the foot. Some embodiments may include an orthotic with incorporated hollow space. Other embodiments may include the flowing material passing through these hollow spaces and subsequently curing within the hollow spaces.

(21) Some embodiments may adjust the reaction rate of the material with time. This method could be used to vary the thickness along the length of the footwear. An embodiment may inject the material from the rear of the footwear and increase the reaction rate after a predetermined time. This embodiment could be employed to create a midsole with a rear portion that is thicker than the front portion. Other embodiments may vary the reaction rates in other ways to create thickness in a predetermined area of the footwear.

(22) FIG. 5 depicts an embodiment with an orthotic 1 and shank 50 incorporated into the midsole. The orthotic 1 and shank 50 are held in place between the upper portion of the footwear 22 and the outsole 21 by structures 30. A material is caused to flow into the space surrounding the orthotic 1 and shank 50. The material subsequently cures forming the midsole.

(23) Shanks are commonly used in footwear to increase rigidity. An incorporated shank would be held in place by the soft and flexible material. One embodiment may include a rigid support member that is a long flat metal member approximately aligned with the lengthwise axis of the footwear. Other embodiments may include rigid support members comprised of different materials, of different shapes, or in different orientations. In some embodiments, the shank includes holes through that the flexible midsole material may flow during production.

(24) While the preferred embodiment of the invention has been described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.