AU2008100181A4 - Cushioned footwear - Google Patents

Description

P/00/009A Section 29

AUSTRALIA

Patents Act 1990 INNOVATION PATENT SPECIFICATION Invention Title: CUSHIONED FOOTWEAR Applicant: O S Holdings (Vic) Pty Ltd The invention is described in the following statement: 1 7019 00 Cushioned Footwear C Field of the Invention The present invention relates generally to footwear, and more C 5 particularly to footwear having cushioning and/or shock absorbing features within the sole to enhance wearer comfort.

00 <oo Background to the Invention _When standing, walking and running the feet bear a substantial 00O proportion of the load in the heel and metatarsal (or ball) regions of each foot.

SThe foot is naturally configured to absorb the impact forces incurred when walking or running on relatively soft surfaces, such as grass, or when the duration of the activity is relatively short. However, when standing and moving on hard surfaces, such as roads and hard floors, and particularly when the activity is sustained for an extended period of time, discomfort and possible injury may be caused to the load bearing regions of the foot.

Accordingly, footwear manufacturers have for some time endeavoured to produce footwear that includes cushioning systems to provide an improved level of comfort for wearers. The need to provide such cushioning systems is particularly pertinent in the design of work footwear, which is worn for extended periods of time, to reduce fatigue, minimize the effects of standing or moving for long periods on hard surfaces such as concrete floors and enhance comfort. The provision of cushioning effects is similarly important in walking and athletic footwear to provide a level of shock absorption when walking and running on hard surfaces.

It would be desirable to provide an article of footwear that reduces impact shock.

It would also be desirable to provide footwear that provides enhanced comfort to a wearer.

Summary of the Invention According to an aspect of the present invention, there is provided an article of footwear including: W:SASKIAPaten Spec 3 0 an insole including a first opening in the a heel region of the insole and 0 Sa second opening in a metatarsal region of the insole each opening being C configured to accommodate a cushioning pad; an outer sole; and c 5 a mid sole located between the insole and outer sole.

The insole may consist of a non-woven textile material of fibre board used in conventional insoles. The mid sole is formed for a material having at 00 least some impact absorbing characteristics, an example of a suitable material being expanded polyurethane. The outer sole may be formed from oo 10 polyurethane to form a tough outer skin.

SThe two openings in the insole are positioned in a heel region of the insole and in a metatarsal region of the insole respectively. Accordingly, the two openings positioned to correspond substantially with the load bearing regions of the foot.

Each opening accommodates a pad formed from a resilient material designed to provide cushioned support and enhanced comfort to a wearer.

One example of suitable resilient material for forming the cushioning pads is cellular polyurethane.

In a preferred embodiment, the cushioning pad positioned in the first opening of the insole extends at least midway into the mid sole.

In yet another embodiment, the portion of the cushioning pad extending at least midway into the mid sole is substantially dome-shaped.

In another form of the invention, periphery of the first opening overlaps the underlying cushioning pad positioned in the first opening of the insole.

In yet another form, the cushioning pad positioned in the first opening of the insole is adapted to receive the periphery of the first opening to provide a flush uppermost surface.

Brief Description of the Drawings The invention will now be described in further detail by reference to the attached drawings illustrating example forms of the invention. It is to be understood that the particularity of the drawings does not supersede the generality of the preceding description of the invention. In the drawings: W:SASKIAIPatont Spe.Bqoots doc 0 Figure 1A is a section view of an article of footwear according to an C)embodiment of the present invention.

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SFigure 1B is a perspective view of the section shown in Figure 1A.

Figure 2A is a top down view of a cushioned foot bed according to an C 5 embodiment of the present invention.

Figure 28 shows the cushioned foot bed of Figure 2A as viewed from oo underneath.

Figure 2C is a side on view through a section of the cushioned foot bed _of Figures 2A and 28.

00oo SDetailed Description Referring now to Figures 1 A and 1 B, there is illustrated an article of footwear 100 including an insole 102 to which the lower edge of an upper 104 is secured by conventional means such as stitching. A mid sole 106 is moulded to the underside of the insole 108 with the edges of the mid sole 110 being moulded around the upper 112. An outer sole 114 is moulded or otherwise secured to the underside of the mid sole 116.

The insole 102 is formed from a non-woven textile material or fibre board shaped in the general shape of a foot to fit within the base of an article of footwear 118. The mid sole 106 is formed from a material having at least some impact absorbing characteristics, preferably a resilient material such as expanded polyurethane. The outer sole 114 is formed from polyurethane to form a tough outer skin which is resistant to penetration by stones and other objects, thereby forming what is referred to as a dual density sole.

The insole 102 includes two openings, a first opening 120 positioned in a heel region 122 of the insole and a second opening 124 positioned in a metatarsal region 126 of the insole. Accordingly, the positions of the openings 120, 124 are configured to correspond substantially with the load bearing regions of the foot.

Each opening 120, 124 accommodates a pad 128, 130 formed from a resilient material designed to absorb impact shock and provide cushioned support to enhance the comfort of a wearer. One example of suitable resilient material for forming the cushioning pads 128, 130 is cellular polyurethane.

The cushioning pads 128, 130 are configured to fit snugly into the respective W:ASASKIAPatet Specootsdoc 0 openings 120, 124 forming a substantially flush uppermost surface where the Scushioning pad meets the insole 102 to ensure that no undesirable ridges are Sformed at the meeting points between the two materials. The cushioning pads 128, 130 are secured in their respective positions using means such as c 5 stitching the outer edge 132 of the cushioning pad to a periphery of the opening 134, or by use of adhesive.

o The cushioning pad 128 positioned in the heel region 122 (also hereinafter referred to as the heel pad) extends partway and preferably at least midway into the mid sole 106 to enhance the cushioning effect. That is, as oo 00 shown in Figures 1A and 1B, the heel pad 128 extends at least halfway into c the thickness of the mid sole 106. The underside of the heel pad 128, or the portion of the heel pad that extends into the mid sole 106, is preferably substantially dome-shaped. The dome-shape provides the greatest depth of cushioning material and accordingly the greatest cushioning and shock absorbing effects substantially in the centre of the load bearing region or heel strike zone. The cushioning and shock absorbing effect is decreased or tapered towards the edges of the heel strike zone by reducing the depth of the heel pad 128, thereby providing improved stability of the insole surface.

The provision of openings in the insole to accommodate cushioning pads has distinct advantages over prior art methods, by providing direct load transfer to maximise the absorption of impact shock. This provides enhanced comfort to the wearer, particularly when compared with some prior art arrangements in which the insole overlays the cushioning material, such that the insole being of relatively rigid construction interferes with the ability of the cushioning pad to effectively load transfer.

The periphery of the opening 136 in the heel region of the insole may overlap the underlying heel pad 128. The cushioning pad 128 includes a recess 138 around its upper edge to receive the periphery of the opening 136 to provide a substantially flush uppermost surface where the cushioning pad meets the insole to ensure that no undesirable ridges are formed at the meeting points between the two materials as previously described. This provides effective means for securing the heel pad in position to the underside of the insole by allowing the recessed region of the heel pad to be secured to W:ASASKIAPmenm Spec Boots.dOc 00 the underside of the periphery of the opening using an adhesive or equivalent 0 0means.

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C The region of the insole intermediate 140 to the heel region 122 and metatarsal region 126 which corresponds to the under arch region of a wearer's foot, is underlain by a nylon shank 142 to provide under arch support.

The nylon shank 142 is of substantially more rigidity than the insole 102 to provide additional support and prevent sharp objects (such as the head of a 00 Sshovel for example) from penetrating the sole 106, 114 during use. Preferably, _the nylon shank 142 separates from the underside of the insole 108 towards oo 10 the heel region of the insole, in order to accommodate the heel cushion 128 Sthere between. This enables the nylon shank 142 to be continued into the heel region 122 without compromising wearer comfort. Moreover, the toe region 144 of the insole 102 may be underlain by particle cardboard 146 or similar to provide reinforcement and stiffening to this region.

The manufacture of footwear articles in accordance with the present invention involves providing two openings 120, 124 in the insole 102 in the heel 122 and metatarsal 126 regions. The upper 112 is then secured to the insole 102 using conventional means such as stitching (at 104). A heel cushion 128 and a metatarsal cushion 130 are positioned in their respective openings 120, 124 and secured to the insole 102. In a preferred embodiment, the metatarsal cushion 130 is secured to the insole 102 by stitching the periphery of the metatarsal pad 132 to the periphery of the opening 134, whilst a recess 138 in the heel pad is secured to the underside of the periphery of the insole 136 using a suitable adhesive or equivalent means.

The mid sole 106 is moulded to the underside of the insole 108 with cushioning pads 120, 124 in place, thereby encasing the cushioning pads and securing them in place. Finally the outer sole 114 is moulded to the underside of the mid sole 116.

Referring now to Figures 2A to 2C, a foot bed or inner sock 200 may be placed within the article of footwear 100 as an overlay to the insole 102 to provide additional cushioning and support to the wearer and enhance comfort.

The foot bed 200 may be loose within the article of footwear 100, or may be adhered to the upper surface of the insole 102.

W:SASKIA\Patent Spe BOOts doc 0 The cushioned foot bed 200 has an upper surface 202 which is in 0 contact with the sole of a wearer's foot, and a lower surface 204 which Scontacts and/or is adhered to the uppermost surface of the insole 102. The foot bed 200 is formed from three independent layers bonded or moulded c 5 together. The underside of a first cushioning layer 206 forms the lower surface of the foot bed 200. The first cushioning layer 206 is formed from cellular oO polyurethane. The upper layer of the foot bed is an absorbent layer 208 such as a nylon or cotton scrim to draw water vapour and perspiration away from the foot, helping to keep shoes and feet dry, and reducing foot odour. The 00 oo absorbent layer 208 has a textured surface to enhance wearer comfort. An c intermediate cushioning layer 210 is formed from open foam to facilitate the flow of air between the first cushioning layer 206 and the absorbent layer 208 of the foot bed. An example of a suitable material is EVA foam.

The textured surface of the absorbent layer 208 of the foot bed 200 is formed by printing a material onto the absorbent layer to form a pattern of raised regions 212. The material may be printed on the scrim 208 in any suitable pattern such as for example the series of dots illustrated in Figure 2A.

The material printed onto the absorbent layer 208 could be any material providing the textured effect.

In one particular embodiment of the invention, the material printed onto the absorbent layer 208 to provide the textured effect is tourmaline.

Referring now to Figure 2B, the first cushioning layer 206 includes a pad 214 in a heel region of the foot bed 200 which is formed from PORON®, a cellular urethane having superior shock absorption properties to minmise impact shock to the feet and joints of the wearer whilst providing long lasting resilience, flexibility and softness.

In addition to the PORON® heel pad 214, the first cushioning layer 206 further includes a series of through holes 216 which pass through the intermediate cushioning layer 210 and the absorbent layer 208 to facilitate air flow through the cushioned foot bed 200. Each of the through holes 216 may be set into a corresponding recessed region 218 which provides a suction effect to draw air through the respective hole.

The cushioned foot bed 200 is preferably designed to fit the natural shape of the foot thereby providing optimal support for the wearer's foot. The W:ASASKMJAPme Spec Bootsdoc 8 0 first cushioning layer 206 increases substantially in thickness from a region corresponding to the metatarsal region of a wearer's foot 220 towards a region Scorresponding to the heel 224 of a wearer's foot.

The arrangements of cushioning pads and cushioned foot beds C 5 provided by the present invention facilitate cushioning and absorption of impact shock to the regions of the foot that are most susceptible to discomfort oO and injury due to high stress forces.

The provision of an opening in the insole in both the heel and metatarsal regions to accommodate a cushioning pad therein facilitates the 00 oo transfer of impact energy from the foot of the wearer directly to the resilient C properties of the cushioning pad without the interference of the insole there between.

The above described improvements are applicable not only to work footwear as exemplified in the drawings, but also walking, athletic and casual footwear, or any other type of footwear where enhancing wearer comfort is of concern.

It is to be understood that various additions, alterations and/or modifications may be made to the parts previously described without departing from the ambit of the invention.

W:ASASKIAPalent SpecBOOts doc

Claims (4)

1. An article of footwear including: an insole including a first opening in the a heel region of the insole and C 5 a second opening in a metatarsal region of the insole each opening being configured to accommodate a cushioning pad; an outer sole; and a mid sole located between the insole and outer sole. oo 00

2. An article of footwear according to claim 1, wherein the cushioning pad c positioned in the first opening of the insole extends at least midway into the mid sole.

3. An article of footwear according to claim 2, wherein the portion of the cushioning pad extending at least midway into the mid sole is substantially dome-shaped.

4. An article of footwear according to any one of the preceding claims, wherein a periphery of the first opening overlaps the underlying cushioning pad positioned in the first opening of the insole. An article of footwear according to claim 4, wherein the cushioning pad positioned in the first opening of the insole is adapted to receive the periphery of the first opening to provide a flush uppermost surface. W:SASKIAPatert SpeeBooUdoC