US20140033577A1

US20140033577A1 - Shoe Construction and Method of Constructing a Shoe

Info

Publication number: US20140033577A1
Application number: US13/954,711
Authority: US
Inventors: Christopher Robert Uda
Original assignee: Falcon Footwear Inc
Current assignee: Falcon Footwear Inc
Priority date: 2012-08-02
Filing date: 2013-07-30
Publication date: 2014-02-06

Abstract

A shoe construction and method of constructing a shoe may include a shoe upper, and a midsole band configured to be stitched around a periphery of the shoe upper separated from a lowermost periphery of the shoe upper by a distance. The midsole band may be folded over the stitched periphery toward the lowermost periphery. The midsole band may be stitched around the lowermost periphery of the shoe upper. An insole board may be attached to an upper surface of the lowermost periphery of the stitched shoe upper and midsole band. An outsole may be attached to a lower surface of the lowermost periphery of the stitched shoe upper and midsole band, and to a lower surface of the insole board, such that the stitched shoe upper and midsole band do not overlay the outsole. An insole pad may be inserted into the shoe construction.

Description

CROSS REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Provisional Patent Application Ser. No. 61/679,008, filed on Aug. 2, 2012, which is expressly incorporated herein in its entirety by reference thereto.

FIELD OF INVENTION

The present invention relates to a shoe construction and a method of constructing a shoe.

BACKGROUND INFORMATION

Various shoe constructions and methods of constructing shoes are known. For example, one method of shoe construction includes attaching a shoe upper to a shoe sole, and then applying a strip of material, called a “foxing,” that covers and seals the joint between the shoe upper and the shoe sole. Another method of shoe construction includes attaching a shoe upper to a molded shoe sole having vertical sidewalls, called a “foxing-like band,” that surround and are attached to the shoe upper. These two shoe constructions utilizing a foxing or a foxing-like band may be subject to significant import duties based on their particular configurations, e.g., based on the overlap in a vertical plane of the shoe sole and the shoe upper. Accordingly, there is a need for shoe constructions and methods of constructing shoes that are not subject to import duties for a foxing or a foxing-like band.

SUMMARY

A shoe construction according to an example embodiment of the present invention may include a shoe upper, and a midsole band configured to be stitched around a periphery of the shoe upper separated from a lowermost periphery of the shoe upper by a distance, configured to be folded over the stitched periphery toward the lowermost periphery of the shoe upper, and configured to be stitched around the lowermost periphery of the shoe upper.
The shoe upper may include decorative overlays attached to the shoe upper by adhesive, heat sealing and/or stitching.
A decorative surface of the midsole band may be configured to be visible upon folding over the midsole band.
An insole board may be attached to an upper surface of the lowermost periphery of the stitched shoe upper and midsole band by adhesive and/or heat sealing. The insole board may be made of paper, cardboard and/or paperboard, and/or is woven, stitched and/or glued together. The insole board may include an arch support underlying ball-of-foot, arch and/or heel regions of the shoe construction. The arch support may include a metal support attached to an underside of the insole board by rivets, fasteners and/or adhesives.
An outsole may be attached to a lower surface of the lowermost periphery of the stitched shoe upper and midsole band, and to a lower surface of the insole board by adhesive and/or heat sealing, such that the stitched shoe upper and midsole band do not overlay the outsole. The outsole may be made of foam, polymer and/or rubber.
An insole pad may be inserted into the shoe construction. The insole pad may be made of foam, polymer and/or rubber.
A method of constructing a shoe according to an example embodiment of the present invention may include providing a shoe upper, stitching a midsole band around a periphery of the shoe upper separated from a lowermost periphery of the shoe upper by a distance, folding the midsole band over the stitched periphery toward the lowermost periphery of the shoe upper, and stitching the midsole band around the lowermost periphery of the shoe upper.
The method may include attaching decorative overlays to the shoe upper by adhesive, heat sealing and/or stitching.
A decorative surface of the midsole band may be configured to be visible upon folding over the midsole band.
The method may include attaching an insole board to an upper surface of the lowermost periphery of the stitched shoe upper and midsole band by adhesive and/or heat sealing. The insole board may include an arch support underlying ball-of-foot, arch and/or heel regions of the shoe. The arch support may include a metal support attached to an underside of the insole board by rivets, fasteners and/or adhesives.
The method may include attaching an outsole to a lower surface of the lowermost periphery of the stitched shoe upper and midsole band, and to a lower surface of the insole board by adhesive and/or heat sealing, such that the stitched shoe upper and midsole band do not overlay the outsole.
The method may include inserting an insole pad into the shoe.
Example embodiments of the present invention are described in more detail below with reference to the appended Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 a and 1 b schematically show a side view and a bottom view of a shoe upper according to an example embodiment of the present invention.

FIGS. 2 a and 2 b schematically show a side view and a bottom view of a shoe upper and a midsole band according to an example embodiment of the present invention.

FIGS. 3 a and 3 b schematically show a side view and a bottom view of a shoe upper, a midsole band and an insole board according to an example embodiment of the present invention.

FIGS. 4 a and 4 b schematically show a side view and a bottom view of a shoe upper, a midsole band, an insole board and an outsole according to an example embodiment of the present invention.

FIG. 5 schematically shows a flowchart for constructing a shoe according to an example embodiment of the present invention.

DETAILED DESCRIPTION

A shoe construction may comprise the following components:
a) a shoe upper having decorative overlays;
b) a midsole band stitched around a periphery of the shoe upper separated from the lowermost periphery by a distance, folded over the stitched periphery, and stitched around the lowermost periphery;
c) an insole board attached to an upper surface of the lowermost periphery of the stitched shoe upper and midsole band;
d) an outsole attached to a lower surface of the lowermost periphery of the stitched shoe upper and midsole band, and to a lower surface of the insole board, such that the stitched shoe upper and midsole band do not overlay the outsole; and
e) an insole pad inserted into the shoe construction.
A method of constructing a shoe may comprise the following steps:
a) providing a shoe upper;
b) stitching a midsole band around a periphery of the shoe upper separated from the lowermost periphery by a distance;
c) folding the midsole band over the stitched periphery;
d) stitching the midsole band around the lowermost periphery of the shoe upper;
e) attaching an insole board to an upper surface of the lowermost periphery of the stitched shoe upper and midsole band;
f) attaching an outsole to a lower surface of the lowermost periphery of the stitched shoe upper and midsole band, and to a lower surface of the insole board, such that the stitched shoe upper and midsole band do not overlay the outsole; and
g) inserting an insole pad into the shoe construction.
FIGS. 1 a to 4 b schematically show an example embodiment of a shoe construction that results in a complete shoe construction 1, as shown in FIGS. 4 a and 4 b. The complete shoe construction 1 includes a shoe upper 10, a midsole band 20, an insole board 30, an outsole 40 and an insole pad 50.
FIGS. 1 a and 1 b schematically show an example embodiment of a shoe upper 10. The shoe upper 10 may be shaped so as to receive a wearer's foot and cover at least part of an upper portion of the wearer's foot. The shoe upper 10 may include one or more decorative overlays 11 attached on its outer, visible surface. The decorative overlays 11 may be attached to the shoe upper 10 by adhesive, heat sealing, stitching and/or other methods.
As shown in FIG. 1 a, the shoe upper 10 may also include a periphery 12 that extends around the entire periphery of the shoe upper 10 near the eventual bottom surface of the complete shoe construction. As shown in FIG. 1 b, the shoe upper 10 may also include a lowermost periphery 13 that extends inward toward the center of the shoe upper 10 near the eventual bottom surface of the complete shoe construction.
FIGS. 2 a and 2 b schematically show an example embodiment of a shoe upper 10, as described herein, and an attached midsole band 20. The midsole band 20 may be a substantially flat piece of material, and/or an elongate band or strip of material having a decorative surface 21 facing outwards in the complete shoe construction 1.
Initially, the midsole band 20 may be completely stitched 22 around the periphery 12 of the shoe upper 10. The stitching 22 may be spaced a distance away from the lowermost periphery 13 of the shoe upper 10, which distance may be constant or variable around the periphery 12. The midsole band 20 may be stitched 22 in an orientation in which the decorative surface 21 initially faces inwards toward the center of the shoe construction. After stitching 22 around the periphery 12 of the shoe upper 10, the midsole band 20 may be folded over onto itself toward the lowermost periphery 13 of the shoe upper 10, such that the decorative surface 21 of the midsole band 20 faces outwards, i.e., is visible in the complete shoe construction 1. Thus, according to this example embodiment, it should be understood that FIG. 2 a shows the stitching 22 only for illustrative purposes because the stitching 22 is not visible after folding over the midsole band 20. After folding over the midsole band 20, the midsole band 20 may be again stitched 23 to the lowermost periphery 13 of the shoe upper 10, as shown in FIG. 2 b.
Alternatively or additionally, the stitching 22 around the periphery 12 of the shoe upper 10 may be performed on the decorative surface 21 of the midsole band 20, such that the stitching 22 and the decorative surface 21 may remain visible in the complete shoe construction 1. In this alternative example embodiment, the midsole band 20 may not be folded over between stitching 22 to the periphery 12 of the shoe upper 10, and stitching 23 to the lowermost periphery 13 of the shoe upper 10.
FIGS. 3 a and 3 b schematically show an example embodiment of a shoe upper 10 and a midsole band 20, as described herein, and an attached insole board 30. The insole board 30 may be shaped to have a periphery that substantially conforms to the periphery 12 of the shoe upper 10 and underlie substantially all of a wearer's foot. The insole board 30 may be attached to an upper surface of the lowermost periphery 13 of the stitched shoe upper 10 and midsole band 20, as shown in FIG. 3 b. That is, the insole board 30 may be inserted into an interior of the shoe upper 10 and attached to the upper surface of the lowermost periphery 13 of the stitched shoe upper 10 and midsole band 20. The insole board 30 may be attached to the shoe upper 10 and midsole band 20 by adhesive, heat sealing, and/or other methods.
The insole board 30 may be made of paper, cardboard, paperboard and/or other fibrous materials. Additionally or alternatively, the insole board 30 may be woven, stitched and/or glued together. Further, the insole board 30 may have an arch support. The arch support may extend substantially between the heel, arch and/or ball-of-foot regions of a wearer's foot. The arch support may include a metal strip 31 of material attached to an underside of the insole board 30 in order to provide rigidity, form and/or flexion. For example, the arch support may be attached to the insole board 30 by rivets, fasteners, adhesives, and/or other methods.
FIGS. 4 a and 4 b schematically show an example embodiment of a complete shoe construction 1, including a shoe upper 10, a midsole band 20 and an insole board 30, as described herein, and an attached outsole 40 and an inserted insole pad 50 (shown in dashed lines). The outsole 40 may be a substantially flat piece of material that is shaped to have a periphery that substantially conforms to, or is slightly larger than, the periphery 12 of the shoe upper 10, underlies substantially all of a wearer's foot and is configured to contact the ground when worn. The outsole 40 may be made of foam, polymer, rubber and/or other materials.
The outsole 40 may be attached to a lower surface of the lowermost periphery 13 of the stitched shoe upper 10 and midsole band 20, and to a lower surface of the insole board 30. That is, the outsole 40 may be attached to the lower surfaces of the shoe upper 10, midsole band 20 and insole board 30, thereby forming the outsole 40 of the complete shoe construction 1 that makes contact with the ground. The outsole 40 may be attached to the shoe upper 10, the midsole band 20 and the insole board 30 by adhesive, heat sealing, and/or other methods.
An insole pad or thick insole sock 50 may be inserted into the shoe construction to overlay the insole board 30. The insole pad or thick insole sock 50 may be shaped to have a periphery that substantially conforms to, or is slightly smaller than, the periphery 12 of the shoe upper 10, underlies substantially all of a wearer's foot and is configured to provide cushioning and/or support for a wearer's foot. That is, the insole pad 50 may function in a manner similar to a midsole in conventional shoe constructions. The insole pad 50 may be made of suitable cushioning materials, such as for example, foam, polymer, rubber and/or other materials.
In the complete shoe construction 1, the midsole band 20 may be configured to simulate a foxing or a foxing-like band. However, unlike a “foxing,” the midsole band 20 of the example embodiment that simulates a foxing does not cover and seal the joint between the shoe upper and the shoe sole, and unlike a “foxing-like band,” the midsole band 20 of the example embodiment that simulates a foxing-like band is not an integrally molded vertical sidewall of the shoe sole that surrounds and is attached to the shoe upper. The shoe upper 10 and midsole band 20 may not overlay the outsole 40 in a vertical plane. Instead, in a horizontal plane, the outsole 40 may overlay portions of the shoe upper 10 and midsole band 20, as shown in FIGS. 2 b, 3 b and 4 b, for example. Thus, as shown in FIG. 4 a, the shoe upper 10 and midsole band 20 do not overlay the outsole 40 in a vertical plane, such that the example embodiment of the shoe construction according to the present invention may not be subject to import duties for a foxing, or a foxing-like band.
Alternatively or additionally, the outsole 40 may overlay the shoe upper 10 and midsole band 20 in a vertical plane at limited locations around the periphery of the complete shoe construction 1. For example, as shown in FIG. 4 a, the outsole 40 may overlay the shoe upper 10 and midsole band 20 in a vertical plane at the toe and/or heel sections of the shoe construction. Alternatively, the outsole 40 may overlay the shoe upper 10 and midsole band 20 in a limited manner at any location or locations around the periphery of the complete shoe construction. However, such limited amounts of overlay may still not subject the example embodiment of the shoe construction according to the present invention to import duties for a foxing, or a foxing-like band.
FIG. 5 schematically shows a flowchart of a method 60 for constructing a shoe according to an example embodiment of the present invention.
At step 61, a shoe upper 10 may be provided. The shoe upper 10 may include one or more decorative overlays 11 attached to the shoe upper 10 by adhesive, heat sealing, stitching and/or other methods.
At step 62, a midsole band 20 may be stitched 22 around a periphery 12 of the shoe upper 10, the periphery 12 being spaced from the lowermost periphery 13 by a distance.
If the midsole band 20 is stitched 22 to the periphery 12 such that the decorative surface 21 of the midsole band 20 faces inward toward the center of the shoe, then the method proceeds to step 63, in which the midsole band 20 may be folded over toward the lowermost periphery 13 of the shoe upper 10 such that the decorative surface 21 is visible on an outer surface of the shoe. As a result, the stitching 22 may be hidden from view by the folded over midsole band 20 in the complete shoe construction 1. Additionally, the midsole band 20 may be stitched again to the periphery 12 when the decorative surface 21 of the midsole band 20 faces outward toward an outer surface of the shoe, such that the additional stitching may remain visible in the complete shoe construction 1.
Alternatively, the midsole band 20 may be stitched 22 to the periphery 12 such that the decorative surface 21 of the midsole band 20 faces outward, i.e., is visible on an outer surface of the shoe. In such an alternative embodiment, step 63 of folding over the midsole band 20 may then be skipped, and step 62 may be followed directly by step 64. In this alternative, the stitching 22 may remain visible in the complete shoe construction 1.
At step 64, the midsole band 20 may be stitched 23 around the lowermost periphery 13 of the shoe upper 10, thereby securing the midsole band 20 to shoe upper 10 with the decorative surface 21 of the midsole band 20 facing outward toward an outer surface of the shoe.
At step 65, an insole board 30 may be attached to an upper surface of the lowermost periphery 13 of the stitched shoe upper 10 and midsole band 20 by adhesive and/or heat sealing.
At step 66, an outsole 40 may be attached to a lower surface of the lowermost periphery 13 of the stitched shoe upper 10 and midsole band 20, and to a lower surface of the insole board 30 by adhesive and/or heat sealing, such that the stitched shoe upper 10 and midsole band 20 do not overlay the outsole 40.
At step 67, an insole pad 50 may be inserted into the shoe construction.
Although FIG. 5 shows a preferred order of steps of the method 60 of constructing a shoe, some steps of the method 60 may be performed in a different order without adversely affecting the complete shoe construction 1. For example, steps 65 and 66 may be switched such that the outsole 40 is attached to the stitched shoe upper 10 and midsole band 20 before the insole board 30 is attached to the stitched shoe upper 10 and midsole band 20. Other modifications, variations and/or combinations of the method 60 of constructing a shoe may also be possible.
In the method 60 for constructing a shoe according to an example embodiment of the present invention, the midsole band 20 may be configured to simulate a foxing or a foxing-like band. However, unlike a “foxing,” the midsole band 20 of the example embodiment that simulates a foxing does not cover and seal the joint between the shoe upper and the shoe sole, and unlike a “foxing-like band,” the midsole band 20 of the example embodiment that simulates a foxing-like band is not an integrally molded vertical sidewall of the shoe sole that surrounds and is attached to the shoe upper. The shoe upper 10 and midsole band 20 may not overlay the outsole 40 in a vertical plane. Instead, in a horizontal plane, the outsole 40 may overlay portions of the shoe upper 10 and midsole band 20, as shown in FIGS. 2 b, 3 b and 4 b, for example. Thus, as shown in FIG. 4 a, the shoe upper 10 and midsole band 20 do not overlay the outsole 40 in a vertical plane, such that the example embodiment of the shoe construction according to the present invention may not be subject to import duties for a foxing, or a foxing-like band.
Alternatively or additionally, the outsole 40 may overlay the shoe upper 10 and midsole band 20 in a vertical plane at limited locations around the periphery of the complete shoe construction 1. For example, as shown in FIG. 4 a, the outsole 40 may overlay the shoe upper 10 and midsole band 20 in a vertical plane at the toe and/or heel sections of the shoe construction. Alternatively, the outsole 40 may overlay the shoe upper 10 and midsole band 20 in a limited manner at any location or locations around the periphery of the complete shoe construction. However, such limited amounts of overlay may still not subject the example embodiment of the shoe construction according to the present invention to import duties for a foxing, or a foxing-like band.
Although the present invention has been described with reference to particular examples and exemplary embodiments, it should be understood that the foregoing description is in no manner limiting. Moreover, the features described herein may be used in any combination.

Claims

What is claimed is:

1. A shoe construction, comprising:

a shoe upper; and

a midsole band configured to be stitched around a periphery of the shoe upper separated from a lowermost periphery of the shoe upper by a distance, configured to be folded over the stitched periphery toward the lowermost periphery of the shoe upper, and configured to be stitched around the lowermost periphery of the shoe upper.

2. The shoe construction according to claim 1, wherein the shoe upper includes decorative overlays attached to the shoe upper by adhesive, heat sealing and/or stitching.

3. The shoe construction according to claim 1, wherein a decorative surface of the midsole band is configured to be visible upon folding over the midsole band.

4. The shoe construction according to claim 1, further comprising:

an insole board attached to an upper surface of the lowermost periphery of the stitched shoe upper and midsole band by adhesive and/or heat sealing.

5. The shoe construction according to claim 4, wherein the insole board is made of paper, cardboard and/or paperboard, and/or is woven, stitched and/or glued together.

6. The shoe construction according to claim 4, wherein the insole board includes an arch support underlying ball-of-foot, arch and/or heel regions of the shoe construction.

7. The shoe construction according to claim 6, wherein the arch support includes a metal support attached to an underside of the insole board by rivets, fasteners and/or adhesives.

8. The shoe construction according to claim 1, further comprising:

an outsole attached to a lower surface of the lowermost periphery of the stitched shoe upper and midsole band, and to a lower surface of the insole board by adhesive and/or heat sealing, such that the stitched shoe upper and midsole band do not overlay the outsole.

9. The shoe construction according to claim 8, wherein the outsole is made of foam, polymer and/or rubber.

10. The shoe construction according to claim 1, further comprising:

an insole pad inserted into the shoe construction.

11. The shoe construction according to claim 10, wherein the insole pad is made of foam, polymer and/or rubber.

12. A method of constructing a shoe, comprising:

providing a shoe upper;

stitching a midsole band around a periphery of the shoe upper separated from a lowermost periphery of the shoe upper by a distance;

folding the midsole band over the stitched periphery toward the lowermost periphery of the shoe upper; and

stitching the midsole band around the lowermost periphery of the shoe upper.

13. The method according to claim 12, further comprising:

attaching decorative overlays to the shoe upper by adhesive, heat sealing and/or stitching.

14. The method according to claim 12, wherein a decorative surface of the midsole band is configured to be visible upon folding over the midsole band.

15. The method according to claim 12, further comprising:

attaching an insole board to an upper surface of the lowermost periphery of the stitched shoe upper and midsole band by adhesive and/or heat sealing.

16. The method according to claim 15, wherein the insole board includes an arch support underlying ball-of-foot, arch and/or heel regions of the shoe.

17. The method according to claim 16, wherein the arch support includes a metal support attached to an underside of the insole board by rivets, fasteners and/or adhesives.

18. The method according to claim 12, further comprising:

attaching an outsole to a lower surface of the lowermost periphery of the stitched shoe upper and midsole band, and to a lower surface of the insole board by adhesive and/or heat sealing, such that the stitched shoe upper and midsole band do not overlay the outsole.

19. The method according to claim 12, further comprising:

inserting an insole pad into the shoe.