US20210112916A1

US20210112916A1 - Footwear

Info

Publication number: US20210112916A1
Application number: US16/657,217
Authority: US
Inventors: Louk B.J.A. Schulten
Original assignee: Wolverine Outdoors Inc
Current assignee: Wolverine Outdoors Inc
Priority date: 2019-10-18
Filing date: 2019-10-18
Publication date: 2021-04-22

Abstract

A system and method for footwear with a handless entry construction. A heel band may be provided in the footwear that is sufficiently deformable and sufficiently resilient to handlessly a) facilitate insertion of a wearer's foot into the footwear and b) move upward relative to a ground surface to engage a heel of the wearer's foot in order to aid in securing the wearer's foot within the footwear.

Description

FIELD OF THE INVENTION

The present disclosure relates generally to footwear, and more particularly to footwear that can be slipped on a wearer's foot and held securely on the wearer's foot, and a method for making the same.

BACKGROUND

There are a variety of conventional footwear designs in the market that enable a user to easily put on the footwear without substantial use of their hands. This type of conventional footwear is often described as a slip-on design, where, often times, the user puts on the footwear by inserting their foot through any opening in the footwear and pushing forward.
One type of conventional slip-on footwear incorporates gores on sides of the foot in the forefoot region of the footwear. The gores are defined by a void between a portion of the footwear that covers the toes and upper portion of the forefoot (i.e., the vamp) and the portions of the footwear in the forefoot that cover the medial and lateral sides of the foot (i.e., the side panels). A piece of elastic is secured in the gore, allowing the void to expand and provide additional room for the foot to be inserted into the footwear. After the foot has been inserted, the elastic can retract to reduce the size of the void and secure the foot within the footwear.
Another type of conventional slip-on footwear incorporates stalks or rods that extend into an inner layer of a sole support at multiple connection points. These stalks or rods may be deformable elements that deform relative to the connection points from a native position to which the deformable element naturally returns when no deforming force is present. The connection points are considered to provide a point of failure for this type of slip-on footwear, and increase the manufacturing cost over the conventional gore-type of slip-on footwear. This type of footwear also has the downside that the stalks or rods, in order to be sufficiently rigid to return to the natural state, can provide ridges that rub or provide discomfort to the wearer. The result is footwear that often costs more and feels worse than more conventional slip-on footwear, similar to the conventional slip-on footwear described above with the gores and elastic.
However, it is noted that the conventional gore-type slip-on footwear is not without its own downsides. Many wearers have complained that this type of conventional slip-on footwear feels as though it is poorly secured due in large part to the gore design. The elastic may stretch as the user walks, creating the feeling that the footwear is loose or going to slip off. The wearer may appreciate the ease of slipping on the footwear but may limit their use of the footwear to circumstances that avoid the loose feeling, such as preferring casual walking over running.

SUMMARY

A system and method according to one embodiment may include footwear with a handless entry construction. A heel band may be provided in the footwear that is sufficiently deformable and sufficiently resilient to handlessly a) facilitate insertion of a wearer's foot into the footwear and b) move upward relative to a ground surface to engage a heel of the wearer's foot in order to aid in securing the wearer's foot within the footwear.
In one embodiment, a footwear may include an upper configured to receive a foot, and a sole assembly secured to the upper and having a longitudinal axis extending from a forefoot region to a heel region of the sole assembly. The sole assembly may be positioned between the foot and a ground surface. The sole assembly may include an outsole configured to provide traction with respect to the ground surface.
The sole assembly may include a heel band integral with a sole portion of the sole assembly, where the heel band is movable from a resting state to a deformed state to allow hands-free insertion of the foot into the upper. The heel band may be resilient to move away from the deformed state to secure a heel of the foot in response to insertion of the foot within the upper.
In one embodiment, an outsole may be integral to the sole assembly and may be the sole portion of the sole assembly that is integral with the heel band.
In one embodiment, the heel band may include a dynamic pivot integral to the sole assembly and configured to resiliently support the heel band to cantilever about the sole assembly. The dynamic pivot may operate as a type of spring element integral to the sole assembly that is sufficiently tensioned to allow handless insertion of the foot into the footwear and to urge the heel band to secure the heel of the foot after the foot is inserted into the footwear. The dynamic pivot may define at least a portion of a sidewall of the sole assembly.
In one embodiment, the upper may be attached or joined with an interior surface of the heel band, such that movement of the heel band results in a corresponding movement of the upper. The upper may be flexible to distort in conjunction with the heel band to aid hands-free insertion and securement of the foot within the footwear. In one embodiment, the upper may include a flexible heel counter that distorts as the heel band moves down toward the outsole of the footwear.
In one embodiment, a footwear is provided with a foot receiving space capable of receiving a foot, and a sole portion operable to provide support for the foot in the foot receiving space, where the sole portion has a longitudinal axis extending from a forefoot region to a heel region of the footwear. The footwear may also include a heel band integral with the sole portion, where the heel band is movable from a resting state to a deformed state to provide hands-free insertion of the foot into the foot receiving space. The heel band may be resilient to move away from the deformed state to secure a heel of the foot in response to insertion of the foot within the foot receiving space.
The footwear in one embodiment may include an upper that defines at least a portion of the foot receiving space for insertion of the foot.
The heel band in one embodiment may include a medial-side dynamic pivot and a lateral-side dynamic pivot. The heel band may include an interior heel support surface extending from the medial-side dynamic pivot to the lateral-side dynamic pivot of the sole portion, and the heel band may be curved such that the interior heel support surface is operable to engage and support the heel of the foot.
A method of manufacturing footwear is provided in accordance with one embodiment, and includes providing an upper constructed to receive a foot, and molding a one-piece sole assembly having a sole portion and a heel band. The one-piece sole assembly may include a longitudinal axis extending from a forefoot region to a heel region, where the one-piece sole assembly is positionable between the foot and a ground surface. The method may include attaching, to the heel band, an upper that is constructed to receive the foot, and the molding step may include providing a resilient material to facilitate deformation of the heel band to allow hands-free insertion of the foot within the upper.
Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a lateral side view of footwear in accordance with one embodiment.

FIG. 2 shows an expanded view of the footwear in FIG. 1.

FIG. 3 shows a medial side view of the footwear in FIG. 1.

FIG. 4 shows an expanded view of the footwear in FIG. 3.

FIG. 5 shows a medial side view of a sole assembly in accordance with one embodiment.

FIG. 6 shows a top view of the sole assembly in FIG. 5.

FIG. 7 shows a front view of the sole assembly in FIG. 5.

FIG. 8 shows a rear view of the sole assembly in FIG. 5.

FIG. 9 shows a lateral side view of the sole assembly of FIG. 5.

FIG. 10. shows a bottom view of the sole assembly of FIG. 5.

FIG. 11 shows a lateral side view of the footwear in a resting state in accordance with one embodiment.

FIG. 12 shows a lateral side view of the footwear in a distorted state in accordance with one embodiment.

FIG. 13 shows a lateral side view of the footwear in a secured state in accordance with one embodiment.

FIG. 14 shows a top view of the footwear in a resting state in accordance with one embodiment.

FIG. 15 shows a top view of the footwear in a distorted state in accordance with one embodiment.

FIG. 16 shows a top view of the footwear in a secured state in accordance with one embodiment.

DETAILED DESCRIPTION

A system and method according to one embodiment may include footwear with a handless entry construction. A heel band may be provided in the footwear that is sufficiently movable and sufficiently resilient to handlessly a) facilitate insertion of a wearer's foot into the footwear and b) move upward relative to a ground surface to engage a heel of the wearer's foot in order to aid in securing the wearer's foot within the footwear.
I. Overview
Footwear in accordance with one embodiment of the present disclosure is shown in FIGS. 1-10 and generally designated 100. The footwear 100 includes an upper 120 joined with a sole assembly 130. The upper 120 defines an opening 140 (e.g., an ankle opening) through which a foot F may be placed to slip a wearer's foot F into the footwear 100. The upper 120 may also define, at least in part, a space 150 or void in which the foot F is inserted and secured within the footwear 100.
A handless entry construction is provided in accordance with one embodiment to facilitate entry of the foot F through the opening 140 into and securely held within the space 150. The handless entry construction may include a heel band 200 that is resilient and movable from a resting state to an insertion state (e.g., a deformed state) that facilitates entry of the foot F into the space 150. The heel band 200 may also be sufficiently resilient to displace itself from the insertion state to a secured state in which the heel band 200 engages a heel H of the foot F to facilitate securing the foot F within the space 150 of the footwear 100. The heel band 200 in one embodiment may be integral to the sole assembly 130, and the heel band 200 may include one or more dynamic pivots 210, 212 constructed to allow the heel band 200 to cantilever relative to the sole assembly 130.
The upper 120 may be affixed to at least a portion of the heel band 200, such as to an interior surface of the heel band 200, and may deform in a heel region of the upper 120 in response to deformation or movement of the heel band 200 in accordance with one embodiment. The heel band 200 may urge this region of the upper 120 and may engage the heel H of the foot F after the foot F has been inserted within the space 150 of the footwear 100.
II. Footwear Structure Overview
As described herein, the footwear 100 in the illustrated embodiments of FIGS. 1-10 may include a sole assembly 130 and an upper 120. The sole assembly 130 may include a heel band 200 capable of facilitating handless insertion and securement of the foot F within a space 150 of the footwear 100.
The sole assembly 130 may include an outsole 132 that provides traction with respect to the ground on which the wearer may walk or run. The sole assembly 130 may include a midsole 134 disposed between the outsole 132 and the upper 120. The midsole 134 in the illustrated embodiment is integral to the outsole 132; however, it is to be understood that the present disclosure is not so limited. For example, the midsole 134 may be a separate structure adhered or joined with the outsole 132. As another example, the midsole 134 may be disposed continuously between the outsole 132 and the upper 120 or implemented in discrete parts. The midsole 134 may be constructed to provide a mechanical interface between the upper 120 and the outsole 132. Such a mechanical interface may be a cushion interface or an adhesive interface, or a combination thereof.
The outsole 132 may form a tread constructed to contact the ground for traction purposes during use. The outsole 132 in the illustrated embodiment may include a base surface from which one or more features or shapes project to provide a traction surface for the outsole 132. The base surface may include features or shapes that do not project to provide a primary traction surface but rather provide other aesthetic or functional aspects, such as grooves for controlling flex of the outsole 132 during use or sipes to direct water, or both.
The outsole 132 may be manufactured from a conventional outsole material that is selected to provide the desired balance between comfort, wear, traction, and cost. For example, the outsole 132 may be manufactured from a conventional rubber compound or from other suitable wear-resistant materials. The sole assembly 130, including the outsole 132, maybe manufactured using injection or pour molding techniques utilizing conventional molding apparatuses.
Generally speaking, the midsole 134 provides cushioning for the wearer's foot F and the outsole 132 provides durability and traction for the footwear 100. Although the midsole 134 may vary from application to application, the midsole 134 of the illustrated embodiment is manufactured from a relatively resilient material selected to provide the footwear 100 with a desired level of cushioning. The midsole 134 in the illustrated embodiment is formed of the same materials as the outsole 132 of the sole assembly 130. Alternatively, the midsole 134 may be formed of a different material. Example materials for the midsole 134 include ethyl vinyl acetate (“EVA”) or polyurethane. The midsole 134 generally includes an upper surface 144, and may include a lower surface in configurations where the midsole 134 is separate from the outsole 132 or not integrated as a single piece with the outsole 132.
The midsole 134 may be secured to the upper 120 according to a variety of techniques. To provide some examples, the midsole 134 may be adhered to the upper 120, or a Strobel board (not shown) may be adhered to the midsole 134, and the upper 120 may be stitched to the Strobel board. As another example, the midsole 134 may be molded directly onto the bottom of the upper 120 in direct contact with a lasting board. In yet another example, the upper 120 may be slip lasted and adhered to the midsole 134 or attached to the midsole 134 in the molding process for the midsole 134.
In one embodiment, as discussed herein, a sole assembly 130 may include both the outsole 132 and the midsole 134 in an integrated one-piece construction. For instance, the outsole 132 and the midsole 134 may be molded as a single piece. Alternatively, the sole assembly 130 may be formed by securing the outsole 132 to the lower surface of the midsole 134.
The upper 120 may be manufactured in a variety of ways, and may be formed of a variety of materials. For instance, the upper 120 may include one or more fabric, leather, or polymer-based elements, or any combination thereof. In one example, the upper 120 may include a knit or woven fabric manufactured to form the upper 120 as a single piece construction or unitary construction. As another example, the upper 120 may include multiple elements joined together (e.g., via adhesive and/or stitching), and which may be the same or different materials.
In one embodiment, the footwear 100 may include one or more cushioning layers positioned above the sole assembly 130. For instance, the one or more cushioning layers may include a footbed or insole that can be positioned inside the space 150 of the upper 120. The one or more cushioning layers may include a sock liner positioned inside the upper 120, where the sock liner may be perforated to allow airflow through the sock liner. For example, the sock liner may be covered with an array of small apertures that extend vertically through the sock liner. The apertures may cover substantially the entire surface of the sock liner. Alternatively, the apertures may exist only in select regions of the sock liner. The sock liner may include alternative structure for allowing air to flow through the sock liner.
III. Heal Structure
As described herein, in one embodiment of the present disclosure, the sole assembly 130 may include a heel band 200. The heel band 200 may be integrated with a sole portion of the sole assembly 130 to provide a unitary construction. As discussed herein, the sole portion of the sole assembly 130 that is integrated with the heel band 200 may include the outsole 132 or the midsole 134, or both. As an example, the heel band 200 and the outsole 132 may be molded or manufactured as a unitary component.
The heel band 200, as described herein, may include an interior heel surface 220 extending from a lateral side 162 to a medial side 164 of the footwear 100, relative to longitudinal axis 160 of the footwear 100 that extends from a forefoot region to a heel region of the footwear 100. The heel band 200 may be integrally joined with the sole portion of the sole assembly 130 proximate a medial-side dynamic pivot 210 and proximate a lateral-side dynamic pivot 212. The heel band 200 may be shaped to conform generally to the heel H of a foot F, such that the heel band 200 curves from the medial-side dynamic pivot 210 to the lateral-side dynamic pivot 212. In FIG. 5, the heel band 200 extends upward at an angle 173 relative to a base plane 170, which corresponds generally to a plane parallel to a ground contacting plane of the outsole 132. A rear portion 224 of the heel band 200 may define an apex of the curvature from the medial to lateral sides 164, 162, such that starting from the medial side 164, the heel band 200 extends upward along a path 172 at an angle 173 and curves toward the longitudinal axis 160, which generally intersects the rear portion 224 of the heel band 200. The lateral side of the heel band 200 may generally mirror this curvature of the medial side of the heel band 200, relative to the longitudinal axis 160.
Alternatively, the lateral and medial sides of the heel band 200, including the curvatures thereof, may be different from each other. As an example, the positions of the medial-side and lateral-side dynamic pivots 210, 212 along the longitudinal axis 160 may be different from each other—although they are shown to be even or aligned with each other in the illustrated embodiment of FIG. 6.
In the illustrated embodiment of FIG. 6, both the medial-side dynamic pivot 210 and the lateral-side dynamic pivot 212 are positioned along the longitudinal axis 160 to align with an arch region or midfoot region of the sole assembly 130. It is to be understood that the positions of the medial-side and lateral-side dynamic pivots 210, 212 may be shifted forward or backward relative to the positions shown in the illustrated embodiments, depending on the application. The position of the medial-side and lateral-side dynamic pivots 210, 212 along the longitudinal axis 160 may affect the angle 173 of the heel band 200 relative to the outsole 132 or upper surface 144 of the midsole 134.
The interior heel surface 220 may extend from the medial-side dynamic pivot 210, located proximate to an arch region or midfoot region of the sole, to the lateral-side dynamic pivot 212, and may be shaped to conform generally to the heel H of a foot F. The heel band 200 may include a rear portion 224 that, in one embodiment, forms both the uppermost and rearmost portion of the heel band 200. The rear portion 224 may also form the apex of curvature for the interior heel surface 220 in its extension from the medial-side to the lateral-side and to generally conform to the contour of a heel H of the foot F.
The angle 173 in the illustrated embodiment is about 40°; however, the angle 173 may change depending on the application. For instance, the angle 173 may be changed to accommodate a different look or feel for the footwear 100. As another example, as discussed herein, the angle 173 may be changed to affect hands-free insertion and securement of the foot F within the footwear 100.
It is noted that the angle 173 may affect the properties of the heel band 200 related to ease of deformability for hands-free insertion of the foot F into the space 150 and resiliency of the heel band 200 to displace from the deformed position to engage the heel H of the foot F and help secure the foot F within the space 150. As described herein, the heel band 200 may move and distort (e.g., the dynamic pivots 210, 212 may distort) to enable hands-free insertion into the space 150. This may involve the dynamic pivots 210, 212 allowing the heel band 200 to cantilever relative to the base plane 170, such that the angle 173 and the rear portion 224 is displaced closer to the base plane 170 or the sole assembly 130. Decreasing the angle 173 lessens the change in angle provided to allow handsfree insertion of the foot F into the space 150. As a result, less movement and less distortion may be provided to allow handsfree insertion of the foot F into the space 150. Increasing the angle 173 increases the change in angle provided to allow handsfree insertion of the foot F into the space 150, yielding more distortion and more movement to allow handsfree insertion.
The angle 173 may also affect properties of the heel band 200 that relate to the ability of the footwear 100 to secure the heel H of the foot F after insertion of the foot F into the space 150 in a handsfree manner. For instance, increasing the angle 173 increases the amount of distortion on the dynamic pivots 210, 212 used to provide handsfree insertion. And increased distortion may yield greater spring force in the dynamic pivots 210, 212 to urge the rear portion 224 of the heel band 200 over the heel H of the foot F into a secured position after the foot F has been inserted into the space 150. Decreasing the angle 173 may have the opposite effect. Decreasing the angle 173, decreases the distortion provided to allow hands-free insertion of the foot F, and reduces the amount of spring force in the dynamic pivots 210, 212 to urge the rear portion 224 to the secured position after the foot F has been inserted into the space 150.
Material properties of the heel band 200, including the medial-side dynamic pivot 210 and the lateral-side dynamic pivot 212, may also affect operation as it relates to ease of insertion of the foot F in a handsfree manner and displacement of the heel band 200 for securement of the foot F after insertion. For instance, properties, such as elasticity and hardness, may affect ease of distortion and movement of the heel band 200 in response to hands-free insertion of the foot F into the space 150. These properties may also affect the amount of spring force built up in the heel band 200 as the foot F is inserted into the space 150 and the heel band 200 is distorted. In one embodiment, there may be a tradeoff between a) the ease of insertion and b) the spring force necessary for moving the heel band 200 to a secured position relative to the heel H after insertion of the foot F. This tradeoff may lead to selection of an angle 173 and material properties that yield dynamic pivots 210, 212 capable of satisfying these constraints. In the illustrated embodiment, the angle 173 is about 40°, the durometer or hardness of the heel band 200 is about 55C+/−3.
It is noted that material thickness of the heel band 200 in one or more regions of thereof, including the dynamic pivots 210, 212, may affect ease of hands-free insertion and operability to secure the heel H in a hands-free manner after insertion. For instance, increasing the thickness or the amount of material in the dynamic pivots 210, 212 may decrease the elasticity of the dynamic pivots 210, 212, thereby making the dynamic pivots 210, 212 more resistant to distortion during insertion of the foot F, and increasing the spring force built up in the dynamic pivots 210, 212 after insertion of the foot F in order to move the rear portion 224 of the heel band 200 from the distorted position to a secured position in which the heel band 200 substantially secures the heel H of the foot F. In other words, making the dynamic pivots 210, 212 more or less elastic can be achieved in a variety of ways, including via material selection, changing the angle 173, and changing the material thickness. The elasticity and hardness of the dynamic pivots 210, 212 may affect the spring force in the heel band 200 that urges the heel band 200 to cantilever upward from a distorted position to allow the heel band 200 to secure the heel H in a handsfree manner. The heel band 200 may be pushed down by the foot F as the wearer wiggles her foot F into the footwear 100, and after the foot F is wiggled into the footwear 100, the heel band 200 may pop up to secure the heel H of the foot F within the footwear 100.
The interior heel surface 220 of the heel band 200 that is proximate the rear portion 224, in one embodiment, may tilt in response to the heel band 200 being pushed down by the foot F. For instance, as depicted in the illustrated embodiment of FIG. 12, the interior heel surface 220 near the rear portion 224 is tilted somewhat to face toward the heel H of the foot F in response to the foot F pushing down the heel band 200. In other words, the heel band 200 may stretch in the area proximate the rear portion 224 such that the interior heel surface 220 tilts relative to the remaining portions of the interior heel surface 220. This tilt of the interior heel surface 220 may facilitate entry of the foot F in a handsfree manner. It is to be understood that the present disclosure is not limited to the tilting of the interior heel surface 220 in the manner shown in FIG. 12. For instance, the interior heel surface 220 may be configured such that the angle of the interior heel surface 220 proximate the rear portion 224 remains substantially the same relative to the remaining portions of the interior heel surface 220 as the heel band 200 is pushed downward.
The dynamic pivots 210, 212, in one embodiment, may be at least partially displaced away from the longitudinal axis 160 as the heel band 200 cantilevers toward the base plane 170 during insertion of the foot F into the space 150. This displacement may facilitate widening of the space 150 during insertion of the foot F, thereby aiding handsfree insertion of the foot F into the space 150. This outward distortion or widening can be seem in the illustrated embodiment of FIG. 15.
In the illustrated embodiment, as discussed herein, the upper 120 may be connected to the interior heel surface 220 of the heel band 200 such that the upper 120 may flex in response to movement of the heel band 200. As an example, the upper 120 may be stitched to the rear portion 224 of the heel band 200, with an optional recess 226 in an outer surface of the heel band 200 configured to accept the stiches. The recess may substantially prevent the stiches from protruding from the outer surface of the heel band 200, such that in one embodiment, if the heel band 200 is inverted, a wearer's foot F does not rub or abrade the stiches proximal to the outer surface during insertion of the foot F.
In addition to alternative to stitching, adhesive may be utilized to join the upper 120 to the heel band 200. For instance, a portion of the upper 120 adhered to a region corresponding to the interior heel surface 220 and the dynamic pivots 210, 212 may be displaced away or outwardly from the longitudinal axis 160 in response to outward movement of the dynamic pivots 210, 212 during insertion of the foot F into the space 150. This displacement of the portion of the upper 120 near the dynamic pivots 210, 212 may widen the upper 120 in this region, facilitating insertion of the foot F into the space 150.
As another example, a portion of the upper 120 adhered to a region corresponding to the interior heel surface 220 and the rear portion 224 may be displaced toward the base plane 170 along with the rear portion 224 in response to insertion of the foot F through the opening 140 and in to the space 150. This portion of the upper 120 may be displaced upwardly along with the rear portion 224 after the foot F is fully inserted into the space 150 and the heel H of the foot F clears the rear portion 224 of the heel band 200.
In an alternative embodiment, the heel band 200 may be manufactured separate from the sole portion of the sole assembly 130. In this configuration, the heel band 200 may be attached to the sole portion in a variety of ways, including adhesive or a fastener. The heel band 200, for instance, may include a medial end and a lateral end. The medial end may be connected to a medial side of the sole assembly 130 and the lateral end may be connected to a lateral side of the sole assembly 130. A rear portion 224 of the heel band 200, as discussed herein, may be positioned to deform to facilitate handless entry of a foot F within the space 150 of the footwear 100, and after the foot F is inserted within the space 150, the heel band 200 may be sufficiently resilient to displace from the deformed position to a position that secures the heel H of the foot F to facilitate securing the foot F within the space 150.
The heel band 200 in this alternative construction may form all or a portion of a dynamic pivot 210, 212 to enable the heel band 200 to cantilever relative to the sole portion of the sole assembly 130. For instance, the joint or connection between the medial end of the heel band 200 and the sole portion may form the dynamic pivot 210, 212, such that part of the heel band 200 and part of the sole portion provide the dynamic pivot 210, 212.
A method of manufacturing the footwear with the heel structure is provided in accordance with one embodiment. The method may include providing an upper 120 constructed to receive a foot F, and molding a one-piece sole assembly 130 having a sole portion and a heel band 200. The one-piece sole assembly 130 may include a longitudinal axis 160 extending from a forefoot region to a heel region, where the one-piece sole assembly 130 is positionable between the foot F and a ground surface.
The method may include attaching, to the heel band 200, an upper 120 that is constructed to receive the foot F. The heel band 200 may be formed of a resilient material to facilitate deformation of the heel band 200 to allow hands-free insertion of the foot F within the upper 120. The sole portion may be an outsole 132 in one embodiment.
The molding process in one embodiment may include molding a dynamic pivot 210, 212 between the heel band 200 and the outsole 132, where the dynamic pivot 210, 212 allows the heel band 200 to cantilever about the outsole 132 in response to insertion of the foot F within the upper 120.
The molding process, as described herein, may involve injection molding in multiple layers with different or similar types of materials. The materials may vary from application to application. As an example, the material may include foam bead material, such as expanded polystyrene, expanded polypropylene, expanded thermoplastic polyurethane (eTPU), expanded thermoplastic polyethylene (eTPE), or expanded polyetherblockamide (PEBA), or a combination thereof. As another example, the materials may include rubber or plastic.
IV. Method of Operation
A method of inserting the foot F into the space 150 of the footwear 100 is shown in the illustrated embodiments of FIGS. 11-16. The method may include insertion of the foot F into the footwear 100 in a hands-free manner, such that the wearer need not use her hands to put on the footwear 100. It is to be understood that the wearer could use her hands if desired; however, in the method described herein, use of hands is considered unnecessary to insert and secure the foot F within the footwear 100.
The method may include providing the footwear 100 in accordance with one embodiment described herein, as shown in FIGS. 11 and 14. The footwear 100 in the illustrated embodiment is shown in a resting state on a ground surface prior to an attempt to insert the foot F through the opening 140 and into the space 150. As depicted in the illustrated embodiments of FIGS. 12 and 15, the wearer may insert her foot F through the opening 140 with the bottom of her heel H contacting the rear portion 224 of the heel band 200, causing the heel band 200 to distort. Specifically, the dynamic pivots 210, 212 of the heel band 200 may distort allowing the rear portion 224 to be displaced toward the base plane 170. With this distortion, the opening 140 may be sufficient for the wearer to slide her entire foot F into the space 150. This state of the footwear 100 may be considered a distorted state.
After the foot F has been received in the space 150 and the heel H has cleared the rear portion 224 of the heel band 200, as shown in the illustrated embodiments of FIGS. 13 and 16, the dynamic pivots 210, 212 may cause the heel band 200 to cantilever upward away from the base plane 170. The heel band 200 may substantially secure the heel H of the foot F at this stage, facilitating securement of the foot F within the footwear 100. This may be considered a secured state of the footwear 100. It is noted that the heel band 200 may be positioned slightly differently between the secured state and the resting state due in part to the position and shape of the wearer's foot F. However, these two positions may be similar with the angle 173 in the secured state and the resting state being similar or the same.
In one embodiment, in the resting state, the rear portion 224 of the heel band 200 is disposed to be even with, or forward of, a rear outsole portion of the outsole 132 along the longitudinal axis 160. In the deformed state, the heel band 200 is pivoted toward the outsole 132 such that the rear portion 224 is disposed aft of the rear outsole portion of the outsole 132 along the longitudinal axis 160. This may facilitate allowing the heel H to clear the heel band 200 as the foot F is inserted into the space 150 and to move to a secured position, thereby providing hands-free securement of the foot F within the footwear 100.
In an alternative embodiment, the wearer of the footwear 100 may insert her foot F into the space 150 by contacting the heel band 200 causing it to invert such that the interior heel surface 220 curves toward the forefoot and potentially down toward the sole assembly 130, and perhaps contacting the bottom surface of the space 150. The foot F may slide over the heel band 200 into the space 150, and after the foot F is received within the space 150, the heel band 200 may be sufficiently resilient to slide out from under the foot F and move to secure the heel H similar to that shown in FIGS. 13 and 16.
Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).
The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.

Claims

1. A footwear comprising:

an upper configured to receive a foot;

a sole assembly secured to said upper and having a longitudinal axis extending from a forefoot region to a heel region of said sole assembly, said sole assembly positioned between the foot and a ground surface;

said sole assembly including an outsole configured to provide traction with respect to the ground surface; and

said sole assembly including a heel band that is integral with a sole portion of the sole assembly, said heel band being deformable from a resting state to a deformed state to provide hands-free insertion of the foot into said upper, said heel band being resilient to move away from said deformed state to secure a heel of the foot in response to insertion of the foot within said upper.

2. The footwear of claim 1 wherein said outsole is integral with said sole assembly, and wherein said sole portion is said outsole.

3. The footwear of claim 1 wherein said heel band includes a dynamic pivot integral to the sole assembly, wherein said dynamic pivot is configured to resiliently support said heel band to cantilever about said dynamic pivot.

4. The footwear of claim 3 wherein said dynamic pivot defines a sidewall of said sole assembly, and wherein said dynamic pivot is deformed in said deformed state of said heel band such that said sidewall of said sole assembly is displaced away from said longitudinal axis.

5. The footwear of claim 4 wherein said upper formed of a flexible material that defines a void capable of receiving the foot and an ankle opening through which the foot is insertable into said void.

6. The footwear of claim 5 wherein said upper is attached to an interior heel support surface of said heel band, and wherein, in said deformed state, said flexible material of said upper is displaced laterally relative to said longitudinal axis, whereby lateral displacement of said flexible material of said upper provides additional lateral space for inserting the foot into said void of said upper.

7. The footwear of claim 4 wherein said upper includes a heel counter, and wherein said heel counter is movable in response to deformation of said heel support to allow insertion of the foot into said upper.

8. The footwear of claim 3 wherein:

said heel band includes a medial-side dynamic pivot and a lateral-side dynamic pivot;

said heel band includes an interior heel support surface extending from said medial-side dynamic pivot to said lateral-side dynamic pivot of said sole assembly; and

said heel band is curved such that said interior heel support surface is operable to engage and support the heel of the foot.

9. The footwear of claim 8 wherein, in said deformed state, said heel band is inverted relative to said medial-side dynamic pivot and said lateral-side dynamic pivot such that a rear band portion of said heel band is displaced forward relative to a position of said rear band portion in said resting state along said longitudinal axis.

10. The footwear of claim 9 wherein, in said deformed state, said rear band portion of said heel band is displaced toward said outsole relative to a position of said rear band portion in said resting state.

11. The footwear of claim 8 wherein, in said resting state, a rear band portion of said heel band is disposed to be even with or forward of a rear outsole portion of said outsole along said longitudinal axis, and wherein, in said deformed state, said heel band is pivoted toward said outsole such that said rear band portion is disposed aft of said rear outsole portion of said outsole along said longitudinal axis.

12. The footwear of claim 1 wherein said sole assembly is injection molded as a one-piece sole assembly that integrally includes said heel band and said outsole.

13. The footwear of claim 1 wherein said heel band is sufficiently resilient to move from said deformed state, in which the heel is insufficiently secured, to slip over the heel to securely support the heel in a hands-free manner.

14. The footwear of claim 1 wherein said sole assembly includes a midsole that is said sole portion.

15. A footwear comprising:

a foot receiving space capable of receiving a foot;

a sole portion operable to provide support for the foot in said foot receiving space, said sole portion having a longitudinal axis extending from a forefoot region to a heel region of the footwear; and

a heel band being integral with said sole portion, said heel band being movable from a resting state to a deformed state to provide hands-free insertion of the foot into said foot receiving space, said heel band being resilient to move away from said deformed state to secure a heel of the foot in response to insertion of the foot within said foot receiving space.

16. The footwear of claim 15 wherein said sole portion is an outsole, and wherein said outsole is configured to provide traction with respect to a ground surface.

17. The footwear of claim 15 wherein said heel band includes a dynamic pivot that is integral to said sole portion, wherein said dynamic pivot is configured to resiliently support said heel band to cantilever about said dynamic pivot.

18. The footwear of claim 15 comprising an upper that defines at least a portion of said foot receiving space for insertion of the foot.

19. The footwear of claim 15 wherein:

said heel band includes an interior heel support surface extending from said medial-side dynamic pivot to said lateral-side dynamic pivot of said sole portion; and

20. The footwear of claim 15 comprising a forefoot band coupled to said sole portion, wherein said forefoot band and said heel band are operable to define said foot receiving space.

21. A method of manufacturing footwear, said method comprising:

providing an upper constructed to receive a foot;

molding a one-piece sole assembly having a sole portion and a heel band, the one-piece sole assembly including a longitudinal axis extending from a forefoot region to a heel region, the one-piece sole assembly being positionable between the foot and a ground surface;

attaching, to the heel band, an upper that is constructed to receive the foot; and

said molding the one-piece sole assembly including providing a resilient material to facilitate deformation of the heel band to allow hands-free insertion of the foot within the upper.

22. The method of claim 21 wherein the sole portion is an outsole, and wherein said molding the one-piece sole assembly includes molding a dynamic pivot between the heel band and the outsole, wherein the dynamic pivot allows the heel band to cantilever about the outsole in response to insertion of the foot within the upper.

23. The method of claim 21 wherein said molding includes providing:

the heel band including a medial-side dynamic pivot and a lateral-side dynamic pivot;

the heel band including an interior heel support surface extending from the medial-side dynamic pivot to the lateral-side dynamic pivot of the one-piece sole assembly; and

the heel band being curved such that the interior heel support surface is operable to engage and support a heel of the foot.