WO2010062722A2

WO2010062722A2 - Multilayer shoe sole

Info

Publication number: WO2010062722A2
Application number: PCT/US2009/063008
Authority: WO
Inventors: Dino Carlo Orsini; Al Melillo
Original assignee: Speciality Footwear International, Llp
Priority date: 2008-11-02
Filing date: 2009-11-02
Publication date: 2010-06-03
Also published as: WO2010062722A3

Abstract

The present invention provides a shoe having a sole that includes a midsole disposed between an outer sole and an inner sole, and a foot engaging sole attached to the inner sole. The outer sole includes a ground contact layer and one or more first cushion layers that increase in hardness from the ground contact layer to the midsole. The inner sole includes a top layer and one or more second cushion layers that decrease in hardness from the midsole to the top layer. The midsole has a hardness greater than the first cushion layers and the second cushion layers. Typically, the first cushion layers and second cushion layers have a hardness of between 20 Shore D and 45 Shore D, and the midsole has a hardness of between 45 Shore D and 70 Shore D.

Description

MULTILAYER SHOE SOLE

Field of Invention

The present invention relates generally to the field of footwear, and more particularly to a multilayer shoe sole.

Background Art

A significant amount of development has been carried out in recent years to improve the soles of shoes, especially footwear for everyday use and for running and/or jumping. Good impact absorption is an essential property for the soles of running and walking shoes, as well as for shoes used in sports which require jumping, e.g., basketball and aerobics. Not only must a sole absorb shock, but it must be durable to withstand repeated cycles of compression and expansion and it must do so resiliency. The sole must be dense and rigid enough to prevent the wearer's foot from bottoming out upon impact.

Today, humans are almost totally insulated from the natural environments. Such removal from the natural environment has had devastating consequences for the human body. Tests conducted on men walking on hard surfaces such as cement and dirt floor have concluded that by age 29, a man living in modern environment shows the body posture deterioration to be found in a man of 45 living on dirt floor. Various technologies exist in the shoe making industry in an attempt to provide an apparatus that minimizes painful impact of a hard floor.

One example can be found in the United States Patent Number 4,627,179 issued to McElroy. The ' 179 patent teaches a shock absorbing insole construction including an upper layer of plastic material having a storage modulus which is about 100 times the storage modulus of a lower layer of material and both materials having a relatively high loss factor. The upper layer is a polyethylene-vinyl acetate and the lower layer is a viscoelastic polyurethane polymer.

Another example can be found in the United States Patent Number 4,890,397 to Harada et al. Briefly, Harada teaches a shoe for use in sports involving running and having an outer ground engaging sole, an inner foot engaging sole and a midsole there between, the midsole having therein, at least at the outer portion of the heel, a shock absorbing member with a shock absorbing synthetic resin foam layer bonded at its upper and lower surfaces to hard plates. Yet another example can be found in the United States Patent Number 6,079,125 issued to Quellais. The '125 patent teaches a sole with three layers, including an outer or ground contact sole having flexibility, ground-gripping, and abrasion-resistance properties, an upper or comfort layer positioned directly beneath the foot and having elastic shock- absorption properties, and an intermediate layer or rib positioned directly between the upper portion of the contact layer and the lower portion of the comfort layer and having torsional rigidity properties which provide both for the distribution of shocks sensed by the contact layer and for their diffusion over the comfort layer before they come into contact with the foot.

The United States Patent Application Publication Number 20060121268 teaches a composite panel having at least two directly contiguous layers or sections of filler- containing foamed plastics, which are each composed of thermoplastic cross-linked and closed-cell foamed material, having at least different hardness and/or color and/or density, and which are bonded to one another without the use of an adhesive. The manufacturing takes place by the foaming and cross-linking of plastic layers in a press. The composite panel is suitable for use in orthopedic technology.

As yet another example is found in the United States Patent Number 5,675,915. The '915 patent teaches an impact absorbing device for parachutists. A conventional shoe may be modified by riveting or otherwise fastening hook and loop material to the bottom of the overshoe. An impact absorbing sole having a top surface including hook and loop material may be quickly attached to and detached from the modified overshoe. The '915 patent also discloses fastening straps in lieu of or in addition to the hook and loop fastener. The fastening straps may encircle the forefoot area and/or the heel and ankle. The sole may have three layers of solid material or the middle layer may include apertures, which correspond to the heel and ball areas of the foot, for receiving cushioning inserts. The layers may be made of a high density open cell urethane foam, a microcellular ethylene vinyl acetate (EVA) polyethylene foam, a viscoelastic plasticized polyurethane polymer, or a viscoelastic urethane rubber polymer. The layers may be laminated together using any conventional adhesive.

Finally, the United States Patent Number 5,974,695 teaches a structure for enhancing the stability of a midsole including a plurality of strands which extend from a position on top of the midsole to a location secured to the bottom of the midsole. The strands are secured to an energy return system which is positioned on the top of the midsole. The initial strike imparted on the lateral side of the midsole compresses both the midsole and the strands. The strands, which separate during the initial strike from the midsole and assume an arcuate shape, enhance the shock absorbing properties of the shoe. As the foot rotates, the heel exerts pressure on the energy return system, and the strands are then pulled inwardly thereby restricting the outward movement of the midsole. The foot is further unlikely to assume a substantially pronated position due to the tension in the strands along the medial portion of structure in combination with the shock absorption upon initial strike.

However, these examples fail to both eliminate the painful, stressful, dissolving impact of a hard floor while at the same time providing a firm platform to enhance body posture. As a result, there is a need for a shoe and shoe sole that alleviates the painful impact that hard surfaces have on the human body, while at the same time providing a firm platform to enhance body posture.

Summary of the Invention

The present invention strikes the proper balance between soft components and stable-firm components that has eluded shoemakers in the past. The present invention alleviates the painful impact that hard surfaces have on the human body by eliminating 75% to 95% of a heel strike, while at the same time providing a firm platform to enhance body posture.

In one embodiment, the present invention provides a shoe having a sole that includes a midsole disposed between an outer sole and an inner sole, and a foot engaging sole attached to the inner sole. The outer sole includes a ground contact layer and one or more first cushion layers that increase in hardness from the ground contact layer to the midsole. The inner sole includes a top layer and one or more second cushion layers that decrease in hardness from the midsole to the top layer. The midsole has a hardness greater than the first cushion layers and the second cushion layers. Typically, the first cushion layers and second cushion layers have a hardness of between 20 Shore D and 45 Shore D, and the midsole has a hardness of between 45 Shore D and 70 Shore D.

In another embodiment, the present invention provides a shoe having a sole that includes a midsole having a hardness of between 55 Shore D and 65 Shore D disposed between an outer sole and an inner sole, and a foot engaging sole attached to the inner sole. The outer sole includes a ground contact layer, a first cushion layer A having a lower hardness of between 20 Shore D and 25 Shore D and an upper hardness of between 25 Shore D and 30 Shore D, and a first cushion layer B having a lower hardness of between 30 Shore D and 35 Shore D and an upper hardness of between 35 Shore D and 40 Shore D. The inner sole includes a top layer, a second cushion layer A having an lower hardness of between 35 Shore D and 40 Shore D and an upper hardness of between 30 Shore D and 35 Shore D, and a second cushion layer B having a lower hardness of between 30 Shore D and 25 Shore D and an upper hardness of between 25 Shore D and 20 Shore D. The foot engaging sole includes a leather cover, a thermoplastic polymer layer contoured to support a foot and a backbone layer.

In yet another embodiment, the present invention provides a method of manufacturing a sole for a shoe by providing a midsole having a hardness greater than a first cushion layer and a second cushion layer, providing an outer sole having a ground contact layer and one or more first cushion layers that increase in hardness from the ground contact layer to the midsole, and providing an inner sole having a top layer and one or more second cushion layers that decrease in hardness from the midsole to the top layer. The midsole attached between an outer sole and an inner sole. A foot engaging sole is attached to the inner sole.

The present invention is described in detail below with reference to the accompanying drawings.

Brief Description of the Drawings

The above and further advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings, in which:

FIGURE 1 is a cross-section of a shoe sole in accordance with one embodiment of the present invention;

FIGURE 2 is a cross-section of a shoe sole in accordance with another embodiment of the present invention; and

FIGURE 3 is a flow chart of a method of manufacturing a shoe sole in accordance with another embodiment of the present invention

Description of the Invention

While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.

The human body has two contradicting needs. On one hand, the human body needs a rather firm supporting component for proper spine posture; on the other hand, a softer footwear component is desirable to protect joints and muscles against the force generated by striking a hard surface and to provide comfort. These two conflicting needs have challenged the shoe industry many years. Shoemakers have not been able to strike a proper balance between the two or to provide a solution to address both needs until now.

The present invention not only creates a more comfortable shoe, but also uses advances in material constructions with novel technologies in counterbalancing forces in conjunction. The present invention achieves a superior degree of balancing the competing forces and needs mentioned above. The present invention provides a system whereby the two central elements are interrelated to deliver comfortable and stable footwear.

A softer footwear component is effective in neutralizing heel strike when it is placed between a hard surface generating the strike and another firmer component. This is the reason why the softest component in the present invention is placed immediately next to the floor. This first component of the sole can in some cases eliminate up to 94% of the impact of a heel strike. Since the human body needs a rather firm supporting component for proper posture, the materials need to be rather stable and firm in the immediate vicinity of the foot. The second firm component provides the proper degree of support for proper body posture and floats on a rather soft package, which neutralizes the impact of any floor on joints and muscles.

Now referring to FIGURE 1, a cross-section of a shoe sole 100 in accordance with one embodiment of the present invention is shown. The sole 100 includes a midsole 102 disposed between an outer sole 104 and an inner sole 106, and a foot engaging sole 108 attached to the inner sole 106. The outer sole 104 includes a ground contact layer 110 and one or more first cushion layers 112 that increase in hardness from the ground contact layer 110 to the midsole 102. The inner sole 106 includes a top layer 114 and one or more second cushion layers 116 that decrease in hardness from the midsole 102 to the top layer 116. The midsole 102 has a hardness greater than the first cushion layers 112 and the second cushion layers 116. Typically, the first cushion layers 112 and second cushion layers 116 have a hardness of between 20 Shore D and 45 Shore D, and the midsole 102 has a hardness of between 45 Shore D and 70 Shore D. Note that the layers shown in FIGURE 1 are not to scale.

The sole 100 eliminates between 75% and 94% of a heel strike (depending materials and configuration) and provides a firm platform for proper body posture of a wearer. For example, the outer sole 104 eliminates between 25% and 35% of a heel strike, the inner sole 106 eliminates between 25% and 35% of the heel strike, and the midsole 102 eliminates between 25% and 30% of the heel strike. The first cushion layers 112, the second cushion layers 116 and the midsole 102 are preferably made of an ethylene-vinyl acetate material, but can be made of any thermoplastic polymer, such as a polyurethane, a polyester elastomer, a rubber, a polyamide, a PEBE, a PEBA, a PBT, a TR, a TPR, a Texon or any combination thereof. The ground contact layer 110 and the top layer 114 are preferably made of leather or a synthetic leather material. The foot engaging sole 108 is typically made of leather along with one or more materials that provide comfort, yet prevent lateral and horizontal distortions.

Referring now to FIGURE 2, a cross-section of a shoe sole 200 in accordance with another embodiment of the present invention is shown. The sole 200 includes a midsole 102 having a hardness of between 55 Shore D and 65 Shore D disposed between an outer sole 104 and an inner sole 106, and a foot engaging sole 108 attached to the inner sole 106. The outer sole 104 includes a ground contact layer 110, a first cushion layer A 202 having a lower hardness of between 20 Shore D and 25 Shore D and an upper hardness of between 25 Shore D and 30 Shore D, and a first cushion layer B 204 having a lower hardness of between 30 Shore D and 35 Shore D and an upper hardness of between 35 Shore D and 40 Shore D. The inner sole 106 includes a top layer 114, a second cushion layer A 206 having an lower hardness of between 35 Shore D and 40 Shore D and an upper hardness of between 30 Shore D and 35 Shore D, and a second cushion layer B 208 having a lower hardness of between 30 Shore D and 25 Shore D and an upper hardness of between 25 Shore D and 20 Shore D. The foot engaging sole 108 includes a leather cover 210, a thermoplastic polymer layer 212 contoured to support a foot and a backbone layer 214. Note that the layers shown in FIGURE 2 are not to scale.

The sole 100 eliminates between 75% and 94% of a heel strike (depending materials and configuration) and provides a firm platform for proper body posture of a wearer. For example, the outer sole 104 eliminates between 25% and 35% of a heel strike, the inner sole 106 eliminates between 25% and 35% of the heel strike, and the midsole 102 eliminates between 25% and 30% of the heel strike. The first cushion layers 202 & 204, the second cushion layers 206 & 208, and the midsole 102 are preferably made of an ethylene-vinyl acetate material, but can be made of any thermoplastic polymer, such as a polyurethane, a polyester elastomer, a rubber, a polyamide, a PEBE, a PEBA, a PBT, a TR, a TPR, a Texon or any combination thereof. The ground contact layer 110 and the top layer 114 are preferably made of leather or a synthetic leather material. The foot engaging sole 108 is typically made of leather along with one or more materials that provide comfort, yet prevent lateral and horizontal distortions. The backbone layer 214 is preferably a leather adhesive composite material having an imbedded metal shank.

Now referring to FIGURE 3, a flow chart 300 of a method of manufacturing a shoe sole in accordance with another embodiment of the present invention is shown. A midsole 102 is provided in block 302 wherein the midsole 102 has a hardness greater than a first cushion layer 112 and a second cushion layer 116. An outer sole 104 is then provided in block 302 wherein the outer sole 104 has a ground contact layer 110 and one or more first cushion layers 112 that increase in hardness from the ground contact layer 110 to the midsole 102. An inner sole 106 is then provided in block 304 wherein the inner sole 106 has a top layer 114 and one or more second cushion layers 116 that decrease in hardness from the midsole 102 to the top layer 114. The midsole 102 is attached between the outer sole 104 and the inner sole 106 in block 308. A foot engaging sole 108 is attached to the inner sole 106 in block 310.

The present invention has been demonstrated in a variety of settings. The initial demonstration occurred at the factory with a focus group of factory workers to use the components one at a time and the package as a whole at the end. Additional demonstrations were conducted with 60 individuals for a period of seven to ten days. These individuals were on their feet for most of the day, between 10 to 14 hours, and did a lot of walking. All of them had tried different styles of shoes over the years to minimize pain and fatigue, but they reported that the present invention was vastly superior to anything they had tried before. This demonstration revealed that the present invention delivers a high degree of comfort for a long period of time.

Another example of the present invention will now be described proceeding from the bottom to the top of the outsole, where the bottom is defined as the side that contacts the floor. The first layer is the outsole and can be made out of leather, which best insulation a person from the floor and provides sufficient abrasion and elasticity characteristics. The second layer can be made of EVA that has an average Shore D value of about 25. EVA is a soft element derivitized from crude oil. Typically, a Shore D of about 15 is not used in footwear because it would be deformed by a person over about 175 lbs. This layer neutralizes up to about 35 % of the heel strike force. This layer also has an increasing gradient of hardness from bottom to top with the bottom section having a Shore D value of about 23, and the top section having a Shore D value of about 27 for an average of about 25 Shore D.

The third layer still includes EVA, but with an average of about 35 Shore D, harder and firmer than the previous layer. It is positioned neutralizes up to about 65 % of the heel strike force in addition to the 35% from the last layer. Similar to the last layer, it has an increasing gradient of hardness such that the bottom section has a Shore D value of about 33 and the top section has a Shore D value of about 37 for a combined average of about 35 Shore D.

The fourth element can be made of EVA as well with an average Shore D value of about 60, which is the hardest, most dense layer of EVA. This layer absorbs up to about 30% of the remaining heel strike force. Combining with the previous layers, the combination eliminates at least about 94% of the heel strike force. It should be noted that there is a difference within layers 2 and 3. In the second layer, for instance, the lower part has a Shore D value of about 23 and the higher part has a Shore D value of about 27. In other words, the lower surface of each of the last two layers is softer than the upper surface. This is done in order to crate as much buffer as possible between the floor and the foot.

The fifth layer is also made of EVA, and has medium firmness with an average Shore D value of 35. The bottom side of this layer has a hardness value of about 37 Shore D, and the top side has a hardness value of about 33. Again, a gradient of hardness is present, but in a reverse order.

The sixth layer is also made of EVA with an average Shore D value of about 25 and is softer than the previous layer. This layer delivers the maximum of comfort possible for the human body. This layer has a decreasing gradient of hardness, where the bottom section has a hardness value of about 27 Shore D and the top section has a hardness value of about 23.

The seventh layer is a welt. The purpose of this layer is to provide a platform for the foot. This is typically made of leather, which is placed for esthetic and practical reasons. Esthetically this component serves as the outsole package providing sufficient consistencies and be able to stand the pressure of the human body. This layer is the part of the outsole that one can directly visualize.

The eighth layer is another firm surface. It can be made of Texon and can be called the lasting midsole. Texon is an artificial material made of leather dust and strong adhesive. This layer serves as the backbone of the shoe with a steel shank inserted. This element is rather firm, which the foot needs to register as a firm platform. This firm element rests on a multiplicity of elements. All of them providing at the bottom level to neutralize the heel strike force and provides comfort underneath the firm surface of the Texon midsole.

The ninth layer includes one or more layer of insert. The layer physically contacting the foot is typically made of leather with a clean surface. The back of the leather is typically made out of PU or EVA with raised contours. The raised contours provide support to the ridge of the foot, the area most affected by fatigue.

It will be understood that particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention can be employed in various embodiments without departing from the scope of the invention. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.

The use of the word "a" or "an" when used in conjunction with the term "comprising" in the claims and/or the specification may mean "one," but it is also consistent with the meaning of "one or more," "at least one," and "one or more than one." The use of the term "or" in the claims is used to mean "and/or" unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and "and/or." Throughout this application, the term "about" is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.

As used in this specification and claim(s), the words "comprising" (and any form of comprising, such as "comprise" and "comprises"), "having" (and any form of having, such as "have" and "has"), "including" (and any form of including, such as "includes" and "include") or "containing" (and any form of containing, such as "contains" and "contain") are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

The term "or combinations thereof as used herein refers to all permutations and combinations of the listed items preceding the term. For example, "A, B, C, or combinations thereof is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, MB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.

All of the compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.

Although preferred embodiments of the present invention have been described in detail, it will be understood by those skilled in the art that various modifications can be made therein without departing from the spirit and scope of the invention as set forth in the appended claims.

Claims

CLAIMSWhat is claimed is:

1. A shoe having a sole comprising: a midsole disposed between an outer sole and an inner sole; the outer sole comprising a ground contact layer and one or more first cushion layers that increase in hardness from the ground contact layer to the midsole; the inner sole comprising a top layer and one or more second cushion layers that decrease in hardness from the midsole to the top layer; the midsole having a hardness greater than the first cushion layers and the second cushion layers; and a foot engaging sole attached to the inner sole.

2. The shoe of claim 1, wherein the sole eliminates at least 75% of a heel strike and provides a firm platform for proper body posture of a wearer.

3. The shoe of claim 1, wherein the sole eliminates at least 90% of a heel strike and provides a firm platform for proper body posture of a wearer.

4. The shoe of claim 1, wherein: the outer sole eliminates between 25% and 35% of a heel strike; the inner sole eliminates between 25% and 35% of the heel strike; and the midsole eliminates between 25% and 30% of the heel strike.

5. The shoe of claim 1, wherein: the first cushion layers, the second cushion layers and the midsole comprise a thermoplastic polymer; and the ground contact layer and the top layer comprise a leather or a synthetic leather material.

6. The shoe of claim 5, wherein the thermoplastic polymer comprises an ethylene- vinyl acetate, a polyurethane, a polyester elastomer, a rubber, a polyamide, a PEBE, a PEBA, a PBT, a TR, a TPR, a Texon or any combination thereof.

7. The shoe of claim 1, wherein: the first cushion layers have a hardness of between 20 Shore D and 45 Shore D; the midsole has a hardness of between 45 Shore D and 70 Shore D; and the second cushion layers have a hardness of between 20 Shore D and 45 Shore D.

8. The shoe of claim 1, wherein: the first cushion layers comprise a first cushion layer A having a hardness of between 20 Shore D and 30 Shore D and a first cushion layer B having a hardness of between 30 Shore D and 40 Shore D; the midsole has a hardness of between 55 Shore D and 65 Shore D; and the second cushion layers comprise a second cushion layer A having a hardness of between 30 Shore D and 40 Shore D and a second cushion layer B having a hardness of between 20 Shore D and 30 Shore D.

9. The shoe of claim 1, wherein: the first cushion layers comprise a first cushion layer A having a lower hardness of between 20 Shore D and 25 Shore D and an upper hardness of between 25 Shore D and 30 Shore D, and a first cushion layer B having a lower hardness of between 30 Shore D and 35 Shore D and an upper hardness of between 35 Shore D and 40 Shore D; the midsole has a hardness of between 55 Shore D and 65 Shore D; and the second cushion layers comprise a second cushion layer A having an lower hardness of between 35 Shore D and 40 Shore D and an upper hardness of between 30 Shore D and 35 Shore D, and a second cushion layer B having a lower hardness of between 30 Shore D and 25 Shore D and an upper hardness of between 25 Shore D and 20 Shore D.

10. The shoe of claim 1, wherein the foot engaging sole comprises: a leather cover; a thermoplastic polymer layer contoured to support a foot; and a backbone layer.

11. The shoe of claim 10, wherein the backbone layer comprises a leather adhesive composite material having an imbedded metal shank.

12. A shoe having a sole comprising: a midsole having a hardness of between 55 Shore D and 65 Shore D disposed between an outer sole and an inner sole; the outer sole comprising a ground contact layer, a first cushion layer A having a lower hardness of between 20 Shore D and 25 Shore D and an upper hardness of between 25 Shore D and 30 Shore D, and a first cushion layer B having a lower hardness of between 30 Shore D and 35 Shore D and an upper hardness of between 35 Shore D and 40 Shore D; the inner sole comprising a top layer, a second cushion layer A having an lower hardness of between 35 Shore D and 40 Shore D and an upper hardness of between 30 Shore D and 35 Shore D, and a second cushion layer B having a lower hardness of between 30 Shore D and 25 Shore D and an upper hardness of between 25 Shore D and 20 Shore D; and a foot engaging sole attached to the inner sole comprising a leather cover, a thermoplastic polymer layer contoured to support a foot and a backbone layer.

13. The shoe of claim 12, wherein the sole eliminates at least 75% of a heel strike and provides a firm platform for proper body posture of a wearer.

14. The shoe of claim 12, wherein the sole eliminates at least 90% of a heel strike and provides a firm platform for proper body posture of a wearer.

15. The shoe of claim 12, wherein: the outer sole eliminates between 25% and 35% of a heel strike; the inner sole eliminates between 25% and 35% of the heel strike; and the midsole eliminates between 25% and 30% of the heel strike.

16. The shoe of claim 12, wherein: the first cushion layers, the second cushion layers and the midsole comprise a thermoplastic polymer; and the ground contact layer and the top layer comprise a leather or a synthetic leather material.

17. The shoe of claim 16, wherein the thermoplastic polymer comprises an ethylene- vinyl acetate, a polyurethane, a polyester elastomer, a rubber, a polyamide, a PEBE, a PEBA, a PBT, a TR, a TPR, a Texon or any combination thereof, first layer of the first element provides at least about 35% dampening effect.

18. The shoe of claim 12, wherein the backbone layer comprises a leather adhesive composite material having an imbedded metal shank.

19. A method of manufacturing a sole for a shoe comprising the steps of: providing a midsole having a hardness greater than a first cushion layer and a second cushion layer; providing an outer sole comprising a ground contact layer and one or more first cushion layers that increase in hardness from the ground contact layer to the midsole; providing an inner sole comprising a top layer and one or more second cushion layers that decrease in hardness from the midsole to the top layer; attaching a midsole between an outer sole and an inner sole; and attaching a foot engaging sole to the inner sole.

20. The method of claim 19, wherein: the first cushion layers, the second cushion layers and the midsole comprise a thermoplastic polymer; and the ground contact layer and the top layer comprise a leather or a synthetic leather material.

21. The method of claim 19, wherein: the first cushion layers have a hardness of between 20 Shore D and 45 Shore D; the midsole has a hardness of between 45 Shore D and 70 Shore D; and the second cushion layers have a hardness of between 20 Shore D and 45 Shore D.

22. The method of claim 19, wherein: the first cushion layers comprise a first cushion layer A having a hardness of between 20 Shore D and 30 Shore D and a first cushion layer B having a hardness of between 30 Shore D and 40 Shore D; the midsole has a hardness of between 55 Shore D and 65 Shore D; and the second cushion layers comprise a second cushion layer A having a hardness of between 30 Shore D and 40 Shore D and a second cushion layer B having a hardness of between 20 Shore D and 30 Shore D.

23. The method of claim 19, wherein: the first cushion layers comprise a first cushion layer A having a lower hardness of between 20 Shore D and 25 Shore D and an upper hardness of between 25 Shore D and 30 Shore D, and a first cushion layer B having a lower hardness of between 30 Shore D and 35 Shore D and an upper hardness of between 35 Shore D and 40 Shore D; the midsole has a hardness of between 55 Shore D and 65 Shore D; and the second cushion layers comprise a second cushion layer A having an lower hardness of between 35 Shore D and 40 Shore D and an upper hardness of between 30 Shore D and 35 Shore D, and a second cushion layer B having a lower hardness of between 30 Shore D and 25 Shore D and an upper hardness of between 25 Shore D and 20 Shore D.

24. The method of claim 19, wherein the foot engaging sole comprises: a leather cover; a thermoplastic polymer layer contoured to support a foot; and a backbone layer.

25. The method of claim 24, wherein the backbone layer comprises a leather adhesive composite material having an imbedded metal shank.