US20090133288A1

US20090133288A1 - Footwear with two-plate system

Info

Publication number: US20090133288A1
Application number: US12/359,330
Authority: US
Inventors: Alvaro Z. Gallegos
Original assignee: Individual
Current assignee: Individual
Priority date: 2003-04-07
Filing date: 2009-01-25
Publication date: 2009-05-28

Abstract

The present invention relates to footwear which has improved shock absorbency due to cushioning within a two-plate system. The orthotic or upper plate and bottom plate are separated by cushioning. The orthotic plate preferably provides rigid support between heel and metatarsal region. The bottom plate may utilize multiple rigid segments whereby the toe region is flexible. The bottom plate may also have gripping elements which are permanently or removeably attachable to the plate to compensate for wear, or for a change in activities. The cushioning between the upper and bottom plates distributes force produced at individual points on the bottom plate over the entire upper plate, thereby eliminating pressure points on the foot.

Description

This application is a continuation in part application of U.S. patent application Ser. No. 11/463, 694, filed Aug. 10, 2006, which is a continuation of U.S. patent application Ser. No. 10/409,751, filed Apr. 7, 2003, now U.S. Pat. No. 7,111,416.
1. Technical Field
The present invention relates to footwear which has improved shock absorbency, comfort, and versatility.
2. Background Art
The following patents are believed to be representative of prior art efforts to solve the problems addressed by the current invention and other problems: U.S. Pat. Nos. 2, 682, 712; 4,377,042; 5,317,822; 5,353,522; 5,410,821; 5,615,497; 5,996,252; 5,727,334; 6,345,454; 3,538,628; 4,279,083; 4,377,042; 4,463,505; 5,317,822; 5,339,543; 5,353,522; 5,410,821; 5,555,650; 5,615,497; 5,727,334; 5,782,014; 5,836,090; 5,867,923; 5,996,252; 6,205,683; 6,345,454; 6,389,712; US Publications 2003/0200675; 2005/0144254; and 2003/0230007.

SUMMARY OF THE INVENTION

It is an objective of the present invention to provide improved footwear.
Accordingly, in one possible embodiment, footwear is provided that may comprise one or more elements such as, for example, an upper and a rigid orthotic plate adjacent to the upper. Padding having a top side and a bottom side is positioned adjacent a lower surface of the rigid orthotic plate.
A bottom plate may comprise a rigid front portion and a rigid rear portion. The rigid front portion and the rigid rear portion may be connected by a flexible portion in the metatarsal region of the footwear whereby the rigid front portion is bendable with respect to the rigid rear portion. Padding is positioned between the rigid orthotic plate and the bottom plate such that the bottom side of the padding is positioned adjacent an upper surface of the bottom plate. The padding forms a shock absorbing layer thereby preventing contact between the rigid orthotic plate and the bottom plate.
In one embodiment, the rigid orthotic plate extends from a metatarsal region of the footwear to a heel area of the footwear. A front section associated with the rigid orthotic plate is bendable with respect to the rigid orthotic plate at the metatarsal region of the footwear. The bendable front section extending from the rigid orthotic plate and the front portion of the bottom plate may bend at the same or approximately the same position in the metatarsal region.
The front section can be secured to the rigid orthotic plate or separate from it such that the front section is movable with respect to the rigid orthotic plate. In one embodiment, the front section comprises padding or covered padding, which can be extension of the padding between the shoes and/or the like.
In one embodiment, only the padding is positioned between the rigid orthotic plate and the bottom plate. The bottom plate may comprise a smaller maximum thickness than a maximum thickness of the rigid orthotic plate. The rigid orthotic plate may comprise an arched portion between the heel area and the metatarsal region of the footwear. A lower surface of the rigid orthotic plate may be substantially flat from the metatarsal region to the heel area of the footwear.
The footwear of claim may comprise a plurality of gripping members extending from the lower side of a bottom plate. The gripping members may be mounted so that they do not extend into the padding where they might engage the orthotic plate. The shock absorbing layer formed by the padding isolates and prevents interconnection between the rigid orthotic plate and the gripping members. The gripping members may or may not be removable.
The present invention provides methods for making footwear which may comprise one or more steps such as utilizing an orthotic plate that is rigid from a heel of the footwear to a metatarsal region of the footwear and providing a toe section extending from the metatarsal region to a toe end of the footwear for use with the orthotic plate. The toe section can be bendable with respect to the orthotic plate at the metatarsal region. Other steps might comprise securing the orthotic plate to an upper and to a top side of padding. Additional steps may comprise securing to the bottom of the padding a bottom plate comprising a first rigid section and a second section. The first rigid section can extend between the heel and the metatarsal region of the footwear, with the second section then extending between the metatarsal region of the footwear and a toe region. The second section is moveable with respect to the first rigid section to permit the user to flex the toes. The second section may also be rigid.
Padding can be utilized between the orthotic plate and the bottom plate to form a shock absorbing layer which isolates the orthotic plate from the bottom plate thereby preventing contact between the orthotic plate and the bottom plate.
The method may further comprise steps such as securing the first rigid section to the second rigid section with a flexible portion to permit movement of the first rigid section with respect to the second rigid section. The footwear method may further comprise providing that the toe section is comprised of the padding, which may be covered, and used for flexibly supporting the user's toes.
The method may further comprise utilizing only the padding between the orthotic plate and the bottom plate. The method may comprise forming the orthotic plate with a raised arch section. The method may further comprise securing a plurality of gripping members to extend from the lower side of the bottom plate such that mountings for the gripping members do not extend into the padding at all or do not extend to the extent they might contact the orthotic plate. In this way, the shock absorbing layer formed by the padding isolates and prevents interconnection between the orthotic plate and the gripping members.
In another embodiment, a method for making footwear may comprise utilizing a first plate that is rigid from a heel of the footwear to a metatarsal region of the footwear, securing the first plate with respect to an upper, a top side of padding, and a bottom plate of the footwear so that the padding is between the first plate and the bottom plate. The padding can be used to form a shock absorbing layer to isolate the first plate from the bottom plate thereby preventing contact between the first plate and the bottom plate. Other steps might comprise providing that the bottom plate is formed as a rigid first section and a second section. The first section extends between a heel of the footwear and a metatarsal region of the footwear. The second section extends between the metatarsal region and a toe of the footwear. Other steps may comprise flexibly joining the second section to the first section at the metatarsal region of the footwear. In this embodiment, the first section and the second section bend with respect to each other to allow a toe region between the metatarsal region of the footwear and the toe end of the footwear to bend starting from the metatarsal region. In one embodiment, the second section can be rigid or semi-rigid or flexible.
The method may utilize a toe region extending from the first plate which is flexible. In one embodiment, only the padding is between the first plate and the bottom plate, which may comprise at least the first section.

BRIEF DESCRIPTION OF DRAWINGS

For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like elements may be given the same or analogous reference numbers of a water purifier apparatus in accord with the present invention.
While the present invention will be described in connection with presently preferred embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalents included within the spirit of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an embodiment of the footwear;

FIG. 2 is a bottom view of an embodiment of the footwear;

FIG. 3 is a side view of an embodiment of the footwear;

FIG. 4 is a perspective view of an embodiment of the footwear;

FIG. 5 is a side view of a footwear embodiment showing a multi-piece orthotic plate;

FIG. 6 is a side view of a footwear embodiment with a plate and gripping members;

FIG. 7 is a view of an embodiment of high-top footwear with a plate and gripping members;

FIG. 8 is an expanded view of an embodiment of footwear;

FIG. 9 is an embodiment of a ski boot;

FIG. 10 is the bottom view of an embodiment of the footwear;

FIGS. 11 A, B, and C are side views of possible embodiments of the gripping members that could be utilized in the footwear;

FIG. 12 is an expanded view of an embodiment of the footwear which may or may not have removable and replaceable components, and/or may or may not utilize closed-cell foam padding;

FIG. 13 is an expanded view of an embodiment of the footwear which may or may not utilize removable and replaceable components, and/or may or may not utilize foam padding;

FIG. 14 is an expanded view of an embodiment of the footwear which may or may not utilize removable and replaceable components, and/or may or may not utilize open-cell foam padding; and

FIG. 15 is a view of an embodiment of layered padding may or may not utilize layers of open-cell and closed-cell foam and/or other types of padding.

FIG. 16 is a side view of an embodiment of the present invention which can utilize an upper plate or orthotic and a lower plate which permit movement between the metatarsal region or balls of the feet and the toes;

FIG. 17 is an exploded view of an embodiment of the present invention wherein a rigid orthotic (upper plate) and a first rigid lower plate portion extend between the heel and the metatarsal region, whereby movement from the metatarsal region can be provided with a second rigid portion for the lower plate and a moveable and/or flexible portion for use with the rigid orthotic (upper plate).

FIG. 18 is a side view of a possible embodiment of an embodiment of the present invention wherein a moveable toe portion of an upper plate operates in conjunction with a moveable toe region of a lower plate, and wherein the upper and lower plates are rigid between the heel and the metatarsal region.

While the present invention will described in connection with presently preferred embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalents included within the spirit of the invention and as defined in the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

For purposes of the description of this invention, the terms “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” and other related terms shall be defined in relation to embodiments of the present invention as it is shown and illustrated in the accompanying figures. However, it is to be understood that the invention may assume various alternative structures and processes and still be within the scope and meaning of this disclosure. Further, it is to be understood that any specific dimensions and/or physical characteristics related to the embodiments disclosed herein are capable of modification and alteration while still remaining within the scope of the present invention and are, therefore, not intended to be limiting.
One way to increase the comfort and also shock absorbency of footwear is to increase the amount of shock absorbing material and/or by using padding comprised of various materials, especially foam. This is notably advantageous in athletic footwear worn by runners or other athletes who are involved in rigorous sporting activities since the wearer's footwear and body encounters substantial forces especially from the hard surfaces which are contacted by the wearer's footwear. And, even in the footwear of this invention worn by non-athletes, padding makes the footwear more comfortable. Other types of padding may comprise cushioning material of various types, air bladders or bubbles, springs, hydraulics and/or other cushioning mechanism.
In conjunction with the superior shock absorbing advantages of the padding, the padding may be fixably secured or may be wholly or partially removeably attached and interchanged with padding types and/or varying thicknesses that are used for special purposes such as marathons or long distance runs. Also, when the padding shows wear or loses some of the shock absorbing capabilities or has changed compressibility, the worn padding can be replaced with new padding. If desired, by making parts or components of the footwear replaceable, the durability of the footwear may also be enhanced.
Several variations of footwear of this invention are illustrated in FIGS. 1-18. FIG. 1 shows one variation of the footwear with an upper 30 having an inside 31 and an outside 34. The footwear also has an orthotic plate or upper plate 50 that has a first surface 53 and a second surface 55. In one embodiment, the orthotic or upper plate 50 is rigid, at least between the heel and the metatarsal region to support the user's foot, which is also rigid between the heel and the metatarsal region. A flexible joint 131 (See FIG. 5, 8, 16-18), which may be of many different types, may be provided at the metatarsal region. In this way, the toe region is moveable and may be supported by an extension from the orthotic, which may be. rigid or flexible and/or may simply comprise a padded region. Other embodiments are discussed hereinafter. Orthotic or upper plate 50 may have various shapes such as a curved and raised arch section that is higher than the heel and toe regions. In this embodiment, the heel region can be higher than the toe region.
A layer of padding 13, having an upper portion 16 and a bottom side 8, can also serve as the wear surface. In another embodiment, a bottom plate is utilized. Upper portion 16 may be utilized to support the toe portion of the foot rather than an extension from orthotic or upper plate 50. Thus, the orthotic or upper plate may be rigid between the heel and metatarsal region, and then padding may support the toe region.
In one possible embodiment, there are stabilizing blades 19 within the padding. The style of the upper 30 and the manner of securing it to orthotic plate 50 will vary depending on the design of the footwear. The upper 30 includes all types of footwear, and the invention is especially advantageous in closed footwear such as in athletic shoes, work boots, hiking boots, etc. The upper 30 may be construction of any type of material such as canvas, leather, synthetic leather, vinyl, plastic, etc., or a combination thereof and any other materials known to or used by one of ordinary skill in the art. The upper 30 can be secured to the orthotic plate or upper plate using conventional techniques such as gluing, but it could also be stitched and/or secured by adhesive. Alternatively, the upper 30 may be removeably attached to the orthotic plate such as by a stud and aperture connection, Velcro ®, i.e., mated hooks and loops, as shown in FIG. 8. As an alternative, other means of attachment such as fasteners, adhesives, magnets, a wedge and aperture connection, a screw, a bolt, a hinge, a staple, a nut, studs, snaps, wedges and a combination thereof may be used, to allow replacement or interchanging of the orthotic plate. An insole 145, with appropriately sized sides 132 and 137, which may be made of textile material such as cotton, felt, linen, polyester, or leather, silicon, or other such materials that one of the ordinary skill of the art uses as insoles may also be placed inside the footwear as in, e.g., FIG. 5.
The orthotic plates of the footwear provide superior support, and typically have a raised arch area 28, see e.g., FIGS. 3-4, and may also have a flexible or a semi-flexible front portion. The front portion is then bendable with respect to the rigid portion of the orthotic or upper plate. Further, the orthotic plate has a first surface 124 and second surface 126. The orthotic plate may be a unitary piece or may be formed of more than one piece, with for example, a first piece 122 that typically extends from the metatarsal region to or beyond the front toe area 135, and a second piece 130 that extends to the rear most portion of the footwear. The second piece 130 is preferably rigid or nearly rigid. A hinge-like area 131 adjacent to the end 121 of the first piece 122 may be semi-flexible or flexible, e.g., FIG. 5. This region may be a soft or flexible plastic, or may comprise a groove, or any other means for permitting movement. If desired, the angle of movement may be in the range of about 30 degrees plus or minus ten or twenty degrees. If desired, the bending may be mostly or perhaps all in the upper direction, as if the user's toes are pulled upwardly. The orthotic plate typically extends from a metatarsal area 137 of a wearer's foot, or the balls of the foot, to the heel region and/or rearmost portion of the footwear generally proximate to the heel area. In other embodiments, a bottom plate 80 may also be incorporated below the padding, forming a two-plate system. See FIGS. 6-8, and 12-14. The bottom plate may also be formed so as to bend in concert with the upper plate 50.
The footwear of this invention has cushioning 13 or padding below the orthotic plate 50. There may also be an undersole or outsole 25, see FIGS. 3-4, beneath the cushioning or padding 13, but the padding or portions thereof may also serve as the wear surface 8. See FIGS. 1-2. The undersole or outsole of 25 may be fixedly or removeably attached to the padding by the various ways known to one skilled in the art. The undersole or outsole 25 may be rigid or semi-rigid. In one possible embodiment, the padding 13 can be removable, changeable, and replaceable and is preferably provided in a shape substantially similar and/or identical to the shape of the orthotic plate, such that it will cover the lower surface of the entire orthotic plate. In other embodiments, the padding can extend at least the length and the width of the footwear, although in some embodiments, the padding may be thinner and/or tapered 13 a in the toe area of the footwear. See e.g., FIG. 6. The padding may be of a variety of heights and may vary depending upon the wearer's needs and/or uses as well as the type of padding utilized. In one embodiment, the padding is between about ½ inch to about 3½ inches in height in its uncompressed state, but may be of a lesser or greater height as well. In the embodiments without a bottom plate, e.g., FIGS. 1-4, the padding is preferably about one ½ inch to about 3 ½ inches in height and in the embodiments with a bottom plate 80, see e.g., FIGS. 6-8, and 12-15 the padding may be about ½ inch to about 2 inches in height, but may be of other heights as well.
The padding or cushioning layer 13 may comprise a variety of materials especially foamed materials which have elastic or rebounding properties, such as materials comprised of silicon, neoprene, natural rubber foams, synthetic rubber foams and polyurethane, polyether and polyester foams neoprene, Vinyl Nitrile, Styrene-Butadiene Rubber (SBR), Polyethylene (PE), ethyl vinyl acetate (EVA), ethylene propylene terpolymer (EPT), EPT/PE/Butyl Rubber, Neoprene/EPT/SBR, epicblorohydrin (ECH), and nitrile (NBR) or a combination thereof, or other cushioning materials known or used by one skilled in the art. Alternatively, in the two plate system other means can be used as cushioning such as leaf and coil wound springs, with or without padding (not shown). The density and cell characteristics of the padding of the foam material are believed to be critical features in terms of providing the appropriate cushioning and rebound characteristics for cushioning and may vary depending upon the type of activity of footwear in question.
In one embodiment, the cushioning or padding, such as foam 14, has a low to medium density so it is deformable. A low density padding comprises material within the range of about 0.08 g/cm.sup.3 to about 0.50 g/cm.sup.3. An even more preferred range of densities for padding is material between about 0.1 g/cc to 0.30 g/cc.
The padding 13 may be constructed of a closed-cell foam 14 b material, see. e.g., FIG. 12, having a density in the range of about 0.08 g/cc to 0.50 g/cc, or of other suitable densities known to one skilled in the art. Alternatively, open-cell foam 14 a material, e.g., FIG. 14, having a density in the range of about 0.08 g/cc to 0.40 g/cc may be used, or of other suitable densities known to one skilled in the art.
Closed-cell foam material, in general, may demonstrate a greater resistance to wear as compared to open-cell foams. Open cell foam is a material where the open-air chambers in the foam are interconnected. This makes for extremely soft and highly compressible foam. While open-cell foam may be very comfortable, it has some disadvantages because of the high compressibility of the foam, especially if it is of a density which is too low or of a material that absorbs water. In contrast, the open air chambers in the closed-cell foam are completely surrounded by foam and not interconnected. As a result, the closed cell foam does not compress easily, yet provides good shock absorbency since the air pockets in the foam are completely encapsulated. As a further alternative, since open-cell foam is typically more comfortable, i.e., more compressible and since closed-cell foam provides firmer support, a dual or multi-density padding may also be used, alternating layers of closed-cell foam 14 b arid open-cell foam 14 a, with the closed cell foam giving stability and the open cell foam giving a cushioning effect. See e.g., FIG. 15. Depending upon the materials used and the characteristic desired, the alternating layers may each be of about 0.25 inches to about 1 inch in thickness, but may also be of other thicknesses.
The foam padding may be fabricated by pouring foamed materials into a frame that is heated and processed into sheets that are then cut to size. However, the cost of cutting and shaping foam is high and results in significant material wastage. To avoid wasting materials, the padding is preferably molded for each size and style of footwear. Additionally, a portion of the foam may be compression molded.
In some cases, depending upon the characteristics of the foam materials and the height of foam used, the materials may have undesired deformation. To counteract any undesired deformation and/or to control the characteristics of the low density foam, the padding may further may have supporting or stabilizing blades incorporated therein. See FIGS. 1-4. In these circumstances, the stabilizing blades 19 may be incorporated into the foam and/or a semi-rigid plate or rigid plate may be positioned below the underside of the cushioning with or without stabilizing blades in the cushioning.
The stabilizing blades 19 are made of rigid, semi-rigid flexible, and/or semi-flexible materials such as rubber, plastic or denser foams made from EVA, silicon, neoprene, and the like incorporated into the foam, as well as plastic, rubber, metal, metal alloys, vinyl. There are multitudes of ways the stabilizing blades 19 may be arranged or position within the foam and/or cushioning. For example, FIGS. 1-2 show footwear wherein the stabilizing blades are parallel to one another. FIGS. 3-4 in contrast, show footwear wherein the stabilizing blades are arranged in a cross hatch or grid fashion. The blades may be placed throughout the foam or may be concentrated in certain areas, or alternatively spaced consistently, or fairly consistently. The blades 19 are preferably about ½ inch to about 1½ inches apart, but may be of other distances. The blades may also be straight, waved, and/or curved. The blades could also be arranged in a variety of other ways by example, but without limitation such as triangles, rectangles, hexagons, octagons (not shown). The blades may also zigzag through the foam, and may alternatively be arranged in a wave like patterns (not shown). There are many ways the stabilizing blades may be incorporated into the foam. They may be incorporated into the foam at the time of the original manufacture of the foam, or heat bonded or glued to already made foam. There are other means which also may be used to stabilize the foam such as a plurality of small springs.
As an alternative or in addition to the stabilizing blades, a rigid or semi-rigid bottom 80 plate may be placed beneath the foam layer. See FIGS. 6-8, 12-14, 16-18. If a bottom plate is used along with the orthotic plate or upper plate, the footwear of this invention has a two-plate system. The padding between the upper plate and lower plate insulates the user's foot from all manner of irregular upon which the user may step. For instance, with a rigid upper plate and rigid lower plate, a user might stand comfortably on a pipe or other object.
The bottom plate may comprise metal, plastic, compressed EVA or other compressed foams, silicon, or neoprene foam. The bottom plate may serve as the wear surface, or may alternatively have an outsole further attached to the outer surface of the plate (not shown). The plate may be permanently secured or not For instance, the bottom plate may be glued or heat bonded to the foam, or may be removeably attached through means such as a plurality of hooks and eyes such as Velcro® or may alternatively have telescoping pins with an enlarged end like that of a nail or screw head that attaches at one end to the orthotic plate and attaches at the other end to the plate. The bottom plate 80 may also have gripping members 75 such as spikes, cleats, studs, and the like permanently or removeably attachable to the bottom plate 80.
FIG. 8 shows footwear that is disassembled or exploded in view and shows the first surface 53 of the orthotic or upper plate 50 separated from the bottom surface 35 of the upper 30, the padding 13 separated from the second surface 55 of the orthotic plate 50, and the bottom plate 80 separated from the cushioning 13. Bottom plate 80 may comprise multiple rigid sections which are relatively bendable with respect to each other. For instance, since upper plate or orthotic 50 bends at 131, bottom plate 80 may also bend or flex in the metatarsal region. FIGS. 13-14 also show footwear that is disassembled or exploded, and FIG. 15 shows padding with layers of open-cell foam 14 a and closed-cell foam 14 b. In use, these counterparts are mated and fastened by applying pressure to the hooks and loops, or other fastening means which engage each other.
The orthotic plate 50, which as shown in FIG. 8 comprises a first piece 122, which is typically rigid, and a second piece 130 which may be flexible or rigid, and a hinged area in between 131. The hinge may be formed by a flexible plastic portion, a groove, or may be separate from the first piece 122. In another embodiment, the foam may be used for supporting the toe region with only the first piece 122 being utilized.
The foam padding 13 may be securely attached to the orthotic plate. Alternatively, the orthotic can be removeably attached to the orthotic plate such as by a stud and aperture connection, Velcro® i.e., mated hooks and loops, fasteners, adhesives, magnets, a wedge and aperture connection, a screw, a bolt, a hinge, a staple, a nut, studs, snaps, wedges and a combination thereof or by other means known to one skilled in the art. If a bottom plate 80 is also used, it may be securely attached. Thus, the entire shoe may be secured together.
Alternatively, the bottom plate may be removeably attachable to the padding by the same foregoing means or means such as Velcro® 22 or other hook-and-loop type fasteners. See e.g., FIGS. 8, 12, and 14. Additionally, the orthotic plate 50 may also be removeably attachable to the bottom 35 of the upper 30. Furthermore, the upper may be replaced with another type or style of upper, such as an upper that is a sandal or open toed shoe, a dress upper, a boot, and other types of uppers known to one skilled in the art that have been modified to be removeably attachable such as by the means described herein for the orthotic plate and cushioning.
The components of FIGS. 8 and 15 may be permanently secured together or one or more may be removable. For example, the top 18 and the bottom 20 of the padding 13 may have a layer, strip, or portion 22 of one of the counterpart elements 22 a, 22 b of the hook-and-loop type fasteners, such as Velcro®. Above the top of the cushioning, the orthotic plate may also have at least one of the counterpart elements 22 b of the hook-and-loop type fasteners, such as Velcro®, which is compatible with that the counterpart elements 22 a on the bottom surface 35 of the upper 30. Alternatively, any of the components that are covered with Velcro®, could also have portions of both the hook and loop type elements as long as there are corresponding counterparts on the surface of the adjacent component which is removeably attachable. See e.g., FIGS. 12-15. If Velcro® or Velcro®-like material is used, it is preferably attached to the top or bottom of the components such as the orthotic plate, front portion 122, padding 13, or bottom plate 80 by adhesive, glue, or other suitable means, such as stitching and heat bonding. The entire surface of the orthotic plate and cushioning or other such components may be covered by Velcro® or other attaching means or alternatively only portions such as the perimeter of the components may have Velcro® or attachment portions. It is preferred that the hook-and-loop fasteners used in the present invention be selected from the strongest of those available on the market to resist separation while worn. Still, even when using such strong fasteners the wearer can remove worn padding and quickly install replacement padding or components by separating and then pulling the padding from the bottom of the footwear and aligning and pressing the replacement padding in place. The pressure applied by the wearer's weight further anchors and/or secures the padding and other removable attachable components to the footwear. Once all the layers and/or counterparts which are removeably attachable, interchangeable, and replaceable are connected together with the upper, they look like and function like conventional footwear.
The bottom plate 80 may also be permanently or removeably attached to the padding 13 such as by a stud and aperture connection, Velcro®, i.e., mated hooks and loops, fasteners, adhesives, magnets, a wedge and aperture connection, a screw, a bolt, a hinge, a staple, a nut, studs, snaps, wedges and a combination thereof or by other means known to one skilled in the art. In the embodiment having a plate below the cushioning, the plate preferably extends substantially at least along the length of the cushioning, but may also be tapered upwardly if the foam padding is also tapered or the toe area. See e.g., FIGS. 6-10, and 12-14. Additionally, in some cases, the plate is the wear surface of the footwear. See FIG. 9.
Again, the bottom plate 80 may also have gripping members 75 such as spikes, cleats, studs or other such gripping members which are permanent or removeably attachable to the bottom plate 80 that may be changed for different uses such as golf, soccer, rugby, football and other sports or activities where such footwear is helpful or useful, or removed altogether for other activities where gripping members are unnecessary or unwanted. See FIGS. 6-8, 10, and 12-14. The gripping members 75 are preferably removeably attached to the bottom plate 80 shoe by inserting a threaded end 76 of the gripping member 75 into an aperture 70 in the bottom plate that has corresponding threading 71 and then turning or screwing in the gripping member 75 until it is inserted. See FIGS. 8, 10. The gripping members 75 may be snapped into the apertures and then removed such as by a tool (not shown). The gripping members may comprise a variety of shapes such as a spike end 90, see FIG. 11 a, multi-lobed end 91, see FIG. 11 b, a rounded end 92, see FIG. 11 c, or other shapes known or used by one skilled in the art. Also see e.g. FIGS. 12-14. FIGS. 7 and 9 show embodiments of footwear that have a high top 100, and FIG. 9 has a two-plate system, but no gripping members, although the bottom plate may have a textured surface (not shown). Of course footwear with gripping members may have a high top.
In the two-plate system, the gripping members fit to the bottom plate but preferably do not extend through the padding. Thus, the upper plate or orthotic can be completely insulated from the gripping members, In this invented footwear, the wearer will experience increased comfort and reduced stress when wearing footwear with gripping members, especially when the footwear is worn for several hours and/or when the wearer is involved in rigorous activities and/or when the ground surface is hard. In fact, the gripping members may be hardly noticeable to the wearer, unlike those in conventional footwear.
FIGS. 16-18 shows an embodiment of the invention that can utilize upper plate 50 and bottom plate 80, which may comprise relatively moveable front and rear portions. In one embodiment, lower plate 80 comprises a rear portion 82 and a front portion 84, both of which may be rigid. In this embodiment or in other embodiments, orthotic plate 50 may be rigid between the heel and metatarsal region and flexible in the toe region. This was mentioned hereinbefore with respect to the other drawings, such as FIG. 8.
Thus, in this embodiment, upper. plate or orthotic 50 may comprise or consist of a rear or first portion 130 which is rigid between the heel and metatarsal region. The orthotic may be used to engage the shape of the arched region of the user's foot as well as the heel and metatarsal regions. Rear or first portion 130 may extend as far as from the end of the heel to the metatarsal region The front portion of orthotic 50 is preferably flexible at least at the metatarsal region and may be flexible from the metatarsal region to the ends of the toes. The front portion of orthotic 50 may be part of orthotic 50 or comprise another member, as discussed hereinafter.
Likewise, lower plate 80 may comprise a rear or first rigid portion 82 which extends along the bottom of the shoe from the heel to the metatarsal region. A flex region may then be provided at the metatarsal region indicated generally at 51 for lower plate 30 and at 131 for orthotic or upper plate 50. Thus, both the upper plate or orthotic 50 and the lower plate 80 are made to permit flexing of the toe region. The flex region at 51 and 131 may be implemented in many different ways for each of the upper plate or orthotic 50 and the lower plate 80. For instance, for lower plate 80 and/or upper plate 50, a flexible plastic or rubber portion may be utilized which allows bending or flexing of the footwear. Other means may include a narrow portion, a notched portion, a flexible material joined to both sections, or supported by the padding, or the like.
Thus, the footwear flexes or bends at the metatarsal region at a desired angle, which may be less than about thirty degrees plus or minus ten or twenty degrees from this amount. In one embodiment, the flexing is generally only in an upward direction, as the toes bend upwardly.
Lower plate rear portion 82 and/or front portion 84 of lower plate 80 may also be rigid. Thus, forces on the feet caused by cleats or the like mounted on the moveable front portion 84 or the rear portion 82 are distributed over the user's foot by padding 13 and also by orthotic 50. Thus, the user will not feel the individual cleats.
If desired, front region 122 of upper plate or orthotic 50 may be flexible, cushioned, or the like. Front region 122 of orthotic 50 may comprise an extension of upper plate or orthotic 50 and/or may be completely separate therefrom. Alternative, front region 122 may comprise padding and perhaps the absence of a front portion of orthotic or upper plate 50, as perhaps shown more clearly in FIG. 17. While orthotic or upper plate 50 is preferably rigid from the heel to the metatarsal region, padding 13 is relatively flexible in the toe region. Front region 122 may comprise padding or other material and may be flexible to allow bending of the user's toes as the user walks. Lower plate 80, in this embodiment, comprises two rigid portions that are flexibly joined together in the metatarsal region, as indicated at 51. In this embodiment, the rigid portion of orthotic or upper plate 50 may extend only between the heel and the metatarsal region of the footwear.
In FIG. 18, a concept of the invention is shown in a shoe wherein padding of some type, perhaps an extension of padding 13, is utilized in the fore portion 122 adjacent orthotic or upper plate 50. Fore portion 122 may comprise an insole or covered portion supported by padding or may be constructed in many different ways. The flexible material supports the user's toes.
Preferably rigid sections 82 and 84 of bottom plate 80 are flexibly joined to allow flexing or bending of the footwear, generally by less than about thirty degrees, perhaps plus or minus ten or twenty degrees. In one embodiment, the front region 84 can comprise a thinner portion or tread pattern of lower plate 80, which inherently allows some flexing at least in the metatarsal region as indicated by arrow 51
The resting angled shape of front region 84 can also be varied. For example, the front region resting position may be relatively flat as shown in FIG. 18, or may be angled or rolled more as shown in FIG. 17.
As noted above, the shoes can be secured together during assembly so that the individual components, such as upper, upper plate, padding, and lower plate are not replaceable. Shoes can have a regular sole or a cleated sole, which may comprise or consist of the lower plate. The padding completely insulates the upper plate or orthotic from the lower plate. Thus, a force applied at any point on the lower plate spreads out and is applied uniformly to the user's foot, thereby protecting the foot. While the presently preferred embodiments show only a two part bottom plate, if desired, multiple sections may be utilized on the bottom plate. For example, the front portion may comprise two or more sections. The rear section may provide support between the heel and metatarsal region and have a bendable rear most section. Other configurations could also be utilized.
The above description is that of preferred 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.
Therefore, because many varying and different embodiments may be made within the scope of the inventive concept(s) herein taught. Because many modifications may be made in the embodiment herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative of a presently preferred embodiment and not in a limiting sense.

Claims

1. Footwear comprising:

an upper;

a rigid orthotic plate secured with respect to said upper;

padding having a top side and a bottom side, wherein said top side is positioned adjacent a lower surface of said rigid orthotic plate;

a bottom plate comprising a rigid front portion and a rigid rear portion, said rigid front portion and said rigid rear portion being connected by a flexible portion in said metatarsal region of said footwear whereby said rigid front portion is bendable with respect to said rigid rear portion, said padding being positioned between said rigid orthotic plate and said bottom plate such that said bottom side of said padding is positioned adjacent an upper surface of said bottom plate, said padding forming a shock absorbing layer thereby preventing contact between said rigid orthotic plate and said bottom plate.

2. The footwear of claim 1, wherein said rigid orthotic plate extends from a metatarsal region of said footwear to a heel area of said footwear, and a front section associated with said rigid orthotic plate that is bendable with respect to said rigid orthotic plate at said metatarsal region of said footwear.

3. The footwear of claim 1, further comprising said front section being secured to said rigid orthotic plate such that said front section is movable with respect to said rigid orthotic plate.

4. The footwear of claim 3, wherein said padding forms said front section.

5. The footwear of claim 1, wherein only said padding is positioned between said rigid orthotic plate and said bottom plate.

6. The footwear of claim 1, wherein said bottom plate comprises a smaller maximum thickness than a maximum thickness of said rigid orthotic plate.

7. The footwear of claim 1, wherein said rigid orthotic plate comprises an arched portion between said heel area and said metatarsal region of said footwear.

8. The footwear of claim 1, wherein a lower surface of said rigid orthotic plate is substantially flat from said metatarsal region to said heel area of said footwear.

9. The footwear of claim 1, further comprising a plurality of gripping members extending from said lower side of a bottom plate without extending into said padding, said shock absorbing layer formed by padding isolating and preventing contact between said rigid orthotic plate and said gripping members.

10. A method for making footwear comprising:

utilizing an orthotic plate that is rigid from a heel of said footwear to a metatarsal region of said footwear,

providing a toe section extending from said metatarsal region to a toe end of said footwear for use with said orthotic plate, said toe section being bendable with respect to said orthotic plate at said metatarsal region;

securing said orthotic plate with respect to an upper;

securing said orthotic plate with respect to a top side of padding; and

attaching a bottom plate with a first rigid section and a second section to said footwear, said first rigid section extending between said heel and said metatarsal region of said footwear, said second section extending between said metatarsal region of said footwear and a toe region, said second section being moveable with respect to said first rigid section;

utilizing said padding between said orthotic plate and said bottom plate, said padding forming a shock absorbing layer to isolate said orthotic plate from said bottom plate thereby preventing contact between said orthotic plate and said bottom plate.

11. The method of claim 10, further comprising securing said first rigid section to said second section with a flexible portion to permit movement of said first rigid section with respect to said second rigid section.

12. The method of claim 10, further comprising providing that said toe section is supported by said padding.

13. The method of claim 10, further comprising utilizing only said padding between said orthotic plate and said bottom plate.

14. The method of claim 10, forming said orthotic plate with a raised arch section.

15. The method of claim 10, further comprising securing a plurality of gripping members to extend from said lower side of said bottom plate such that mountings for said gripping members do not extend into said padding, whereby said shock absorbing layer formed by said padding isolates and prevents contact between said orthotic plate and said gripping members.

16. The method of claim 16, further comprising utilizing a rigid said second section.

17. A method for making footwear comprising:

utilizing a first plate that is rigid from a heel of said footwear to a metatarsal region of said footwear;

securing said first plate with respect to an upper;

positioning padding below said first plate;

securing a bottom plate of said footwear to said padding so that said padding is between said first plate and said bottom plate, said padding forming a shock absorbing layer to isolate said first plate from said bottom plate thereby preventing contact between said first plate and said bottom plate; and

providing that said bottom plate is formed as a first section and a second section, said first section extends between a heel of said footwear and a metatarsal region of said footwear, said second section extends between said metatarsal region and a toe of said footwear;

providing that said first section of said bottom plate is rigid; and

flexibly joining said second section to said first section at said metatarsal region of said footwear, whereby said first section and said second section bend with respect to each other to allow a toe region between said metatarsal region of said footwear and said toe end of said footwear to bend starting from said metatarsal region.

18. The method of claim 17, wherein a toe region extending from said first plate is flexible at said metatarsal region of said footwear.

19. The method of claim 17, wherein said second section is rigid.

20. The method of claim 17, wherein only said padding is between said first plate and said bottom plate.