WO2006022678A2

WO2006022678A2 - Insert for an article of footwear

Info

Publication number: WO2006022678A2
Application number: PCT/US2004/025003
Authority: WO
Inventors: Edith Harmon-Weiss; Hans Peterson; Sean B. Murphy; Ping-Chih Shih; Patrick Choe; Andrew Bjornson
Original assignee: New Balance Athletic Shoe, Inc.
Priority date: 2004-08-03
Filing date: 2004-08-03
Publication date: 2006-03-02
Also published as: WO2006022678A3

Abstract

There is provided an insert for an article of footwear including: a compressible core; said compressible core having a top surface, a bottom surface and a peripheral surface; and a casing for surrounding said compressible core, said casing fitting snuggly adjacent said top surface and said bottom surface and being spaced from at least a portion of said peripheral surface; said casing having a first compressibility when fitting snuggly adjacent said top and bottom surfaces and a second compressibility when spaced from said peripheral surface, said second compressibility being greater than said first compressibility. So constructed, when portions of the insert is exposed along the sides of the article of footwear, the insert meets the 'thumb test' of pliability.

Description

TITLE

Insert for an article of footwear

CROSS-REFERENCE TO RELATED APPLICATIONS Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE OF A "MICROFICHE APPENDIX" Not applicable.

FIELD OF THE INVENTION

The present invention relates to inserts for footwear to cushion and support a region of a foot.

BACKGROUND

The present invention is an improvement over known cushioning elements or inserts used in footwear to cushion a wearer's foot by storing and absorbing impact energy. Typical prior art inserts include bladders enclosing material that is pressurized, such as to a pressure greater than the ambient pressure surrounding the cushioning element. Representative materials include gases, viscous liquids, and gels.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the present invention, there is provided an improved and pliable insert for an article of footwear including: a compressible core; the compressible core having a top surface, a bottom surface and a peripheral surface; and a casing for surrounding the compressible core, the casing fitting snuggly adjacent the top surface and the bottom surface and being spaced from at least a portion of the peripheral surface; the casing having a first compressibility when fitting snuggly adjacent the top and bottom surfaces and a second compressibility when spaced from the peripheral surface, the second compressibility being greater than the first compressibility. When pressed, the insert satisfies a desired "thumb test" of elasticity.

In accordance with a second aspect of the present invention, the second compressibility is approximately 10-40% greater than said first compressibility.

In accordance with a third aspect of the present invention, the second compressibility is at least 10% greater than said first compressibility.

In accordance with a fourth aspect of the present invention, the second compressibility is at least 20% greater than said first compressibility.

Additional aspects, features and advantages of exemplary embodiments of the present invention will become better understood with regard to the following description in connection with the accompanying drawing(s). BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-9 depict exemplary embodiments of the present invention in accordance with the teachings presented herein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

It should be apparent to those skilled in the art that the described embodiments of the present invention provided herein are illustrative only and not limiting, having been presented by way of example only. All features disclosed herein, including dimensions, materials, etc may be replaced by alternative features serving the same or similar purpose, unless expressly stated otherwise. Therefore, numerous other embodiments of the modifications thereof are contemplated as falling within the scope of the present invention as defined herein and equivalents thereto.

INTRODUCTION

The present invention is an improved insert for an article of footwear. The insert comprises: a compressible core; the compressible core having a top surface, a bottom surface and a peripheral surface; and a casing for surrounding the compressible core, the casing fitting snuggly adjacent the top surface and the bottom surface and being spaced from at least a portion of the peripheral surface; the casing having a first compressibility when fitting snuggly adjacent the top and bottom surfaces and a second compressibility when spaced from the peripheral surface, the second compressibility being greater than the first compressibility. The second compressibility is approximately 10-40% greater than the first compressibility, with at least 10% greater or at least 20% greater than the first compressibility being preferred. So constructed, if portions of the insert having the second compressibility are exposed along the sides of the article of footwear, a customer, pressing the exposed portions will readily appreciate the insert's cushioning effect.

The internal compressible element may comprise a single unitary member having either a plurality of holes, ridges or none at all to best suit the effect on the foot of the user and to minimize weight where necessary. For decorative effect, the internal compressible element may comprise a plurality of circular/oval/ formations/patterns positioned along the outer edges. Each of the plurality of formations/patterns may still further be enhanced with color for visual impact.

The insert may comprise a variety of shapes to optimally flex with the bend lines of the foot. As shown in the drawings however, one insert is preferably of trapezoidal shape and a second insert is preferably of kidney-like shape.

The material for the casing may be selected from the following exemplary materials bearing in mind that other suitable materials are also contemplated: thermoplastic polyurethane (TPU), polyester-TPU, polyether-TPU, polyester-polyether TPU, polyvinylchloride, polyester, thermo plastic ethyl vinyl acetate, styrene butadiene styrene, TPU blends including natural and synthetic rubbers. The material for the internal compressible element may be selected from the following exemplary materials bearing in mind that other suitable materials are also contemplated: ethyl vinyl acetate co-polymer, thermo-set polyether and poly-ester urethane, ethyl vinyl vcetate co-polymer blends including isoprene rubber, poly-olefins, natural and synthetic rubbers. FIG. 9 depicts a preferred combination of materials. FIGURE 1

FIG. 1 depicts exemplary first and second inserts in accordance with the present invention for use in an article of footwear for cushioning and supporting a region of a foot. Each one of the first and second inserts comprises a casing that encapsulates an inner compressible element. Shown are several views of the casing, casing including the compressible element and the compressible element.

FIGURE 2

FIG. 2 depicts alternative first and second inserts in accordance with the present invention for use in an article of footwear for cushioning and supporting a region of a foot. Each one of the first and second inserts comprises a casing that encapsulates an inner compressible element. As shown, the compressible element includes a plurality of ridges and a plurality of circular patterns positioned along the sides of the element. Each of the plurality of patterns may still be further enhanced with color for visual impact.

FIGURE 3

FIG. 3 depicts additional alternative first and second inserts in accordance with the present invention for use in an article of footwear for cushioning and supporting a region of a foot. Each one of the first and second inserts comprises a casing that encapsulates an inner compressible element. The internal compressible element may compπse a single unitary member having a plurality of holes to best suit the effect on the foot of the user. FIGURE 4

FIG. 3 depicts a further alternative first and second inserts in accordance with the present invention for use in an article of footwear for cushioning and supporting a region of a foot. Each one of the first and second cushions comprises a gas- or air-filled casing having at least one pinch/locator mark. The cushions may include stubs, (as shown), which can be sealed to prevent the cushion from releasing the gas and/or emitting noises each time a step is taken as the gas is sucked in and blown out through the stub. Sealing the stubs also prevents fluids/debris/other objects that may be present on a walking surface from entering the cushion

FIGURES 5 - 8

FIG. 5 depicts bottom, heel and toe views of a sole of an article of footwear including inserts constructed in accordance with the present invention. As shown, the heel portion of the sole includes first and second chambers, each housing an insert. The chambers move, such as by flexing, with respect to one another. At least a portion of the inserts may be exposed to touch e.g., along the medial and lateral sides of the article of footwear.

FIG. 6 depicts top, medial and lateral views of FIG. 5. FIG. 7 depicts sectional views along lines A-A¹, B-B¹ and C-C¹ of FIG. 5. FIG. 8 depicts sectional views taken along lines D- D¹ - L-L¹ of FIG. 5. FIG. 8 also shows a reduced scale 0.5:1 of the bottom, medial and lateral views of the sole having the inserts.

MANUFACTURING OPTIONS In addition to blow molding, various other conventional techniques, e.g., vacuum molding, extruded tube molding, injection molding, etc, may be used to form the insert of the present invention. With respect to blow molding for example, standard blow molding equipment may be used in which a tube of resin is dropped from a die and mandrel. The compressible element or foam is placed on one end of a pin. The other end of the pin is inserted into the blow nozzle of the blow molding equipment. A tube of parasin is dropped over the foam/pin. Mold plates close around foam and parasin. Air is blown up and around foam and pin, pushing the parsin into the cavities of the mold. Component is pulled from the mold. Pin is removed. Components are die cut from flashing. Blow holes in blow molded plastic are high frequency welded shut.

Regarding vacuum molding, the casing is created with two pieces. The first piece is vacuum formed into a shell. The foam is placed in the shell (centered on locator pins to ensure there is an air gap, e.g., a 1-3 mm air gap). A second piece of casing (un-molded film) is placed on top of the first piece and is welded to the first piece of molded casing using a high frequency weld. Two vacuum formed pieces can also be welded together with the insert inside.

With respect to extruded tube molding, an extruded tube is formed. The insert is placed inside the tube and the edges of the tube are high frequency welded.

Regarding injection molding, the casing is created with two pieces. The first piece is injection molded into a shell. The foam is placed in the shell (centered on locator pins to ensure there's a 1-3 mm air gap). A second piece of casing (un-molded film) is placed on top of the first piece and is welded to the first piece of molded casing using a high frequency weld. Two injection molded pieces can also be welded together with the insert inside. With all of the above options, the insert is formed so that it is smaller than the casing (creating a gap, e.g., 1-3 mm air gap).

Claims

CLAIMSWhat is claimed is:

1. An insert including: a compressible core; said compressible core having a top surface, a bottom surface and a peripheral surface; and a casing for surrounding said compressible core, said casing fitting snuggly adjacent said top surface and said bottom surface and being spaced from at least a portion of said peripheral surface; said casing having a first compressibility when fitting snuggly adjacent said top and bottom surfaces and a second compressibility when spaced from said peripheral surface, said second compressibility being greater than said first compressibility.

2. The insert as defined in claim 1 in which said second compressibility is approximately 10- 40% greater than said first compressibility.

3. The insert as defined in claim 1 in which said second compressibility is at least 10% greater than said first compressibility.

4. The insert as defined in claim 1 in which said second compressibility is at least 20% greater than said first compressibility.

5. The insert as defined in claim 1 in which said casing comprises at least one of the following materials and blends thereof: thermoplastic polyurethane (TPU), polyester-TPU, polyether- TPU, polyester-polyether TPU, polyvinylchloride, polyester, thermo plastic ethyl vinyl acetate, styrene butadiene styrene, TPU blends including natural and synthetic rubbers.

6. The insert as defined in claim 1 in which said compressible core comprises at least one of the following materials and blends thereof: foam, ethyl vinyl acetate co-polymer, thermo-set polyether and poly-ester urethane, ethyl vinyl acetate co-polymer blends including isoprene rubber, poly-olefins, natural and synthetic rubbers.

7. The insert as defined in claim 1 in which said casing and said compressible core includes at least one pinch/locator mark extending from an outer surface of said casing to an outer surface of said core.

8. The insert as defined in claim 1 in which said compressible core includes at least one rib formed in said top and bottom surfaces of said core and extending partially or substantially fully width- or lengthwise there across.

9. A shoe product including: a sole; said sole having a heel portion formed to receive an insert; and an insert mounted in said heel portion of said sole and including:

1 ~ r a compressible core; said compressible core having a top surface, a bottom surface and a peripheral surface; and a casing for surrounding said compressible core, said casing fitting snuggly adjacent said top surface and said bottom surface and being spaced from at least a portion of said peripheral surface; said casing having a first compressibility when fitting snuggly adjacent said top and bottom surfaces and a second compressibility when spaced from said peripheral surface, said second compressibility being greater than said first compressibility; said peripheral surface extending beyond said heal portion of said sole.

10. The shoe product as defined in claim 9 in which said second compressibility is approximately 10-40% greater than said first compressibility.

11. The shoe product as defined in claim 9 in which said second compressibility is at least 10% greater than said first compressibility.

12. The shoe product as defined in claim 9 in which said second compressibility is at least 20% greater than said first compressibility.

13. The shoe product as defined in claim 9 in which said casing comprises at least one of the following materials and blends thereof: thermoplastic polyurethane (TPU), polyester-TPU, polyether-TPU, polyester-polyether TPU, polyvinylchloride, polyester, thermo plastic ethyl vinyl acetate, styrene butadiene styrene, TPU blends including natural and synthetic rubbers.

14. The shoe product as defined in claim 9 in which said compressible core comprises at least one of the following materials and blends thereof: foam, ethyl vinyl acetate co-polymer, thermo-set polyether and poly-ester urethane, ethyl vinyl acetate co-polymer blends including isoprene rubber, poly-olefins, natural and synthetic rubbers.

15. The shoe product as defined in claim 9 in which said casing and said compressible core includes at least one pinch/locator mark extending from an outer surface of said casing to an outer surface of said core.

16. The shoe product as defined in claim 9 in which said compressible core includes at least one rib formed in said top and bottom surfaces of said core and extending partially or substantially fully width- or lengthwise there across.

17. A method of making an insert, comprising:

providing a compressible core having top, bottom and peripheral surfaces;

providing a multi-part, open-split insert mold; each of said part having an internal molding cavity; placing said compressible core into said open-split insert mold;

dropping a casing precursor material over said compressible core thereby creating a core- casing precursor combination;

closing said open-split insert mold around said core-casing precursor combination;

molding and cooling said core-casing precursor combination to form said insert by: 1) pushing said casing precursor material into the internal molding cavities of said insert mold to form a casing; and 2) positioning said casing to fit snuggly adjacent said top and bottom surfaces of said core and to be spaced from at least a portion of said peripheral surface of said core;

wherein said casing has a first compressibility when fitting snuggly adjacent said top and bottom surfaces and a second compressibility when spaced from said peripheral surface, said second compressibility being greater than said first compressibility.

18. The method as defined in claim 17 in which said molding process is selected from the following processing methods: blow molding, extrusion molding, injection molding and other suitable polymer processing methods.

19. The method as defined in claim 18 further comprising die cutting said insert to remove any excess casing.

20. The method as defined in claim 17 further comprising high frequency welding said insert to seal said insert;

21. The method as defined in claim 17 in which said second compressibility is approximately 10- 40% greater than said first compressibility.

22. The method as defined in claim 17 in which said second compressibility is at least 10% greater than said first compressibility.

23. The method as defined in claim 17 in which said second compressibility is at least 20% greater than said first compressibility.

24. The method as defined in claim 17 in which said casing comprises at least one of the following materials and blends thereof: thermoplastic polyurethane (TPU), polyester-TPU, polyether-TPU, polyester-polyether TPU, polyvinylchloride, polyester, thermo plastic ethyl vinyl acetate, styrene butadiene styrene, TPU blends including natural and synthetic rubbers.

25. The method as defined in claim 17 in which said compressible core comprises at least one of the following materials and blends thereof: foam, ethyl vinyl acetate co-polymer, thermo-set polyether and poly-ester urethane, ethyl vinyl acetate co-polymer blends including isoprene rubber, poly-olefins, natural and synthetic rubbers.

26. The method as defined in claim 17 further comprising forming in said casing and said compressible core at least one pinch/locator mark extending from an outer surface of said casing to an outer surface of said core.

27. The method as defined in claim 17 further comprising forming in said top and bottom surfaces of said core at least one rib extending partially or substantially fully width- or lengthwise there across.

28. A method of making an insert, comprising:

providing a compressible core having top, bottom and peripheral surfaces;

providing a multi-part, open-split insert mold; each of said part having an internal molding cavity;

placing said compressible core into said open-split insert mold;

dropping a casing precursor material over said compressible core thereby creating a core- casing precursor combination; closing said open-split insert mold around said core-casing precursor combination;

molding and cooling said core-casing precursor combination to: 1) push said casing precursor material into the internal molding cavities of said insert mold to form a casing; and 2) position said casing to fit snuggly adjacent said top and bottom surfaces of said core and to be spaced from at least a portion of said peripheral surface of said core;

29. The method as defined in claim 28 in which said molding process is selected from the following processing methods: blow molding, extrusion molding, injection molding and other suitable polymer processing methods.

30. The method as defined in claim 28 further comprising die cutting said insert to remove any excess casing.

31. The method as defined in claim 30 further comprising high frequency welding said insert to seal said insert;

32. The method as defined in claim 28 in which said second compressibility is approximately 10- 40% greater than said first compressibility.

33. The method as defined in claim 28 in which said second compressibility is at least 10% ψ greater than said first compressibility.

34. The method as defined in claim 28 in which said second compressibility is at least 20% greater than said first compressibility.

35. The method as defined in claim 28 in which said casing comprises at least one of the following materials and blends thereof: thermoplastic polyurethane (TPU), polyester-TPU, polyether-TPU, polyester-polyether TPU, polyvinylchloride, polyester, thermo plastic ethyl vinyl acetate, styrene butadiene styrene, TPU blends including natural and synthetic rubbers.

36. The method as defined in claim 28 in which said compressible core comprises comprises at least one of the following materials and blends thereof: foam, ethyl vinyl acetate co-polymer, thermo-set polyether and poly-ester methane, ethyl vinyl acetate co-polymer blends including isoprene rubber, poly-olefins, natural and synthetic rubbers.

37. The method as defined in claim 28 further comprising forming in said casing and said compressible core at least one pinch/locator mark extending from an outer surface of said casing to an outer surface of said core.

38. The method as defined in claim 28 further comprising forming in said top and bottom surfaces of said core at least one rib extending partially or substantially fully width- or lengthwise there across.

39. A method of making an insert using a blow molding apparatus including a pin and a blow nozzle, comprising:

providing a compressible core having top, bottom and peripheral surfaces;

placing said core on said pin and positioning said core-pin combination directly above said blow nozzle;

inserting said core-pin combination into said open-split insert mold;

v dropping a casing precursor material over said core-pin combination and said blow nozzle so that said core-pin combination and said blow nozzle are surrounded by said casing precursor material; closing said open-split insert mold around said core-casing precursor-pin combination;

blow molding and cooling said core-casing precursor-pin combination to create said insert by: 1) pushing said casing precursor material into the internal molding cavities of said insert mold to form a casing; and 2) positioning said casing to fit snuggly adjacent said top and bottom surfaces of said core and to be spaced from at least a portion of said peripheral surface of said core;

removing said pin from said insert;

die cutting said insert to remove any excess casing; and

high frequency welding said insert to seal said insert;

40. The method as defined in claim 39 in which said second compressibility is approximately 10- 40% greater than said first compressibility.

41. The method as defined in claim 39 in which said second compressibility is at least 10% greater than said first compressibility.

42. The method as defined in claim 39 in which said second compressibility is at least 20% greater than said first compressibility.

43. The method as defined in claim 39 in which said casing comprises at least one of the following materials and blends thereof: thermoplastic polyurethane (TPU), polyester-TPU, polyether-TPU, polyester-polyether TPU, polyvinylchloride, polyester, thermo plastic ethyl vinyl acetate, styrene butadiene styrene, TPU blends including natural and synthetic rubbers.

44. The method as defined in claim 39 in which said compressible core comprises at least one of the following materials and blends thereof: ethyl vinyl acetate co-polymer, thermo-set polyether and poly-ester urethane, ethyl vinyl vcetate co-polymer blends including isoprene rubber, poly-olefins, natural and synthetic rubbers.

45. The method as defined in claim 39 further comprising forming in said casing and said compressible core at least one pinch/locator mark extending from an outer surface of said casing to an outer surface of said core.

46. The method as defined in claim 39 further comprising forming in said top and bottom surfaces of said core at least one rib extending partially or substantially fully width- or lengthwise there across.