CN101961158B - Article of footwear and methods of making same - Google Patents

Abstract

A shoe with a contoured sole that provides cushioning and support for the shoe. The sole has a wave shape that may roughly resemble a sine wave with a series of alternating peaks and troughs.

Description

Shoes and method of making the same

technical field

The invention relates to a shoe with a corrugated sole.

Background technique

Individuals are often concerned with the amount of cushioning provided by a shoe, as well as the aesthetics of the shoe. This is true for shoes worn for non-competitive sports such as casual walking, as well as for competitive sports such as running, due to the large number of impact forces that an individual's feet and legs are exposed to throughout the day. Running, jumping, walking, and even standing place forces on an individual's feet and legs that can cause soreness, fatigue, and injury.

The human foot is a complex and specialized mechanical part capable of withstanding and dissipating many impact forces. Natural fat pads in the heel and forefoot and the flexibility of the arch help cushion the foot. Although the human foot has natural cushioning and rebound characteristics, the foot alone cannot efficiently overcome many of the forces experienced in everyday activities. Soreness and fatigue associated with daily activities can be more intense and their onset accelerated unless the individual wears shoes that provide proper cushioning and support. Discomfort to the wearer can reduce interest in further activities. Just as important, inadequately cushioned shoes can cause injuries such as blisters; damage to muscles, tendons, and ligaments; and stress fractures to bones. Inappropriate shoes can also cause other ailments, including back pain.

A proper shoe should partially complement the natural functionality of the foot by incorporating a shock-absorbing sole (usually comprising an outsole, midsole and insole). Accordingly, there is a need for continuous improvement in the provision of cushioning for footwear.

Contents of the invention

In one embodiment, the shoe includes a contoured foam sole. The corrugated foam sole includes a plurality of spaced peaks, wherein at least one pair of adjacent peaks defines a material-free gap between adjacent peaks, and a plurality of spaced troughs, at least one of which is adapted to engage the ground , and wherein at least one pair of adjacent troughs defines a material-free gap between adjacent troughs.

In another embodiment, a shoe includes a corrugated foam midsole including a first side, a second side, a ridge extending along a width of the midsole between the first side and the second side. A plurality of spaced peaks, and a plurality of spaced troughs extending along the width of the midsole between the first side and the second side. At least one pair of adjacent peaks defines a material-free gap extending along the width of the midsole between adjacent peaks, with one end on the first side and the other end on the second side. At least one pair of adjacent troughs define a material-free gap extending along the width of the midsole between adjacent troughs with one end on the first side and the other end on the second side.

In another embodiment, a shoe includes a contoured midsole and plate. The corrugated midsole includes a first side, a second side, a plurality of spaced crests extending along the width of the midsole between the first and second sides, and along the width of the midsole between the first and second sides. A plurality of spaced troughs between the second sides. The plate is connected to the plurality of spaced peaks, each peak of the plurality of spaced peaks has a height at the first side and the second side of the midsole that is greater than the height between the first side and the second side. The height the region has.

In another embodiment, a shoe includes an upper, a plate connected to the upper, and a corrugated sole having a top surface and a bottom surface, the top surface is connected to the plate, the sole A plurality of spaced peaks including a plurality of gaps defining a top surface and a plurality of spaced troughs defining a plurality of gaps of a bottom surface. The shoe also includes one or more support elements coupled to the sole for providing support. The support element may be arranged between the sole and the plate. In one embodiment, the support element may be arranged in a gap in the top surface of the sole.

In another embodiment, a sole for a shoe includes a midsole having a heel portion, a forefoot portion, a medial sidewall, and a lateral sidewall, wherein the midsole is substantially sinusoidal along at least a portion of the length of the midsole, and wherein the The midsole extends along the width of the midsole. Those of ordinary skill in the art will understand that the terms "sinusoidal" and "sine wave" are used herein to refer to the wavelike shape of the midsole, and their strict mathematical meaning is not intended to be used. In one embodiment, the midsole may extend between the medial and lateral sidewalls across the width of the midsole, and may have a top surface shaped to receive an upper of a shoe. The midsole may be substantially sinusoidal along a portion or substantially the entire length of the midsole. In one embodiment, the outer sidewall and/or inner sidewall may be substantially sinusoidal. In another embodiment, the midsole may be substantially sinusoidal across the width of the midsole. The outer sidewall and/or the inner sidewall may include a plurality of peaks having a rounded top surface, a flat top surface, a pointed top surface, or a combination thereof. The midsole can include foam, and the outsole can be coupled to the midsole.

In yet another embodiment, a sole for a shoe includes a midsole having a top surface, a bottom surface, a medial sidewall, and a lateral sidewall, wherein the midsole is undulating so as to define a plurality of Spaced apart gaps and a plurality of spaced apart gaps within said bottom surface. Each of the plurality of top surface gaps may be disposed between adjacent bottom surface gaps. In one embodiment, the top surface gaps and/or the bottom surface gaps may be substantially evenly spaced. In one embodiment, the one or more gaps extend across the entire width of the midsole. In one embodiment, the outer sidewall and/or the inner sidewall comprise a plurality of peaks, and each peak is disposed between adjacent top surface gaps. The outer sidewall and/or the inner sidewall may include a plurality of peaks having a rounded top surface, a flat top surface, a pointed top surface, or a combination thereof. In one embodiment, the midsole extends between the medial sidewall and the lateral sidewall over the entire width of the sole. In one embodiment, the portion of the midsole between the medial sidewall and the lateral sidewall is not undulating. In one embodiment, the one or more gaps extend across the entire width of the midsole and/or only a portion of the width of the midsole.

In another embodiment, a shoe includes an upper and a foam sole disposed below the upper such that a gap is disposed between the sole and the upper, the sole has a heel portion, a forefoot portion, a medial sidewall, and a lateral sidewall, and wherein the sole extends along the The length of the sole is roughly sinusoidal, wherein the sole extends along the width of the sole. In one embodiment, a plurality of gaps are disposed between the sole and the upper. The outer sidewall and/or the inner sidewall may include a plurality of crests with rounded top surfaces, flat top surfaces, or pointed top surfaces. In one embodiment, the shoe may also include a plate disposed between the upper and the sole. At least a portion of the gap may be disposed between the sole and the plate.

In another embodiment, a method of manufacturing a sole for a shoe includes the steps of: molding a corrugated foam midsole in a mold; removing the foam midsole from the mold; on the shaped piece; and the cooling foam midsole. The mold may include a plurality of spaced apart ridges and at least one injection site disposed between adjacent ridges. In one embodiment, the mold may include 1-20 injection sites. In one embodiment, the mold may include 11 injection sites.

In another embodiment, a shoe includes a corrugated foam sole including a plurality of spaced peaks and a plurality of spaced troughs, wherein at least one pair of adjacent peaks A first gap substantially free of material between adjacent crests is defined, wherein at least one pair of adjacent troughs defines a second gap substantially free of material between adjacent troughs.

In another embodiment, a shoe includes an upper, a plate connected to the upper, a corrugated sole, and a support element disposed between the sole and the plate to provide support for the sole. The sole has a top surface and a bottom surface, the top surface is connected to a plate, the sole includes a plurality of spaced crests defining a plurality of gaps in the top surface, and a plurality of gaps defining a plurality of gaps in the bottom surface. separate slots.

Description of drawings

The accompanying drawings, which are incorporated in and form a part of this specification, illustrate the invention and, together with the description, serve to further explain the principles of the invention and enable a person of ordinary skill in the art to make and use the invention.

Figure 1 is a side view of an exemplary shoe according to an embodiment of the present invention;

2 is a bottom view of the exemplary shoe of FIG. 1 in accordance with an embodiment of the present invention;

Figure 3 is a side view of another exemplary shoe according to an embodiment of the present invention;

4 is a bottom view of the exemplary shoe of FIG. 3 in accordance with an embodiment of the present invention;

5 is a close-up side view of a portion of the midsole of the exemplary shoe of FIG. 3 in accordance with an embodiment of the present invention;

Figure 6 is a side view of another exemplary shoe according to an embodiment of the present invention;

7 is a bottom view of the exemplary shoe of FIG. 6 in accordance with an embodiment of the present invention;

Figure 8 is a side view of another exemplary shoe according to an embodiment of the present invention;

9 is a bottom view of the exemplary shoe of FIG. 8 in accordance with an embodiment of the present invention;

10 is a side view of an exemplary midsole according to an embodiment of the present invention;

Figure 11 is a bottom view of an exemplary foot plate according to an embodiment of the invention; and

12 is a partial side view of the exemplary footplate of FIG. 11 in accordance with an embodiment of the present invention;

13 is a schematic illustration of an exemplary shoe during manufacture according to an embodiment of the present invention;

Figure 14 is a side view of an exemplary shoe according to an embodiment of the present invention;

15 is a bottom view of the exemplary shoe of FIG. 14 in accordance with an embodiment of the present invention;

Figure 16 is a side view of an exemplary shoe according to an embodiment of the present invention;

17 is a bottom view of the exemplary shoe of FIG. 16 in accordance with an embodiment of the present invention;

18 is a side view of an exemplary midsole for the exemplary shoe of FIG. 16 in accordance with an embodiment of the present invention;

19 is a front perspective cutaway view of an exemplary shoe in accordance with an embodiment of the present invention;

Figure 20 is a perspective top view of an insert according to an embodiment of the invention;

Figure 21 is a perspective bottom view of the insert shown in Figure 20 according to an embodiment of the present invention;

Figure 22 is a side view of the insert shown in Figure 20 according to an embodiment of the present invention;

23 is a top perspective view of a midsole with an insert in accordance with an embodiment of the present invention;

Figure 24 is a side view of a shoe with an insert according to an embodiment of the present invention;

Figure 25 is a side view of an insert according to an embodiment of the invention;

Figure 26 is a side view of an insert according to another embodiment of the invention;

Figure 27 is a side view of an insert according to another embodiment of the invention;

Figure 28 is a perspective top view of an insert according to another embodiment of the present invention;

Figure 29 is a perspective bottom view of the insert shown in Figure 28 in accordance with the present invention;

Figure 30 is a side view of an insert with a solid support element according to an embodiment of the invention;

31 is a schematic diagram of an exemplary mold for making a shoe sole according to an embodiment of the present invention;

32 is a schematic illustration of an exemplary post-mold form for making a shoe sole according to an embodiment of the present invention;

Figure 33 is a schematic illustration of an exemplary shoe sole during manufacture according to an embodiment of the present invention;

Figure 34 is a side view of an exemplary shoe according to an embodiment of the present invention;

35 is a bottom view of an exemplary shoe and outsole in accordance with an embodiment of the present invention.

detailed description

The present invention is now described with reference to the drawings, wherein like reference numerals are used to indicate identical or functionally similar elements. While specific configurations and configurations are described, it should be understood that this is done for illustration purposes only. A person of ordinary skill in the art will recognize that other configurations and arrangements can be used without departing from the spirit and scope of the invention. It will be apparent to those of ordinary skill in the art that the present invention can be used in many other applications as well.

A shoe 100 according to an embodiment of the present invention has a sole 200 that is undulated to provide a different and unique walk and/or feel to the shoe 100 while also having a unique aesthetic appearance and providing comfort for the wearer's legs, lower Provides training for the back and/or abdomen. The foot plate 300 is connected to the contoured sole 200 and the upper 400 is connected to the foot plate 300 .

Sole 200 may include a midsole 202 having an undulation with alternating peaks 204 and troughs 206 . In some embodiments, the undulations of midsole 202 may be substantially sinusoidal, whereby one or more peaks and/or troughs may be rounded. In other embodiments, one or more of the peaks and/or troughs may have a generally flat top surface, such as shown in FIG. 34 . In other embodiments, the undulations of midsole 202 may be zigzag, whereby one or more peaks and/or troughs are pointed. In some embodiments, peaks 204 may be positioned approximately equidistant between adjacent valleys 206, and likewise, valleys 206 may be positioned approximately equidistant between adjacent peaks. Between each peak 204 and each valley 206 may be a wall 208 . Gaps 210 devoid of material may exist between adjacent crests 204 and above troughs 206 and gaps 212 devoid of material may exist between troughs 206 and below crests 204 . Gap 210 and gap 212 may extend across the entire width of midsole 202 . In an alternate embodiment, gap 210 and gap 212 may extend along only a portion of midsole 202 . In one embodiment, the wave shape of midsole 202 generally resembles a sine wave. The distance between adjacent peaks 204 or adjacent troughs 206 may be approximately the same, or may vary along the length of midsole 202, or a combination of these.

Midsole 202 may be designed such that each trough 206 contacts or engages the ground, respectively, when a user walks, runs, or performs other movements of their own accord. As each trough 206 contacts or engages the ground, due to the vertical bending of the walls 208 connected to the trough 206, a compressive force is applied that deforms the shape of the gap 210 located above the trough. The compressive force can also deform the shape of the gap 212 on either side of the trough 206 to increase the distance between the trough 206 that contacts or engages the ground and the trough adjacent thereto. Shear forces applied to midsole 202 may have the same effect of bending walls 208 and distorting the shape of gaps 210 and 212 .

Therefore, the material used for the midsole 202 must be soft enough to allow said flexing and deformation to provide adequate cushioning. Suitable materials for midsole 202 may include, but are not limited to, foam and thermoplastic polyurethane. When the midsole 202 is foam, the foam may be, for example, ethylene-vinyl acetate (EVA)-based or polyurethane (PU)-based, and the foam may be an open-cell foam or a closed-cell foam. In other embodiments, the midsole 202 may be elastomer, thermoplastic elastomer (TPE), foam-like plastic (such as foam or foam) and gel-like plastics.

Alone or in combination, aspects of the midsole 202 that uniquely absorb compressive and shear forces may include: (1) the tall and thin shape of the walls 208, (2) the undulating shape of the adjacent walls of the midsole 202 208, (3) material-free gaps 210 and 212 on either side of wall 208; and/or (4) compression of the foam itself (in addition to deformation of the sole geometry). Due to the height and thinness of the walls 208, bending may occur. No material portions or gaps 210, 212 may allow for bending and/or deformation of the material of midsole 202 when loaded. The state of contact of the midsole 202 on the ground in the midfoot region can provide the shoe with a new walking feel. Compared to a typical running shoe, the heel strike can take longer, which results in a lower maximum force. When a force is applied to the midsole, not only does the midsole material compress, but the physical shape of the midsole changes to absorb compressive and shear forces. Due to the tall and thin shape of the walls 212, the angle between the walls 208 of the undulating midsole 202, and/or the absence of material or gaps 210, 212 on either side of the walls 208, physical differences in shape may occur. Variations and/or bends (may include wall 208 that expands into one of the absence of material or gaps 210, 212 on either side of wall 208). For an individual, the unique shape, state of contact of the midsole with the ground in the midfoot region, and/or materials can vary the amount of time spent in each phase of the gait cycle compared to a more traditional running shoe, Thereby it is possible to reduce the maximum force felt by the individual.

The aforementioned effects of compressive and shear forces on midsole 202 may cause the wearer's body to exert more force. By forcing the wearer's body to work harder, the shoe exerts a strengthening exercise on muscles such as those in the wearer's calves, thighs, lower back, buttocks and/or abdomen. Due to this extra effort, when the wearer travels a given distance, the muscles affected will feel the force exerted when walking a distance greater than the given distance, thereby increasing the wearer's exercise. In another embodiment, the forces acting on midsole 202 cause the wearer's body to exert less force. For example, midsole 202 may be used to increase the natural elasticity and energy return capabilities of the foot by storing energy during its compression and returning energy during its expansion. As a result, the muscles used during the activity experience less strain.

To create varying cushioning effects, wall 208 may be shaped to provide gaps 210 and 212 having various shapes. In one embodiment, such as shown in FIGS. 1 and 6 , gap 210 may be generally V-shaped. The angle provided between adjacent walls 208 may be adapted to provide the desired cushioning properties. For example, in one embodiment, the angle between adjacent walls 208 may range from about 10 degrees to about 50 degrees, such as from about 10 degrees to about 40 degrees, or from about 15 degrees to about 35 degrees. In one embodiment, the angle between adjacent walls varies along the length of midsole 202 . For example, in one embodiment, the angle may be greater between one or more pairs of adjacent walls 208 in the heel portion of midsole 202 and between one or more pairs of adjacent walls 208 in the forefoot portion. The room is small. For example, in some embodiments, the angle between walls 208 in the forefoot portion may be from about 30 degrees to about 40 degrees. In some embodiments, the angle between adjacent walls 208 in the heel portion may be from about 15 degrees to about 25 degrees. In another embodiment, such as shown in FIG. 1 , the gap 212 may be generally shaped as an inverted V.

The depth of gaps 210 and 212 can also be varied to provide desired cushioning properties. In one embodiment, such as shown in FIG. 1 , the depth of gap 210 may vary along the length of midsole 202 . For example, gap 210 may be deeper in the heel region of midsole 202 and become progressively shallower toward the forefoot region of midsole 202 .

In another embodiment, such as shown in FIGS. The distance d1 between the surfaces of the two walls 208 formed at and facing each gap 212 is shorter than the distance d2 at the middle portion of the gap 212 . The described embodiments are exemplary only, and gaps 210 and 212 may have any combination of shapes apparent to one of ordinary skill in the art. For example, in one embodiment, midsole 202 may include a combination of V-shaped and Omega-shaped gaps.

The number of walls 208 and the corresponding number of gaps 210 and 212 provided within midsole 202 may vary depending on desired cushioning properties or depending on the length and width of midsole 202 . In one embodiment, such as shown in FIG. 1 , midsole 202 may include ten gaps 210 . In one embodiment, midsole 202 may include 2 to 15 gaps. In another embodiment, midsole 202 may include 5 to 13 gaps. In another embodiment, midsole 202 may include 8 to 12 gaps. In one embodiment, midsole 202 may include at least 5 gaps. In another embodiment, midsole 202 may include at least 10 gaps. The number of gaps 210 and 212 may vary depending on the thickness of the walls 208 , the frequency of the undulations, and/or the angle between adjacent walls 208 .

One or more troughs 206 of midsole 202 may have an outsole member 213 attached thereto to provide additional traction. Outsole member 213 may be rubber or any suitable material commonly used for outsoles. In one embodiment, such as shown in FIGS. 2 and 35 , the trough 206 may have one or more outsole members 213 . In another embodiment, such as shown in FIG. 4 , the outsole member 213 may contact one or more troughs 206 and span a portion of the gap 212 between adjacent troughs 206 . In another embodiment, such as shown in FIG. 7 , midsole 202 may have an outsole member 213 that covers the perimeter of the heel area of midsole 202, and/or an additional outsole that covers the perimeter of the forefoot area of midsole 202. Item 213. The outsole member 213 spans the gap 212 between adjacent troughs 206 and may include a region of reduced thickness 217 allowing the outsole member 213 to flex and elongate as the gap 212 elongates. Outsole member 213 may be made of a suitable polymeric material to allow for such elongation and flexing. The described embodiments are exemplary only, and those of ordinary skill in the art will readily appreciate that the pattern of outsole piece 213 on trough 206 of midsole 202 may have a variety of configurations. Additionally, as shown in FIGS. 2 , 4 , 7 and 9 , bottom surface 215 of each trough 206 may have a profile that varies across the width of midsole 202 . The bottom surface 215 of each trough 206 may have the same profile and/or shape, varying profile and/or shape, and combinations thereof. Those of ordinary skill in the art will readily appreciate that the shape and pattern of outsole member 213 may correspond to the contour or shape of bottom surface 215 of trough 206 .

Midsole 202 may be a single component, such as shown in FIGS. 2 and 4, or may include two or more components. In one embodiment, such as shown in FIG. 9 , the midsole 202 may have a lateral midsole member 214 extending along the lateral side of the shoe 100 and a medial midsole member 216 extending along the medial side of the shoe 100 with a void 218 located on the lateral side. Between midsole member 214 and medial midsole member 216 . Forefoot outsole 220 may be connected to both lateral midsole 214 and medial midsole 216 in such a way that forefoot outsole 220 spans and covers a portion of void 218 at the forefoot of shoe 100 . Similarly, heel outsole piece 222 may be attached to both lateral midsole piece 214 and medial midsole piece 216 in such a way that heel outsole piece 222 spans and covers a portion of void 218 at the heel of shoe 100 . Lateral midsole piece 214 and medial midsole piece 216 may have corresponding undulations such that peaks 204 and troughs 206 of each component align when assembled into shoe 100 . An advantage of having separate lateral midsole piece 214 and medial midsole piece 216 is that it provides a different walking feel or cushioning than the one-piece midsole 202 .

As clearly shown in FIG. 10 , the midsole 202 can be shaped such that the peaks 204 have a greater height at the first and second sides 224 , 226 of the midsole 202 than between the first and second sides 224 , 226 . Area. For example, the top surface 228 of each crest 204 is generally concave, thereby providing a recess for receiving the footplate 300 . In one embodiment, the top surface 228 of some of the crests 204 may have a recess 230 adjacent the first and/or second sides 224, 226 to help align the foot plate 300 within the recess and hold the foot plate 300 in place. bit. In one embodiment, the portion of the midsole between the first and second sides 224, 226 is not undulating, and only the first (eg, lateral) side 224 and/or the second side (eg, medial) 226 are undulating. shape. Portions of the gaps 210 and/or 212 between the first and second sides 224, 226 may be filled.

As best shown in FIGS. 11 and 12 , foot plate 300 may have a bottom surface 302 with a plurality of ridges 304 extending outwardly from bottom surface 302 . Ridge 304 may be shaped to provide a profile corresponding to the size, shape, and contour of top surface 228 of crest 204 of midsole 202 . Ridge 304 may also extend to side 306 of footplate 300 . Ridges 304 thus assist in the alignment of footplate 300 on top surface 228 of crest 204 of midsole 202 .

Footplate 300 may be any suitable thermoplastic or synthetic material, and in some embodiments may be molded or laid-up. In other embodiments, the footplate 300 may be a molded foam such as compression molded foam, TPU or In one embodiment, footplate 300 may be formed separately from midsole 202 and subsequently attached and bonded to midsole 202 by adhesive bonding, welding, or other suitable techniques as would be apparent to those of ordinary skill in the art. Area 308 of bottom surface 302 that contacts top surface 228 of crest 204 may be textured to facilitate attachment of footplate 300 to midsole 202 . In another embodiment, footplate 300 and midsole 202 may be co-molded and thus formed together at the same time.

Midsole 202 may be used in conjunction with a variety of uppers 400 . In one embodiment, upper 400 may have a bootie 402 attached to an upper surface (not shown) of footplate 300 for receiving a wearer's foot. In some embodiments, plate 300 may be placed within shoe 100 and midsole 202 may be directly connected to upper 400 . Upper 402 may be any suitable lightweight and breathable material for an upper known to those of ordinary skill in the art. Upper 402 may be attached to the footboard by adhesive or other conventional attachment techniques. Upper 400 may also have one or more structural members 404 extending from footplate 300 . Structural member 404 provides structure to upper 402 and may extend along the lateral and medial sides and may be used for the trim of shoe 100 . Structural member 404 may also be present in the heel area to provide an inner or outer heel upper, or in the forefoot area to provide an inner or outer toe cap. Structural member 404 may be molded from suitable polymeric materials known to those of ordinary skill in the art. Structural member 404 can also have a variety of shapes and sizes that would be apparent to those of ordinary skill in the art.

Referring to Figures 13 and 31-33, the fabrication of midsole 202 according to an embodiment of the present invention will now be described. Midsole 202 may be molded by injection molding using one or more molds 600, as understood by those of ordinary skill in the art. Mold 600 may include a mold for one or more midsoles 202 . Referring to FIGS. 13 and 31 , mold 600 may include a plurality of ridges 601 corresponding to one or more gaps 212 of midsole 202 . During the molding process, one or more injection sites or injection channels 601 may be used to introduce midsole material into the mold. As shown in Figures 13 and 31, in one embodiment of the present invention, eleven (11) sprues may be used to introduce material into the mold, thereby forming a sprue extending from midsole 202 in the region corresponding to the sprue. Post 232, which will subsequently be removed. In this way, the material can be evenly distributed on the midsole. In the heel portion of the midsole 202, one infusion port may be used for the rearmost peak region, and two infusion ports may be used at each of the next two peaks in the heel region. Two injection ports can also be used at each of the 5th, 7th and 9th peaks in the midsole 202 . In another embodiment, one or more sprues may be used at each peak to introduce midsole material into the mold. Using a sprue for introducing the midsole material into the mold can be beneficial as the sprue can provide a uniform flow of material; can help provide proper curing of the material; can help provide a uniform temperature after filling distribution, which in turn helps create a consistent skin thickness; can help create a consistent midsole from left to right; and helps ensure that the mold is completely filled. Other means of introducing material into the mold during manufacture of midsole 202 may be used. In certain embodiments, other molding methods may be employed including, but not limited to, compression molding, injection molding, and expansion molding, where pellets may be placed in a mold and expanded.

During the manufacturing process, since the midsole 202 may expand when removed from its mold, the mold may have a smaller size than the desired size of the midsole. For example, in one embodiment of the invention using EVA material, the mold may have dimensions that are approximately 65%-75% of the final midsole dimensions. Depending on the expansion rate of the material used, other mold sizes may be used.

32 and 33, in one embodiment, one or more post-mold forms 510 may be used after the midsole 202 is removed from the mold 600 during the manufacturing process. After removal from mold 600 , the top surface of midsole 202 may be placed over post-mold form 610 . Post-mold form 610 may include a plurality of ridges 611 formed on base 612 that correspond to one or more gaps 210 of midsole 202 . In an alternative embodiment, the bottom surface of midsole 202 may be placed over molded form 610 , and ridges 611 may correspond to one or more gaps 212 of midsole 202 . Post-mold form 610 may assist in proper cooling and shaping of midsole 202 . For example, midsole 202 may shrink as it cools and/or completes solidification, and since the form is dimensionally stable, post-molding form 610 may limit and/or control the shrinkage of midsole 202 such that the midsole forms the desired shape. In some (but not necessarily all) embodiments, portions of midsole 202 may have varying thicknesses, and/or may cool at different rates. Thus, without the use of post-mold form 610, midsole 202 would bend or otherwise become oddly shaped. In one embodiment, one or more weights 620 may be placed on midsole 202 as the midsole cools to further assist in proper cooling and shaping. In one embodiment, weighting members 620 may be placed on the midsole 202 in the heel region of the midsole and in the forefoot region. Post-molding form 610 may comprise plastic, ceramic, metal, wood, bamboo, castepoxy, or other suitable material.

Midsole 202 can be molded to accommodate various needs, such as preventing pronation or supination of the sole of the foot. In such cases, certain areas of midsole 202 may be given different properties to allow for such customization. In cases where the inner side of the midsole 202 needs to be customized but not the outer side, or vice versa, it is preferred to use a midsole 202 having the described lateral midsole piece 214 and medial midsole piece 216 . As an alternative or in addition to modifying midsole 202 , inserts may be placed between midsole 202 and plate 300 , or posts may be used to connect midsole 202 to upper 400 , as described in more detail below.

The embodiments of Figures 1-4 and 6-10 have described midsole 202 having a wave shape from toe to heel with peaks 204 and troughs 206, but this is exemplary only. In some embodiments, such as shown in FIGS. 14 and 15 , midsole 202 may be undulated with peaks 204 and troughs 206 only in the forefoot region. In other embodiments, such as shown in FIGS. 16-18, midsole 202 may be undulated with peaks 204 and troughs 206 only in the heel region. In other embodiments, such as shown in FIG. 19 , midsole 202 may also have one or more rows 234 that are undulating with peaks 204 and troughs 206 in a medial-to-lateral direction. In some embodiments, the peaks 204 and grooves 206 of each row 234 may be aligned.

In certain embodiments, the contoured sole 200 may be manufactured to provide a different and unique walk and/or feel of the shoe 100, while also providing a unique aesthetic appearance and improved cushioning and support properties.

Referring to FIGS. 20-22 , embodiments of the present invention may include one or more inserts 500 to provide midsole 202 with desired strength and/or cushioning properties. For example, one or more inserts 500 may be included to render all or portions of midsole 202 stiffer. In this way, for example, insert 500 may help limit pronation or supination of the wearer's foot.

In one embodiment, insert 500 may include one or more support elements 510 connected by connecting members 520 . In one embodiment, the support element 510 includes a curved support surface 511 such that the support element 510 is generally U-shaped, such as shown in FIG. 22 . As shown in FIG. 20, in one embodiment, the support member 510 may include a proximal end 512 and a distal end 514. The proximal end 512 may be rounded, and the height of the support member 510 may gradually decrease from the proximal end 512 to the distal end 514. .

Each support element 510 may be connected to an adjacent support element 510 by a connecting member 520 . In one embodiment, a connecting member 520 extends from a distal end 514 of one support element 510 to a distal end 514 of an adjacent support element 510 . In an alternative embodiment, the connecting member 520 may extend from the distal end 514 of a first support element 510 to the proximal end 512 of an adjacent support element. In other embodiments, the connecting member 520 may extend from any point along the length of a first support element 510 to any point along the length of an adjacent support element 510 . Connecting members 520 may connect non-adjacent support elements. In one embodiment, a support element 510 disposed at an end of the insert 500 may include a connection member 522 that is not connected to an adjacent support element. As shown in FIG. 20, for example, fore foot end support element 516 and rear foot end support element 518 may include connecting members 522 that are not connected at the ends. Alternatively, insert 500 may not include connection members 522 extending from end support elements. In one embodiment, such as shown in FIGS. 20-22 , the insert 500 may include five (5) connected support elements 510 . As will be described in detail below, other combinations of support elements 510 and connecting members 520 for insert 500 may be used to provide the desired stiffness and/or cushioning properties of midsole 202 .

Referring to FIGS. 23 and 24 , in one embodiment, insert 500 may be disposed between midsole 202 and plate 300 and coupled to midsole 202 . In particular, in one embodiment, each support element 510 of insert 500 may be disposed within gap 210 of midsole 202 . In an embodiment where the insert 500 has five (5) support elements 510 , as shown in FIG. 23 , each support element 510 may be disposed within the gap 210 . The bearing surface 511 of the bearing element 510 is preferably shaped to fit snugly within the gap 210 along the inner surface 211 of the gap 210 . The support surface 211 on which the support element 510 is positioned may cover all or part of the inner surface 211 of the gap 210 . For example, in one embodiment, bearing surface 511 may extend from bottom 207 of gap 210 along a portion (eg, halfway) of inner wall 209 , or to the top of inner wall 209 . In one embodiment, support element 510 may not extend fully within gap 210 such that it does not contact bottom 207 of gap 210 . The support surface 511 may cover only the portion of the inner wall 209 between the bottom 207 and the top of the inner wall 209 .

In one embodiment, the support surface 511 is curved such that the support element 510 is generally U-shaped. In other embodiments, support surface 511 may be square, V-shaped, omega-shaped, or otherwise shaped to fit within gap 210 or other portion of midsole 202 . In one embodiment, support element 510 may be secured within gap 210 by an adhesive. In other embodiments, adhesive may not be used, but the snug fit of the support elements within the gaps may be used to hold them in place.

In one embodiment, as shown in FIG. 23 , insert 500 may be disposed generally within the arch region of midsole 202 . In other embodiments, insert 500 may be disposed in the forefoot area, the heel area, and/or along the entire length of midsole 202 . In general, insert 500 may be positioned so as to provide the desired stiffness and/or cushioning properties of midsole 202 .

The dimensions of the support element 510 can also be adjusted such that the support element 510 fits within the gap 210 . In an embodiment of the invention in which the depth of gap 210 varies along midsole 202 , the dimensions of support element 510 may likewise vary along insert 500 . For example, as noted above, gap 210 may be deeper in the heel region of midsole 202 and become shallower toward the forefoot region of midsole 202 . Accordingly, the support element 510 may be larger at the rear of the insert 500 and become smaller towards the front of the insert 500 . For example, the forefoot end support element 516 may be smaller than the rear foot end support element 518 .

Insert 500 may be made from rigid or flexible materials to provide the desired rigidity properties of midsole 202 . In one embodiment, insert 500 includes TPU. Other suitable materials may be used including, but not limited to, elastomers, thermoplastic elastomers (TPE), foamed plastics such as foam and/or foam), gel-like plastic, foam, metal or other suitable materials and combinations thereof.

In one embodiment, insert 500 may be injection molded as a unitary part. In other embodiments, the support element 510 may be molded separately and then attached. In some embodiments, one support element 510 may be made of a different material than the other support element 510 . For example, first support element 510 may be made of a stiffer material than second support element 510 in order to provide desired stiffness or cushioning properties to different areas of midsole 202 . In one embodiment, insert 500 may be molded with midsole 202 . For example, insert 500 may be molded and midsole 202 may be molded under insert 500 , or insert 500 may be molded directly over midsole 202 . In one embodiment, such as shown in FIG. 35, support element 510 may form part of midsole 202 to form a unitary and unitary structure. Support element 510 may be formed within gap 212 , as shown, and/or within gap 210 . In one embodiment, two support elements 510 may be formed in the rearmost gap 212 and one support element may be formed in the next gap 212 . It will be appreciated that support elements 510 may be formed within other gaps in various combinations. In one embodiment, midsole 202 may be molded around insert 500 such that insert 500 fits into the midsole. In one embodiment, insert 500 may be integral with plate 300 . Plate 300 may extend partially or completely into support element 510 .

In one embodiment, one or more support elements 510 of insert 500 may extend across a portion of the width of midsole 202 in order to provide a portion of midsole 202 with desired rigidity properties. For example, as shown in FIG. 23 , support elements 510 may extend inwardly from the inside of midsole 202 over a portion of the width of midsole 202 . During use, support element 510 may provide support to midsole 202 in this region and may limit compression of the midsole. For example, support element 510 may limit compression of wall 208 in an area around the support element when midsole 202 is under load. Thus, insert 500 can impart additional stiffness to the medial side of midsole 202 and can prevent supination, for example.

In other embodiments, support elements may extend inwardly from the outside of midsole 202 over a portion of the midsole. In this way, insert 500 may impart additional stiffness to the lateral side of midsole 202 and may prevent pronation, for example. In still other embodiments, insert 500 may extend substantially the entire width of midsole 202 such that it provides the desired stiffness or cushioning properties across the width of the midsole. In some embodiments, insert 500 may include one or more support elements 510 extending over only a portion of the width of midsole 202 and one or more support elements 510 extending across the entire width of midsole 202 .

In one embodiment, connecting member 520 may be generally flat so that it does not interfere with the placement of plate 300 on midsole 202 . A groove may be formed in the top of midsole 202 to receive connecting member 520 such that connecting member 520 is flush with the top of midsole 202 . As shown in FIG. 23 , connecting members 520 of insert 500 may collectively form a generally curved shape from the perimeter of midsole 202 through the interior of midsole 202 . In one embodiment, connection member 520 may be positioned to provide additional support to insert 500 .

In one embodiment, all or a portion of insert 500 is visible from the side of shoe 100 as shown in FIG. 24 . For example, proximal end 512 of one or more support elements 510 can be seen through gap 210 . In other embodiments, insert 500 may not be visible.

Any number of support elements 510 and connecting members 520 for insert 500 may be used to provide the desired stiffness or cushioning properties of midsole 202 . As shown in FIG. 25 , in one embodiment, the insert 500 may include two (2) support elements 510 . Support element 510 may be sized for the heel portion of midsole 202 . In one embodiment, as shown in FIG. 26 , insert 500 may include two (2) support elements 510 that may be generally sized for the forefoot portion of midsole 202 . In one embodiment, as shown in FIG. 27, insert 500 may include a support member. In other embodiments, insert 500 may include a single support element 510 without connecting member 520 . As shown in FIGS. 28-29 , in one embodiment, insert 500 may include four (4) support elements 510 extending generally across the width of midsole 202 . The connection member 520 may connect adjacent support elements 520 in the middle of the support elements. In one embodiment, the number of support elements 510 may be the same as the number of gaps 210 within midsole 202 .

In an alternate embodiment, insert 500 may be positioned on the underside of midsole 202 . Each support element 510 of insert 500 may be disposed within gap 212 of midsole 202 . The support element 510 may be sized and shaped accordingly. In other embodiments, the insert 500 may include one or more support elements 510 adapted to fit properly over the crest 204 .

In a preferred embodiment, insert 500 may be permanently seated within midsole 202 during the manufacture of shoe 100 . In other embodiments, insert 500 is easily removable from midsole 202 . For example, in one embodiment, support element 510 may be inserted into gap 210 between midsole 202 and plate 300 from the side of shoe 100 . Support element 510 may include a protrusion that may be pulled for subsequent removal of support element 510 from gap 210 . In this manner, insert 500 or support element 510 may be sold "aftermarket" and the user may continue to customize the stiffness or cushioning properties of shoe 100 according to desired use, age of the shoe, or other usage conditions.

In one embodiment, one or more support elements 510 may be solid elements. For example, as shown in FIG. 30 , support element 510 may be completely solid, as shown by support element 513 , or may be partially solid, as shown by support elements 515 and 517 . The solid support element may be filled with the same material as the support surface 511 and form an integral part, or it may be filled with a different material such as foam or other suitable material. In one embodiment, the support element 510 may be filled with a portion of the plate 300 . Solid support elements may be adapted to provide additional support for midsole 202 . In other embodiments, the support element 510 may be hollow, filled with fluid, or filled with pressurized or ambient air.

The above description of specific embodiments will fully disclose the general concept of the invention, and without undue experimentation and without departing from the general concept of the invention, others can use the knowledge of those of ordinary skill in the art to modify these specific embodiments for various applications. It is convenient to change and/or adjust the embodiments. Therefore, such changes and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It should be understood that the words or terms used herein are for the purpose of description and not of limitation, so that the words or terms of the present description are to be interpreted by those of ordinary skill in the art according to the teaching and guidance.

The breadth and scope of the present invention should not be limited by any of the described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

Claims (15)

1. a kind of footwear, it is characterised in that the footwear include：

Wavy foam midsole, the sole includes：

The crest at multiple intervals, a pair adjacent crests of wherein at least are limited between the no material between the adjacent crest Gap；

Wherein, the crest at the plurality of interval along the length of the wavy foam midsole on the direction of toe to heel Extend；And

The trough at multiple intervals, wherein at least one trough is applied to contact ground, and a pair adjacent troughs of wherein at least Limit the gap without material between the adjacent trough；

Described is wavy with alternate crest and trough, and the wavy foam midsole is substantially sinusoidal in shape Ripple；

The footwear also include the plate of the crest for being connected to the plurality of interval；

And the crest at the plurality of interval along the wavy foam midsole width on the direction in outside to inner side Extend, and the trough at the plurality of interval along the wavy foam midsole width on the direction in outside to inner side Extend, wherein the width in sole forms wavy on the direction in outside to inner side with crest and trough form.

2. footwear as claimed in claim 1, it is characterised in that the trough at the plurality of interval is along the wavy foam shoes The length at bottom is upwardly extended in the side of toe to heel.

3. a kind of footwear, it is characterised in that the footwear include：

Bottom in wavy foam, bottom includes in the wavy foam：

First side；

Second side；

Along bottom in the wavy foam width in the wavy foam first side at bottom and described The crest at the multiple intervals extended between two sides；And

Along bottom in the wavy foam width in the wavy foam first side at bottom and described The trough at the multiple intervals extended between two sides；

The adjacent crests of a pair of wherein at least limit the gap without material between the adjacent peaks, the adjacent peaks it Between the gap along in the wavy foam bottom width extend, its one end be located at the wavy foam in bottom First side, and the other end be located at the wavy foam in bottom second side；And

A pair adjacent troughs of wherein at least limit the gap without material between the adjacent trough, between the adjacent trough The gap extend along the width at bottom in the wavy foam, its one end is located at bottom in the wavy foam First side, and the other end is located at second side at bottom in the wavy foam；

Described is wavy with alternate crest and trough, and the wavy foam midsole is substantially sinusoidal in shape Ripple；

The footwear also include the plate of the crest for being connected to the plurality of interval.

4. footwear as claimed in claim 3, it is characterised in that bottom includes two parts in the wavy foam, wherein often Individual part includes：

First side；

Second side；

The multiple intervals extended between first side and second side of the part along the width of the part Crest；And

The multiple intervals extended between first side and second side of the part along the width of the part Trough.

5. footwear as claimed in claim 4, it is characterised in that described two parts at bottom include outer in the wavy foam Sidepiece part and inner part.

6. footwear as claimed in claim 3, it is characterised in that trough described at least one is applied to contact ground.

7. footwear as claimed in claim 3, it is characterised in that each in the crest at the plurality of interval is generally V-shape.

8. footwear as claimed in claim 3, it is characterised in that the substantially Omega of each in the crest at the plurality of interval Shape.

9. footwear as claimed in claim 3, it is characterised in that the crest at the plurality of interval bottom in the wavy foam First side and second side at the height that has more than the bottom in the wavy foam first side And the height having at the region between second side.

10. footwear as claimed in claim 9, it is characterised in that wherein described plate is in the wavy foam described in bottom It is arranged in region between first side and second side in each in the crest at multiple intervals.

11. a kind of footwear, it is characterised in that the footwear include：

Wavy middle bottom, the wavy middle bottom includes：

First side；

Second side；

Width along the wavy middle bottom is between first side and second side at the wavy middle bottom The crest at the multiple intervals for extending；And

Width along the wavy middle bottom is between first side and second side at the wavy middle bottom The trough at the multiple intervals for extending；And

It is connected to the plate of the crest at the plurality of interval；

The crest at wherein the plurality of interval is had at first side and second side at the wavy middle bottom Height more than the height having at region between first side and second side at the wavy middle bottom；

Described is wavy with alternate crest and trough, and the wavy foam midsole is substantially sinusoidal in shape Ripple.

12. footwear as claimed in claim 11, it is characterised in that the plate the wavy middle bottom first side and It is arranged in region between second side in each in the crest at multiple intervals.

13. footwear as claimed in claim 11, it is characterised in that trough described at least one is applied to contact ground.

14. footwear as claimed in claim 11, it is characterised in that the wavy middle bottom include two parts, wherein each The part includes：

First side；

Second side；

The multiple intervals extended between first side and second side of the part along the width of the part Crest；And

The multiple intervals extended between first side and second side of the part along the width of the part Trough.

15. footwear as claimed in claim 14, it is characterised in that described two parts at the wavy middle bottom include outside Part and inner part.