Cushioning system for footwear and related method of manufacture

• US 20030150131A1
• Filed: 02/08/2002
• Published: 08/14/2003
• Est. Priority Date: 02/08/2002
• Status: Active Grant

• Current Assignee: Wolverine World Wide Inc.
• Original Assignee: Wolverine World Wide Inc.
• Inventors: Brown, William J., McManus, Ronald P., Sikes, Gary L.
• Granted Patent: US 6,802,138 B2
• Time in Patent Office: Days
• US Class Current: 36/28
• CPC Class Codes: A43B 13/12 Soles with several layers of different materials
• CPC Class Codes: A43B 13/39 with upset sewing ribs
• CPC Class Codes: A43B 7/144 situated under the heel, i.e. the calcaneus bone
• CPC Class Codes: A43B 7/1445 situated under the midfoot, i.e. the second, third or fourth metatarsal
• CPC Class Codes: A43B 7/145 situated under the toes, i.e. the phalanges
• CPC Class Codes: A43B 9/02 Footwear stitched or nailed through
• CPC Class Codes: A43B 9/06 stitched or nailed through

Abstract

A footwear cushioning system including an insole platform and an insert that cooperate with one another. The insole platform includes a recess defined in the heel and/or forefoot area. The insert includes a footbed and heel and/or forefoot cushion extending from the footbed. The cushions interfit with the respective heel and/or forefoot recess of the insole platform. In a preferred embodiment, the insole platform includes a shank secured thereto, surrounding the heel recess. The insole platform is preferably shaped to define both heel and forefoot recesses and the insert includes cushions that interfit with both recesses. A midsole is secured to the insole platform and an outsole is further secured to the midsole. To assemble the cushion system, the insole platform is secured to the upper. The midsole is then secured to the insole platform. The outsole is adhered to the under surface of the midsole. The insert is fitted into the upper over the insole platform so that the heel and/or sole cushions rest within the corresponding heel and/or sole recesses of the insole platform.

Claims

1. An insole platform for a welted article of footwear comprising:

an insole platform formed in the shape of a foot, said insole platform shaped to define a recess including a bottom wall;

a rib extending downwardly from said insole platform to define a platform recess, said rib to affix a welt to said insole platform.

2. The insole platform of claim 1 comprising a shank secured to said insole platform, wherein said shank extends substantially around said recess.

3. The insole platform of claim 1 comprising an insert including a footbed and a downwardly extending cushion element, said cushion element fitted at least partially within said recess.

4. The insole platform of claim 3 wherein said recess is formed in at least one of a heel and a forefoot of the foot of a wearer.

5. The insole platform of claim 1 wherein said shank is formed of polystyrene and said insole platform is formed of polyvinyl chloride.

6. The insole platform of claim 1 wherein said recess includes at least one side wall connected to said bottom wall.

7. The insole platform of claim 6 wherein said shank includes at least one shank wall extending along at least a portion of said side wall toward said bottom wall.

8. The insole platform of claim 7 wherein shank wall and said side wall are inclined from vertical to center a wearer'"'"'s foot within said recess.

9. A cushioning system for footwear comprising:

an insole platform including an insole plate corresponding to the shape of a human foot and defining a recess bounded by a bottom wall, said recess positioned in a heel region of a foot of a wearer, said insole platform further including an insole rib extending from said insole plate;

an insert corresponding to the shape of a human foot including a cushion element extending from and positioned in the heel region of the foot of the wearer, said insert disposed over said insole platform so that said cushion element fits substantially within said recess.

10. A sole assembly for a welted article of footwear comprising:

an outsole including an upper surface;

a midsole secured to said outsole, said midsole of a sheet construction substantially covering said upper surface;

an insole platform secured to said midsole, said insole platform defining a recess bounded by one or more side walls and a bottom; and

an insert including a footbed and a cushion extending from said footbed and interfit with said recess.

11. The sole assembly of claim 10 wherein said insole platform includes at least one of a heel and a forefoot, and wherein said recess is formed in at least one of the heel and the forefoot.

12. The sole assembly of claim 11 wherein said insert includes a heel cushion extending from said footbed and interfit within said recess formed in the heel.

13. The sole assembly of claim 11 wherein said insert includes at least one of a heel cushion and a forefoot cushion, said heel cushion including a plurality of downwardly extending ribs being forwardly inclined from the vertical, said forefoot cushion including a plurality of downwardly extending ribs and being rearwardly inclined from the vertical.

14. The sole assembly of claim 11 wherein said insert includes at least one of a heel cushion and a forefoot cushion of a solid cushion construction.

15. The sole assembly of claim 11 comprising a shank integrally secured to said insole platform around said recess formed in the heel.

16. The sole assembly of claim 15 wherein said shank includes at least one shank wall that extends adjacent said one or more side walls.

17. The sole assembly of claim 10 wherein said outsole defines a cavity including at least one of a pad positioned in said cavity and a plug molded in said cavity

18. A method for manufacturing a sole assembly for welted footwear comprising:

providing an insole platform including an insole heel portion, an insole forefoot portion, and an insole plate defining an upwardly opening recess bounded by a bottom wall and at least one side wall, the insole platform further including a rib extending therefrom for affixing the insole platform to a welt;

securing the rib to a midsole of a sheet construction; and

securing at least one of the midsole and the insole platform to an outsole, the outsole including an outsole heel portion.

19. The method of claim 18 wherein the outsole defines a heel cavity in the outsole heel portion, the heel cavity including at least one of a heel pad positioned in said heel cavity and a heel plug molded in said heel cavity.

20. The method of claim 19 wherein the midsole is substantially void of any perforations that correspond to the upwardly opening recess in the insole platform.

21. The method of claim 19 comprising disposing an insert over the insole platform the insert including a cushion, wherein the cushion is disposed in the recess.

22. The method of claim 18 wherein a shank is secured to the insole plate, the shank extending around the recess.

23. The method of claim 22 wherein insole platform is molded from polyvinyl chloride and the shank is molded from polystyrene.