Shoe apparatus with improved efficiency

• US 20050268488A1
• Filed: 06/07/2004
• Published: 12/08/2005
• Est. Priority Date: 06/07/2004
• Status: Active Grant

• Current Assignee: Hann Athletic, LLC
• Original Assignee: Energy Management Athletics, LLC
• Inventors: Hann, Lenn R.
• Granted Patent: US 7,334,351 B2
• Time in Patent Office: Days
• US Class Current: 36/27
• CPC Class Codes: A43B 13/141 with a part of the sole being flexible, e.g. permitting articulation or torsion
• CPC Class Codes: A43B 13/16 Pieced soles with several layers of different material A43B13/12
• CPC Class Codes: A43B 13/20 Pneumatic soles filled with a compressible fluid, e.g. air, gas inflatable linings for skiboots A43B5/0407
• CPC Class Codes: A43B 13/206 provided with tubes or pipes or tubular shaped cushioning members

Abstract

A shoe is provided for improving use efficiency through reduction of neuromuscular fatigue. The shoe includes an upper having a generally horizontal bottom wall. The bottom wall includes an upper surface and a lower surface. The upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading. The shoe further includes a sole comprising a midsole and an outsole. The midsole comprises a suspension element, which can have a generally elongated shape. The suspension element further has a center of compression, which is generally aligned with at least one of the first and second centers of loading of the upper. The shoe can have a hinge located within the sole for providing enhanced efficiency to the user. The hinge and suspension element(s) can take various forms. The position and structure of the hinge and suspension element(s) in relation to the midsole can take various forms as well. The biomechanical action of the heel element, forefoot element and hinge can be dynamically coupled to create a highly resilient suspension system with a low rate of loading throughout the stride, thus allowing a natural, “barefoot” gait for the wearer. As a result, the wearer experiences a significant reduction in jarring impacts for any phase of the stride, a corresponding reduction in cumulative fatigue and a lower rate of chronic or traumatic injury. A method of manufacturing a suspension element for a shoe is also provided, and includes the steps of providing a die having a length, a width and a thickness, the length accommodating a plurality of suspension elements; wrapping a plurality of coated or wetted fibers around the width of the die to form the suspension elements; drying or curing the fibers to a substantially integrated form; and separating the plurality of suspension elements into independent suspension elements.

Claims

1. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape at least a portion of which is connected to the lower surface of the generally horizontal bottom wall, the suspension element having a center of compression, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper.

2. The shoe of claim 1 wherein the outsole is connected to a lower exterior surface of the suspension element of the midsole.

3. The shoe of claim 1, wherein the suspension element comprises a first upper suspension arm having a first end and a second end, and a second lower suspension arm having a first end and a second end, each of the first and second ends of the respective first and second suspension arms being joined together to form the suspension element, and forming open first and second sides and a hollow central suspension region therebetween.

4. The shoe of claim 3, wherein the hollow central suspension region is at least partially filled with foam to close the first and second sides for preventing debris from entering the first and second sides.

5. The shoe of claim 1 wherein the sole comprises a generally vertical hinge slit extending the lateral width of the sole, the hinge slit having a horizontal component and a vertical component, the hinge slit extending from a bottom surface of the sole through at least twenty percent of the vertical component of the sole, wherein at least a portion of the horizontal component of the hinge slit is located between a midpoint between the forward center of loading and the rear center of loading, and the forward center of loading from a bottom view.

6. The shoe of claim 1 wherein the sole comprises an openable gap extending the lateral width of the sole, the openable gap having a horizontal component and a vertical component, and extending along a path which generally follows at least a portion of an upper surface of the compression element beginning from a bottom surface of the sole through at least ten percent of the sole in a vertical direction, wherein at least a portion of the horizontal component of the openable gap is located between a midpoint between the forward center of loading and the rear center of loading, and the forward center of loading from a bottom view.

7. The shoe of claim 1 wherein the sole comprises an openable gap extending the lateral width of the sole, the openable gap having a horizontal component and a vertical component, and extending along a path beginning from a bottom surface of the sole through at least ten percent of the sole in a vertical direction, wherein at least a portion of the horizontal component of the openable gap is located between a midpoint between the forward center of loading and the rear center of loading, and the forward center of loading from a bottom view.

8. The shoe of claim 1 wherein the sole comprises an openable gap extending the lateral width of the sole, the openable gap having a horizontal component and a vertical component, and extending along a path which generally follows at least a portion of an upper surface of the suspension element.

9. The shoe of claim 1 wherein the suspension element is at least partially filled with a foam for preventing debris from entering an interior space of the suspension element.

10. The shoe of claim 9 wherein the suspension element comprises a plurality of foam regions, each foam region having foam therein of varying density in relation to at least one other foam region.

11. The shoe of claim 1 wherein the suspension element comprises a side cross-sectional shape of at least one of an elliptical shape, an oval shape, an end-pointed shape, an end-rounded shape, a flat-topped shape, and a bottom-protrusion shape.

12. The shoe of claim 1 wherein the suspension element comprises first and second lateral sides and an aperture located adjacent to at least one of the lateral sides on a top portion of the suspension element.

13. The shoe of claim 1 wherein the suspension element comprises first and second lateral sides and an aperture located between the lateral sides on a top portion of the suspension element.

14. The shoe of claim 13 wherein the aperture is in a generally rectangular shape.

15. The shoe of claim 1 wherein the suspension element comprises first and second lateral sides, and a plurality of fibers generally disposed in a parallel orientation to the lateral sides.

16. The shoe of claim 1 wherein the suspension element comprises first and second lateral sides, and a plurality of fibers generally disposed in a perpendicular orientation to the lateral sides.

17. The shoe of claim 1 wherein the suspension element comprises first and second lateral sides, a first plurality of fibers generally disposed in a first orientation and a second plurality of fibers disposed in a second orientation which is at an angle from the first plurality of fibers.

18. The shoe of claim 17 wherein the angle is 90 degrees.

19. The shoe of claim 1 wherein the midsole comprises a side contour, the suspension element comprises first and second lateral sides, and at least one of the lateral sides follows at least a portion of the side contour of the midsole.

20. The shoe of claim 1 wherein the midsole comprises a side contour, the suspension element comprises first and second lateral sides, and at least one of the lateral sides extends laterally beyond at least a portion of the side contour of the midsole.

21. The shoe of claim 1 wherein the suspension element comprises upper and lower lateral sides, and at least one of the lower later sides extends laterally beyond the at least one of the upper lateral sides.

22. The shoe of claim 21 wherein the midsole comprises a side contour, and at least one of the upper lateral sides follows at least a portion of the side contour of the midsole.

23. The shoe of claim 1 wherein the shoe is one of at least a boot, a hiking shoe, a hiking boot, a running shoe, a cross training shoe, and a walking shoe.

24. The shoe of claim 1 further comprising a second suspension element having a generally elongated shape and a second center of compression, wherein the second suspension element is generally aligned with the other of the at least one of the first and second centers of loading of the upper.

25. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape and a center of compression, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper, the suspension element further comprising a first upper suspension arm having a first end and a second end, and a second lower suspension arm having a first end and a second end, each of the first and second ends of the respective first and second suspension arms being connected to form the suspension element, and forming first and second sides and a central suspension region therebetween, wherein the central suspension region is at least partially filled with foam.

26. The shoe of claim 25 wherein foam closes at least one of the first and second sides for preventing debris from entering the first and second sides.

27. The shoe of claim 25 wherein the central suspension region comprises a plurality of regions, at least two of the regions having foam therein of varying density in relation to one another.

28. The shoe of claim 25 further comprising a second suspension element having a generally elongated shape, a second center of compression, and a second central suspension region, wherein the second suspension element is generally aligned with the other of the at least one of the first and second centers of loading of the upper, and wherein the second central suspension region is at least partially filled with foam.

29. The shoe of claim 28 wherein the foam within the second central suspension region prevents debris from entering the second central suspension region.

30. The shoe of claim 28 wherein the second central suspension region comprises a plurality of regions, at least two of the regions of the second central suspension region having foam therein of varying density in relation to one another.

31. The shoe of claim 25 wherein the sole comprises a forward region generally below the forward center of loading and a rear region generally below the rear center of loading of the upper, the sole further comprising an openable gap extending the lateral width of the sole, the openable gap having a horizontal component and a vertical component, and extending along a path beginning from a bottom surface of the sole through at least ten percent of the sole in a vertical direction, wherein at least a portion of the horizontal component of the openable gap is located between a midpoint between the forward center of loading and the rear center of loading, and the forward center of loading.

32. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape and a center of compression, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper, the suspension element further having a first side and a second side, at least a portion of one of the first and second sides having a generally concave shape inwardly facing toward a line which lengthwise bisects the shoe from a top view.

33. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape and a center of compression, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper, the generally elongated shape having a flat upper region.

34. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape, a center of compression, a first upper suspension arm having a first end and a second end, and a second lower suspension arm having a first end and a second end, each of the first and second ends of the respective first and second suspension arms being connected to form the suspension element, and forming first and second sides and a central suspension region therebetween, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper, the lower suspension arm having a downwardly convex region which spans at least a fraction of a distance between the first and second sides.

35. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape, a center of compression, a first upper suspension arm having a first end and a second end, and a second lower suspension arm having a first end and a second end, each of the first and second ends of the respective first and second suspension arms being connected to form the suspension element, and forming first and second sides and a central suspension region therebetween, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper, the suspension element further comprising a plurality of fibers and a fiber density, wherein the fiber density is higher adjacent to at least one of the first and second sides in relation to the fiber density within at least one other location of the suspension element.

36. The shoe of claim 35 wherein the fiber density is approximately the same adjacent the first and second sides.

37. The shoe of claim 35 wherein the plurality of fibers are generally disposed in a parallel orientation to the first and second sides.

38. The shoe of claim 35 wherein the plurality of fibers are generally disposed in a perpendicular orientation to the first and second sides.

39. The shoe of claim 35 wherein the plurality of fibers is a first plurality of fibers and the suspension element comprises a second plurality of fibers, the first plurality of fibers being generally disposed in a first orientation and the second plurality of fibers being disposed in a second orientation which is at an angle from the orientation of the first plurality of fibers.

40. The shoe of claim 39 wherein the angle is approximately 90 degrees.

41. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape, a center of compression, a first upper suspension arm having a first end and a second end, and a second lower suspension arm having a first end and a second end, each of the first and second ends of the respective first and second suspension arms connected together to form the suspension element, and forming first and second sides and a central suspension region therebetween, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper, the suspension element further comprising a plurality of fibers and a fiber density, wherein the plurality of fibers are generally disposed in at least one of a parallel and a perpendicular orientation to the first and second sides.

42. The shoe of claim 41 wherein the plurality of fibers is a first plurality of fibers and the suspension element comprises a second plurality of fibers, the first plurality of fibers being generally disposed in a first orientation and the second plurality of fibers being disposed in a second orientation which is at an angle from the orientation of the first plurality of fibers.

43. The shoe of claim 42 wherein the angle is approximately 90 degrees.

44. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape, a center of compression, a first upper suspension arm having a first end and a second end, and a second lower suspension arm having a first end and a second end, each of the first and second ends of the respective first and second suspension arms connected together to form the suspension element, and forming first and second sides and a central suspension region therebetween, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper, the suspension element further comprising an aperture located adjacent to at least one of the first and second sides within the first upper suspension arm.

45. The shoe of claim 44 wherein the aperture extends from the first end to the second end of the first upper suspension element.

46. The shoe of claim 44 wherein the aperture is a rectangular shape.

47. The shoe of claim 44 wherein the aperture is a first aperture and wherein the suspension element further comprises a second aperture within the first upper suspension arm adjacent to the other of the first and second sides.

48. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape, a center of compression, a first upper suspension arm having a first end and a second end, and a second lower suspension arm having a first end and a second end, each of the first and second ends of the respective first and second suspension arms connected together to form the suspension element, and forming first and second sides and a central suspension region therebetween, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper, the suspension element further comprising a first molding located proximate at least one of the first and second sides.

49. The shoe of claim 48 further comprising a second molding located proximate the other of the first and second sides.

50. The shoe of claim 49 where the first molding extends from the first end to the second end of the first upper suspension arm.

51. The shoe of claim 48 wherein the first upper suspension arm and the second lower suspension arm are formed as a single unitary structure.

52. The shoe of claim 48 wherein the outsole and the midsole are formed as a single unitary structure.

53. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element, the suspension element comprising a center of compression, a first suspension component and a second suspension component, each suspension component having a generally elongated shape, a first upper suspension arm having a first end and a second end, and a second lower suspension arm having a first end and a second end, each of the first and second ends of the respective first and second suspension arms of the respective first and second suspension components connected together to form the respective suspension components, and forming first and second sides and a central suspension region therebetween for each of the respective suspension components, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper; and

,

a ridged support located between the suspension element and the upper for distributing loading between the first and second suspension components of the suspension element.

54. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape at least a portion of which is connected to the outsole, the suspension element having a center of compression, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper.

55. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape, a center of compression, and first and second lateral sides, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper, wherein the midsole comprises a side contour, and wherein at least one of the lateral sides follows at least a portion of the side contour of the midsole.

56. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape, a center of compression, and first and second lateral sides, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper, wherein the midsole comprises a side contour, and wherein at least one of the lateral sides extends laterally beyond at least a portion of the side contour of the midsole.

57. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape, a center of compression, and upper and lower lateral sides, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper, wherein the midsole comprises a side contour, and wherein at least one of the lower lateral sides extends laterally beyond the at least one of the upper lateral sides.

58. The shoe of claim 57 wherein at least one of the upper lateral sides follows at least a portion of the side contour of the midsole.

59. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading, the forward region having a width, wherein the forward center of loading is represented by a line which traverses the width of the forward center of loading at an angle from the width, and wherein the upper comprises a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape, a center of compression, and first and second lateral sides, wherein the center of compression traverses the suspension element from the first lateral side to the second lateral side

60. The shoe of claim 59 wherein the angle is greater than zero and less than twenty degrees, and wherein the center of compression is generally aligned with the forward center of loading.

61. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole connected to the upper and comprising a generally vertical hinge slit extending the lateral width of the sole, the hinge slit having a horizontal component and a vertical component, the hinge slit extending from a bottom surface of the sole through at least twenty percent of the vertical component of the sole, wherein at least a portion of the horizontal component of the hinge slit is located between a midpoint between the forward center of loading and the rear center of loading, and the forward center of loading from a bottom view.

62. The shoe of claim 61 wherein the midsole further comprises a suspension element having a generally elongated shape and a center of compression, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper.

63. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole connected to the upper and comprising an openable gap extending the lateral width of the sole, the openable gap having a horizontal component and a vertical component, and extending along a path which generally follows at least a portion of an upper surface of the compression element beginning from a bottom surface of the sole through at least ten percent of the sole in a vertical direction, wherein at least a portion of the horizontal component of the openable gap is located between a midpoint between the forward center of loading and the rear center of loading, and the forward center of loading from a bottom view.

64. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole connected to the upper and comprising an openable gap extending the lateral width of the sole, the openable gap having a horizontal component and a vertical component, and extending along a path beginning from a bottom surface of the sole through at least ten percent of the sole in a vertical direction, wherein at least a portion of the horizontal component of the openable gap is located between a midpoint between the forward center of loading and the rear center of loading, and the forward center of loading from a bottom view.

65. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole connected to the upper and comprising an openable gap extending the lateral width of the sole, the openable gap having a horizontal component and a vertical component, and extending along a path which generally follows at least a portion of an upper surface of the suspension element.

66. The shoe of claim 65 wherein the midsole further comprises a suspension element having a generally elongated shape and a center of compression, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper.

67. A method of manufacturing a suspension element for a shoe, comprising the steps of:

providing a die having a length, a width and a thickness, the length accommodating a plurality of suspension elements;

wrapping a plurality of coated fibers around the width of the die to form the suspension elements;

curing the fibers to a substantially integrated form;

separating the plurality of suspension elements into independent suspension elements.

68. The method of claim 67 wherein the step of wrapping comprises wrapping the fiber in an orientation which is parallel to the width of the die.

69. The method of claim 67 wherein the die is elliptical in shape from a cross sectional view of the width and thickness.

70. The method of claim 67 wherein the die comprises an upper surface and a lower surface, and wherein the upper surface comprises a flat portion from a cross sectional view of the width and thickness.

71. The method of claim 67 wherein the die comprises an upper surface and a lower surface, and wherein the lower surface comprises a convex portion from a cross sectional view of the width and thickness.

72. The method of claim 67 wherein the step of separating comprises shaping a first side and a second side created by the separation between two of the plurality of suspension elements, to follow a contour of a midsole of the shoe.

73. The method of claim 67 wherein the step of separating comprises measuring a portion of the length which is wider than at least a portion of a midsole of the shoe before separation.

74. A shoe comprising:

an upper having a generally horizontal bottom wall, the bottom wall having an upper surface and a lower surface, wherein the upper comprises a forward region having a forward center of loading and a rear region having a rear center of loading;

a sole comprising a midsole and an outsole, the midsole comprising a suspension element having a generally elongated shape, a center of compression, a first upper suspension arm having a first end and a second end, and a second lower suspension arm having a first end and a second end, each of the first and second ends of the respective first and second suspension arms connected together to form the suspension element, and forming first and second sides and a central suspension region therebetween, wherein the center of compression is generally aligned with at least one of the first and second centers of loading of the upper, the suspension element further comprising an aperture located adjacent to at least one of the first and second ends.

75. The shoe of claim 74 wherein the aperture is a rectangular shape.

76. The shoe of claim 74 wherein the aperture is a first aperture and wherein the suspension element further comprises a second aperture adjacent to the other of the first and second ends.