Cushioned shoe construction

• US 8,713,818 B2
• Filed: 01/22/2009
• Issued: 05/06/2014
• Est. Priority Date: 01/24/2008
• Status: Active Grant

• Current Assignee: Caleres Incorporated
• Original Assignee: Brown Shoe Company Incorporated
• Inventors: Doerer, Daniel M., Schauster, Mark J.
• Primary Examiner(s): Mohandesi, Jila M
• Application Number:
  US12/357,616
• Publication Number:
  US 20090188131A1
• Time in Patent Office: 1,930 Days
• Field of Search: 36/88, 361/03, 361/07, 36/30.R, 36/31, 36/35.R, 36/28
• US Class Current: 36/30.R
• CPC Class Codes: A43B 13/12 Soles with several layers of different materials
• CPC Class Codes: A43B 13/141 with a part of the sole being flexible, e.g. permitting articulation or torsion
• CPC Class Codes: A43B 13/188 Differential cushioning regions
• CPC Class Codes: A43B 13/189 filled with a non-compressible fluid, e.g. gel, water
• CPC Class Codes: A43B 7/12 Special watertight footwear overshoes A43B3/16
• CPC Class Codes: A43B 7/1425 situated under the ball of the foot, i.e. the joint between the first metatarsal and first phalange
• CPC Class Codes: A43B 7/1435 situated under the joint between the fifth phalange and the fifth metatarsal bone
• 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

Abstract

A shoe construction including a shoe upper, an intermediate composite structure and an outsole. The composite structure underlies at least a portion of the upper and overlies at least a portion of the outsole. The composite structure includes cushion members with one cushion member being positioned to underlie a heel of a wearer and another cushion member being positioned to underlie the ball of the foot. The cushion member underlying the ball may be perforated. The composite structure can also include a relatively rigid lower member which can be perforated in the area of the ball of the foot underlying the cushion member for the ball of the foot. The composite structure can provide a flexure discontinuity in the shoe forward of the midfoot zone of the shoe.

Claims

1. A woman'"'"'s shoe construction including:

an upper shaped and sized to receive a foot portion of a wearer;

an outsole; and

a composite structure positioned in overlying relation to at least a portion of the outsole and for support of a wearer'"'"'s foot, said composite structure including a relatively rigid board member extending from a heel area to a forefoot area but stopping prior to a ball receiving area of the shoe, a first cushion member at the ball receiving area and connected to a front portion of the relatively rigid board member, said first cushion member having a plurality of perforations in the ball area, a second cushion member secured to an upper portion of the board in a heel receiving area of the shoe, said second cushion member being received in a recess extending only partially into the board, and a third cushion member overlying the board, first cushion member and second cushion member, wherein the relatively rigid board member is more rigid than at least the first cushion member.

2. The shoe of claim 1 including a spacer member secured to the board and having said recess therein, said recess being upwardly opening.

3. The shoe construction of claim 1 wherein said heel area of said outsole having a height of less than about 50 mm, said ball receiving area of said outsole having a width of at least about 0.3 times the length of the shoe;

and said composite structure having a composite density of less than about 1 g/cc and greater than about 0.5 g/cc, said ball zone of the composite structure being more flexible than a midfoot portion of the composite structure, said first and second cushion members having a deformability of between about 10% and about 60% and said second cushion having a hardness of between about 61 and about 74 Shore O.

4. The shoe construction of claim 3 wherein the composite structure including an insole positioned between the outsole and the remainder of the composite structure.

5. The shoe construction of claim 4 wherein the composite structure including a sock liner.

6. The shoe construction of claim 3 wherein

the ball zone of the rigid board member having a greater flexibility than the midfoot portion thereof.

7. The shoe construction of claim 1 wherein said heel area of said outsole having a height of less than about 50 mm, said composite structure having density of less than about 1 g/cc and more than about 0.5 g/cc, at least one of the composite structure and the outsole having a first discontinuity zone in the respective ball zone;

wherein said a second cushion member positioned in the first discontinuity zone in overlying relation to at least a portion of the outsole heel zone and having deformability of between about 10% and about 60% and a hardness of between about 61 and 74 Shore O.

8. The shoe construction of claim 7 wherein said first cushion member having density of less than about 1 g/cc and deformability of between about 10% and about 60% and a hardness of less than about 74 Shore O.

9. The shoe construction of claim 8 wherein the relatively rigid board member having a transversely extending first edge, said first cushion member extending forwardly of said first edge.

10. The shoe construction of claim 9 wherein the first cushion member having a transversely extending second edge forward of the first edge and including a second relatively rigid board member extending forwardly of the second edge into a toe zone of the shoe.

11. The shoe construction of claim 10 wherein the first cushion member extending substantially across an inside width of the shoe in the ball zone.

12. The shoe construction of claim 8 wherein at least one portion of the first and second cushion members comprising a polymeric foam.

13. The shoe construction of claim 8 wherein at least one of the first and second cushion members comprising a gel.

14. The shoe construction of claim 8 including a lining including a breathable lining material.

15. The shoe construction of claim 8 wherein the first cushion member having a plurality of perforations.

16. The shoe construction of claim 8 wherein the outsole being a unit molded outsole.

17. The shoe construction of claim 8 wherein the outsole being a formed outsole.

18. The shoe construction of claim 7 wherein a toe zone and the ball zone and heel zone demonstrate a pressure distribution of less than 55 pounds per square inch.