Energy return, cushioning, and arch support plates, and footwear and footwear soles including the same

• US 9,578,920 B2
• Filed: 05/12/2015
• Issued: 02/28/2017
• Est. Priority Date: 05/13/2014
• Status: Active Grant

• Current Assignee: Ariat International, Inc.
• Original Assignee: Ariat International, Inc.
• Inventors: Grott, Marco Aurelio, Buck, Calvin Myron IV
• Primary Examiner(s): Kinsaul, Anna
• Assistant Examiner(s): MANGINE, HEATHER N
• Application Number:
  US14/710,381
• Publication Number:
  US 20150327624A1
• Time in Patent Office: 658 Days
• Field of Search: 36/91, 361/07, 361/08, 36140-150, 361/55, 361/60, 361/62, 36173-176
• US Class Current: 1/1
• CPC Class Codes: A43B 1/0072 made at least partially of transparent or translucent materials
• CPC Class Codes: A43B 13/026 Composites, e.g. carbon fibre or aramid fibre; the sole, one or more sole layers or sole part being made of a composite
• CPC Class Codes: A43B 13/04 Plastics, rubber or vulcanised fibre
• CPC Class Codes: A43B 13/122 characterised by the outsole or external layer
• CPC Class Codes: A43B 13/125 characterised by the midsole or middle layer
• CPC Class Codes: A43B 13/141 with a part of the sole being flexible, e.g. permitting articulation or torsion
• CPC Class Codes: A43B 13/183 Leaf springs
• CPC Class Codes: A43B 13/184 the structure protruding from the outsole
• CPC Class Codes: A43B 13/186 Differential cushioning region, e.g. cushioning located under the ball of the foot resilient heel not included in the sole A43B21/26; resilient supports for the heel of the foot A43B21/32
• CPC Class Codes: A43B 13/188 Differential cushioning regions
• CPC Class Codes: A43B 13/42 Filling materials located between the insole and outer sole; Stiffening materials
• CPC Class Codes: A43B 3/0057 S-shaped
• CPC Class Codes: A43B 3/02 Boots covering the lower leg
• CPC Class Codes: A43B 5/002 Mountain boots or shoes
• CPC Class Codes: A43B 7/14 with foot-supporting parts
• CPC Class Codes: A43B 7/141 having an anatomical or curved form
• CPC Class Codes: A43B 7/142 situated under the medial arch, i.e. under the navicular or cuneiform bones
• CPC Class Codes: A43B 7/143 situated under the lateral arch, i.e. the cuboid 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

Support plates, and footwear soles and articles of footwear containing the same. The support plate generally may provide one or more of heel cushioning, arch support in a midfoot region of the support plate, and integral medial and lateral legs extending from the midfoot region of the support plate towards an anterior end of the support plate. An article of footwear may include a support plate at least partially embedded within a sole assembly, such as a midsole thereof. The support plate may be configured to provide energy return and arch support to a wearer of the article of footwear. The support plate may include a domed structure with radially extending arms extending from a central heel portion, where the domed structure provides heel cushioning to the wearer when a force is transmitted through the midsole to the domed structure.

Claims

1. An article of footwear, comprising:

an upper configured to engage with a wearer'"'"'s foot when the article of footwear is worn on the wearer'"'"'s foot;

a sole assembly coupled to the upper, the sole assembly comprising a midsole and an outsole, the outsole having an outer surface that is configured to engage with a surface on which the wearer is striding; and

a support plate embedded within the sole assembly, the support plate comprising;

an upper surface extending from a posterior end of the support plate to an anterior end of the support plate;

a lower surface opposite the upper surface;

a cushioning heel portion adjacent the posterior end of the support plate, wherein the cushioning heel portion is configured to resiliently compress in response to a heel strike by the wearer;

wherein the cushioning heel portion comprises a domed structure, the domed structure comprising a convex surface that forms a portion of the upper surface of the support plate and a concave surface that is opposite the convex surface and forms a portion of the lower surface of the support plate, wherein the domed structure is oriented such that a heel strike by the wearer of the article of footwear exerts a force on the convex surface of the domed structure, and wherein the convex surface is configured to resiliently compress upon exertion of the force on the convex surface;

wherein the domed structure comprises a plurality of radially extending arms each extending from a central heel region of the cushioning heel portion towards a respective peripheral end of the respective radially extending arm, wherein the central heel region of the domed structure defines a circumferential ridge of the domed structure, and further wherein the plurality of radially extending arms extends radially outward from the circumferential ridge and toward the outsole to elevate the circumferential ridge above the outsole;

a midfoot portion formed integrally with the cushioning heel portion, the midfoot portion comprising an arch support portion that is curved to support an arch of the wearer'"'"'s foot;

a medial leg formed integrally with the cushioning heel portion and the midfoot portion; and

a lateral leg formed integrally with the cushioning heel portion and the midfoot portion, wherein the medial leg and the lateral leg each extend longitudinally from the midfoot portion towards the anterior end of the support plate.

2. The article of footwear according to claim 1, wherein the support plate is at least partially embedded in the midsole of the sole assembly.

3. The article of footwear according to claim 1, wherein the support plate is positioned between the midsole and the outsole of the sole assembly.

4. The article of footwear according to claim 1, wherein a first portion of the support plate is covered by the outsole such that it is not visible from the outer surface of the outsole, and wherein a second portion of the support plate is visible from the outer surface of the outsole.

5. The article of footwear according to claim 1, wherein the support plate is embedded within the sole assembly such that the cushioning heel portion of the support plate is generally positioned under a heel of the wearer'"'"'s foot, and such that the midfoot portion of the support plate is generally positioned under a midfoot region of the wearer'"'"'s foot when the article of footwear is worn.

6. The article of footwear according to claim 1, wherein the support plate is configured to provide energy return during a stride of the wearer of the article of footwear, such that at least a portion of an impact force transferred from the wearer to the support plate is returned to the wearer from the support plate, in order to urge the wearer'"'"'s foot at least one of up and forward.

7. The article of footwear according to claim 1, wherein the midsole comprises a midsole heel region in which the cushioning heel portion of the support plate is at least partially embedded.

8. The article of footwear according to claim 7, wherein the midsole heel region is sufficiently compliant to convey the force from the heel strike by the wearer of the article of footwear to the domed structure of the cushioning heel portion of the support plate.

9. The article of footwear according to claim 8, wherein the midsole heel region of the midsole is more compliant than at least one other area of the midsole.

10. The article of footwear according to claim 8, wherein the midsole heel region of the midsole comprises at least one of a gel and a foam.

11. The article of footwear according to claim 1, wherein the central heel region comprises a through-hole extending from the upper surface to the lower surface of the support plate.

12. The article of footwear according to claim 11, wherein at least one of the plurality of radially extending arms comprises a slot formed therein, wherein each of the slots extends from the through-hole of the central heel region of the support plate towards the respective peripheral end of the respective radially extending arm.

13. The article of footwear according to claim 12, wherein the plurality of radially extending arms forms a continuous, undulating pattern surrounding the central heel region.

14. The article of footwear according to claim 1, wherein the midfoot portion of the support plate extends from the circumferential ridge of the central heel region.

15. The article of footwear according to claim 1, wherein at least a portion of the medial leg of the support plate is positioned to underlie a medial portion of the wearer'"'"'s foot when the article of footwear is worn, and wherein at least a portion of the lateral leg is positioned to underlie a lateral portion of the wearer'"'"'s foot when the article of footwear is worn.

16. The article of footwear according to claim 1, wherein the medial leg and the lateral leg branch out from the midfoot portion of the support plate, such that an open plate space is formed between the medial leg and the lateral leg.

17. The article of footwear according to claim 1, wherein the anterior end of the support plate is defined by the medial leg of the support plate, and wherein a portion of the medial leg adjacent the anterior end of the support plate is configured to underlie an area of the wearer'"'"'s foot adjacent a hallux of the wearer'"'"'s foot.

18. The article of footwear according to claim 1, wherein the medial leg comprises a first portion adjacent a medial edge of the support plate, and a second portion that extends towards a lateral edge of the support plate, past a longitudinal centerline of the support plate, and further wherein the lateral leg comprises a first portion adjacent the lateral edge of the support plate, and a second portion that extends towards the medial edge of the support plate, past the longitudinal centerline of the support plate.

19. The article of footwear according to claim 1, wherein the support plate further comprises at least one cross-brace extending substantially transversely across a longitudinal centerline of the support plate, each of the at least one cross-braces being coupled to both the medial leg and the lateral leg.

20. The article of footwear according to claim 1, wherein the support plate further comprises at least one rib, each of the at least one ribs corresponding to an area of increased stiffness of the support plate, wherein the at least one rib comprises an area of increased thickness projecting from the upper surface of the support plate.

21. The article of footwear according to claim 1, wherein the support plate further comprises at least one groove, each of the at least one grooves corresponding to an area of increased flexibility of the support plate, wherein the at least one groove comprises an area of decreased thickness of the support plate.

22. The article of footwear according to claim 1, wherein the article of footwear comprises a boot.

23. The article of footwear according to claim 22, wherein the outsole comprises a projecting heel.

24. The article of footwear according to claim 1, wherein the medial leg and the lateral leg branch out from the midfoot portion of the support plate, and diverge from each other such that an open plate space is formed between the medial leg and the lateral leg.

25. The article of footwear according to claim 1, wherein the medial leg and the lateral leg diverge away from each other and converge towards each other as they extend from the midfoot portion of the support plate.

26. The article of footwear according to claim 1, wherein the medial leg and the lateral leg together underlie a significant portion of the wearer'"'"'s midfoot and forefoot when the article of footwear is worn, and wherein a first portion of the lateral leg is sized and shaped to receive a second portion of the medial leg that extends across a longitudinal centerline of the support plate, towards a lateral edge of the support plate.

27. The article of footwear according to claim 1, wherein the arch support portion is arched away from the anterior and posterior ends of the support plate such that it has a concave configuration relative to the outsole and extends in a different plane than the anterior and posterior ends of the support plate, and wherein the arch support portion is curved to conform to the arch of the wearer'"'"'s foot when the article of footwear is worn.

28. An article of footwear, comprising:

an upper configured to engage with a wearer'"'"'s foot when the article of footwear is worn on the wearer'"'"'s foot;

a sole assembly coupled to the upper, the sole assembly comprising a midsole and an outsole, the outsole having an outer surface that is configured to engage with a surface on which the wearer is striding; and

a support plate embedded within the sole assembly, the support plate comprising;

an upper surface extending from a posterior end of the support plate to an anterior end of the support plate;

a lower surface opposite the upper surface;

a cushioning heel portion adjacent the posterior end of the support plate, wherein the cushioning heel portion is configured to resiliently compress in response to a heel strike by the wearer;

wherein the cushioning heel portion comprises a domed structure, the domed structure comprising a convex surface that forms a portion of the upper surface of the support plate and a concave surface that is opposite the convex surface and forms a portion of the lower surface of the support plate, wherein the domed structure is oriented such that a heel strike by the wearer of the article of footwear exerts a force on the convex surface of the domed structure, and wherein the convex surface is configured to resiliently compress upon exertion of the force on the convex surface;

a midfoot portion formed integrally with the cushioning heel portion, the midfoot portion comprising an arch support portion that is curved to support an arch of the wearer'"'"'s foot;

a medial leg formed integrally with the cushioning heel portion and the midfoot portion; and

a lateral leg formed integrally with the cushioning heel portion and the midfoot portion;

wherein the medial leg and the lateral leg each extend longitudinally from the midfoot portion towards the anterior end of the support plate;

wherein the medial leg comprises a first portion adjacent a medial edge of the support plate, and a second portion that extends towards a lateral edge of the support plate, past a longitudinal centerline of the support plate; and

further wherein the lateral leg comprises a first portion adjacent the lateral edge of the support plate, and a second portion that extends towards the medial edge of the support plate, past the longitudinal centerline of the support plate.

29. The article of footwear according to claim 28, wherein the support plate is at least partially embedded in the midsole of the sole assembly.

30. The article of footwear according to claim 28, wherein the support plate is positioned between the midsole and the outsole of the sole assembly.

31. The article of footwear according to claim 28, wherein a first portion of the support plate is covered by the outsole such that it is not visible from the outer surface of the outsole, and wherein a second portion of the support plate is visible from the outer surface of the outsole.

32. The article of footwear according to claim 28, wherein the support plate is embedded within the sole assembly such that the cushioning heel portion of the support plate is generally positioned under a heel of the wearer'"'"'s foot, and such that the midfoot portion of the support plate is generally positioned under a midfoot region of the wearer'"'"'s foot when the article of footwear is worn.

33. The article of footwear according to claim 28, wherein the support plate is configured to provide energy return during a stride of the wearer of the article of footwear, such that at least a portion of an impact force transferred from the wearer to the support plate is returned to the wearer from the support plate, in order to urge the wearer'"'"'s foot at least one of up and forward.

34. The article of footwear according to claim 28, wherein the midsole comprises a midsole heel region in which the cushioning heel portion of the support plate is at least partially embedded.

35. The article of footwear according to claim 34, wherein the midsole heel region is sufficiently compliant to convey the force from the heel strike by the wearer of the article of footwear to the domed structure of the cushioning heel portion of the support plate.

36. The article of footwear according to claim 35, wherein the midsole heel region of the midsole is more compliant than at least one other area of the midsole.

37. The article of footwear according to claim 35, wherein the midsole heel region of the midsole comprises at least one of a gel and a foam.

38. The article of footwear according to claim 28, wherein at least a portion of the medial leg of the support plate is positioned to underlie a medial portion of the wearer'"'"'s foot when the article of footwear is worn, and wherein at least a portion of the lateral leg is positioned to underlie a lateral portion of the wearer'"'"'s foot when the article of footwear is worn.

39. The article of footwear according to claim 28, wherein the medial leg and the lateral leg branch out from the midfoot portion of the support plate, such that an open plate space is formed between the medial leg and the lateral leg.

40. The article of footwear according to claim 28, wherein the anterior end of the support plate is defined by the medial leg of the support plate, and wherein a portion of the medial leg adjacent the anterior end of the support plate is configured to underlie an area of the wearer'"'"'s foot adjacent a hallux of the wearer'"'"'s foot.

41. The article of footwear according to claim 28, wherein the support plate further comprises at least one cross-brace extending substantially transversely across a longitudinal centerline of the support plate, each of the at least one cross-braces being coupled to both the medial leg and the lateral leg.

42. The article of footwear according to claim 28, wherein the support plate further comprises at least one rib, each of the at least one ribs corresponding to an area of increased stiffness of the support plate, wherein the at least one rib comprises an area of increased thickness projecting from the upper surface of the support plate.

43. The article of footwear according to claim 28, wherein the support plate further comprises at least one groove, each of the at least one grooves corresponding to an area of increased flexibility of the support plate, wherein the at least one groove comprises an area of decreased thickness of the support plate.

44. The article of footwear according to claim 28, wherein the article of footwear comprises a boot.

45. The article of footwear according to claim 44, wherein the outsole comprises a projecting heel.

46. The article of footwear according to claim 28, wherein the medial leg and the lateral leg branch out from the midfoot portion of the support plate, and diverge from each other such that an open plate space is formed between the medial leg and the lateral leg.

47. The article of footwear according to claim 28, wherein the medial leg and the lateral leg diverge away from each other and converge towards each other as they extend from the midfoot portion of the support plate.

48. The article of footwear according to claim 28, wherein the medial leg and the lateral leg together underlie a significant portion of the wearer'"'"'s midfoot and forefoot when the article of footwear is worn, and wherein a first portion of the lateral leg is sized and shaped to receive a second portion of the medial leg that extends across a longitudinal centerline of the support plate, towards a lateral edge of the support plate.

49. The article of footwear according to claim 28, wherein the arch support portion is arched away from the anterior and posterior ends of the support plate such that it has a concave configuration relative to the outsole and extends in a different plane than the anterior and posterior ends of the support plate, and wherein the arch support portion is curved to conform to the arch of the wearer'"'"'s foot when the article of footwear is worn.