Custom article of footwear and method of making the same

• US 8,959,797 B2
• Filed: 05/06/2012
• Issued: 02/24/2015
• Est. Priority Date: 03/10/2000
• Status: Expired due to Fees

• Current Assignee: Adidas AG
• Original Assignee: Robert M. Lyden
• Inventors: Lyden, Robert M.
• Primary Examiner(s): Kavanaugh, Ted
• Application Number:
  US13/465,021
• Publication Number:
  US 20120216424A1
• Time in Patent Office: 1,024 Days
• Field of Search: 36/27, 36/38, 36/28, 36/78
• US Class Current: 36/27
• CPC Class Codes: A43B 1/0063 made at least partially of material that can be recycled
• CPC Class Codes: A43B 1/0081 made at least partially of hook-and-loop type material hook and loop-type straps for fastening purpose A43C11/1493
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• 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 13/141 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 13/203 provided with a pump or valve
• CPC Class Codes: A43B 13/36 Easily-exchangeable soles protecting-soles A43C13/12
• CPC Class Codes: A43B 23/021 Leather
• CPC Class Codes: A43B 23/0215 Plastics or artificial leather
• CPC Class Codes: A43B 23/026 Laminated layers
• CPC Class Codes: A43B 23/028 Resilient uppers, e.g. shock absorbing
• CPC Class Codes: A43B 23/042 Uppers made of one piece one piece slippers A43B3/106; one piece sandals A43B3/124
• CPC Class Codes: A43B 3/128 characterised by the sole
• CPC Class Codes: A43B 3/26 adjustable as to length or size
• CPC Class Codes: A43B 7/1464 : with adjustable pads to allow custom fit
• CPC Class Codes: A43B 7/22 : with fixed flat-foot insertions, metatarsal supports, ankle flaps or the like
• CPC Class Codes: A43D 1/02 : Foot-measuring devices measuring the shape, pattern or size of the body for diagnostic purposes A61B5/103, e.g. measuring physical dimensions A61B5/107
• CPC Class Codes: A43D 11/006 : Devices for temporarily fixing or aligning insoles on lasts
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: G06Q 30/0621 : Item configuration or customization

Abstract

The present invention teaches a method of making a custom article of footwear. Further, the article of footwear can include a spring element that can provide improved cushioning, stability, and running economy. In addition, the components of the article of footwear can be selected from a wide range of options, and can be easily removed and replaced, as desired.

Claims

1. An article of footwear comprising an anterior side, a posterior side, a medial side, a lateral side, a superior side, an inferior side, a rearfoot area, a midfoot area, a forefoot area, an upper comprising a bottom side, and a spring element, said spring element comprising a superior spring element comprising an integral heel counter and a plurality of inferior spring elements projecting downwardly and rearwardly from said superior spring element, said superior spring element extending substantially between said anterior side and said posterior side of said article of footwear and being affixed to said bottom side of said upper, said plurality of inferior spring elements each comprising an anteriormost side, a posteriormost side, a medialmost side, a lateralmost side, an anterior tangent point, a top surface comprising a top curved configuration, a bottom surface comprising a bottom curved configuration and an inferiormost point and a geometric shape, said plurality of inferior spring elements comprising a first inferior spring element located on said medial side and being positioned across from at least one other of said plurality of inferior spring elements comprising a second inferior spring element located on said lateral side and being separated by a void space located therebetween, and each of said first inferior spring element and said second inferior spring element comprising a tapered configuration between said anteriormost side and said posteriormost side and at least one of said first inferior spring element and said second inferior spring element comprising a tapered configuration between said medialmost side and said lateralmost side, said first inferior spring element and said second inferior spring element each being configured to provide a vertical elevation of at least 10 mm and a horizontal distance in the range between 30-63.5 mm between said anterior tangent point and said inferiormost point and each of said first inferior spring element and said second inferior spring element being located in at least one of said midfoot area and said rearfoot area, said midfoot area and said rearfoot area therefore both being elevated and capable of deflection, said first inferior spring element located on said medial side comprising a first top surface comprising a first too curved configuration and a first bottom surface comprising a first bottom curved configuration and a first geometric shape, and said second inferior spring element located on said lateral side comprising a second top surface comprising a second top curved configuration and a second bottom surface comprising a second bottom curved configuration and a second geometric shape, said first too curved configuration of said first inferior spring element being similar to said second top curved configuration of said second inferior spring element, and said first geometric shape of said first inferior spring element being different and asymmetric relative to said second geometric shape of said second inferior spring element, said plurality of inferior spring elements comprising a third inferior spring element located in said forefoot area comprising a third top surface comprising a third top curved configuration and a third bottom surface comprising a third bottom curved configuration and a third geometric shape, said third top curved configuration being different from both said first top curved configuration and said second top curved configuration, said third bottom surface substantially comprising a convex third bottom curved configuration and said third geometric shape being different from both said first geometric shape and said second geometric shape.

2. An article of footwear comprising an anterior side, a posterior side, a medial side, a lateral side, a superior side, an inferior side, a rearfoot area, a midfoot area, a forefoot area, an upper comprising a bottom side, and a spring element, said spring element comprising a superior spring element comprising an integral heel counter and a plurality of inferior spring elements projecting downwardly and rearwardly from said superior spring element, said superior spring element extending substantially between said anterior side and said posterior side of said article of footwear and being affixed to said bottom side of said upper, said plurality of inferior spring elements each comprising an anteriormost side, a posteriormost side, a medialmost side, a lateralmost side, an anterior tangent point, a top surface comprising a top curved configuration, a bottom surface comprising a bottom curved configuration and an inferiormost point and a geometric shape, said plurality of inferior spring elements comprising a first inferior spring element located on said medial side and being positioned across from at least one other of said plurality of inferior spring elements comprising a second inferior spring element located on said lateral side and being separated by a void space located therebetween, and each of said first inferior spring element and said second inferior spring element comprising a tapered configuration between said anteriormost side and said posteriormost side and at least one of said first inferior spring element and said second inferior spring element comprising a tapered configuration between said medialmost side and said lateralmost side, said first inferior spring element and said second inferior spring element each being configured to provide a vertical elevation of at least 10 mm between said anterior tangent point and said inferiormost point and each of said first inferior spring element and said second inferior spring element being located in at least one of said midfoot area and said rearfoot area, said midfoot area and said rearfoot area therefore both being elevated and capable of deflection, said first inferior spring element located on said medial side comprising a first top surface comprising a first top curved configuration and a first bottom surface comprising a first bottom curved configuration and a first geometric shape, and said second inferior spring element located on said lateral side comprising a second top surface comprising a second top curved configuration and a second bottom surface comprising a second bottom curved configuration and a second geometric shape, said first top curved configuration of said first inferior spring element being similar to said second top curved configuration of said second inferior spring element, and said first geometric shape of said first inferior spring element being different and asymmetric relative to said second geometric shape of said second inferior spring element.

3. An article of footwear comprising an anterior side, a posterior side, a medial side, a lateral side, a superior side, an inferior side, a rearfoot area, a midfoot area, a forefoot area, an upper comprising a bottom side, a heel counter, and a spring element, said spring element comprising a superior spring element comprising a plurality of inferior spring elements projecting downwardly and rearwardly from said superior spring element, said superior spring element extending substantially between said anterior side and said posterior side of said article of footwear and being affixed to said upper, said plurality of inferior spring elements each comprising an anteriormost side, a posteriormost side, a medialmost side, a lateralmost side, an anterior tangent point, a top surface comprising a top curved configuration, a bottom surface comprising a bottom curved configuration and an inferiormost point and a geometric shape, said plurality of inferior spring elements comprising a first inferior spring element located on said medial side and being positioned across from at least one other of said plurality of inferior spring elements comprising a second inferior spring element located on said lateral side and being at least partially separated by a void space located therebetween, said first inferior spring element and said second inferior spring element each being configured to provide a vertical elevation of at least 10 mm between said anterior tangent point and said inferiormost point and each of said first inferior spring element and said second inferior spring element being located in at least one of said midfoot area and said rearfoot area, said midfoot area and said rearfoot area therefore both being elevated and capable of deflection, said first inferior spring element located on said medial side comprising a first top surface comprising a first top curved configuration and a first bottom surface comprising a first geometric shape, and said second inferior spring element located on said lateral side comprising a second top surface comprising a second top curved configuration and a second bottom surface comprising a second geometric shape, said first top curved configuration of said first inferior spring element being similar to said second top curved configuration of said second inferior spring element, and said first geometric shape of said first inferior spring element being different and asymmetric relative to said second geometric shape of said second inferior spring element.

4. The article of footwear according to claim 3, wherein at least one of said plurality of inferior spring elements comprises a void space located between at least two inferior spring element sub-portions.

5. The article of footwear according to claim 4, further comprising an outsole element affixed to and extending between said at least two inferior spring element sub-portions.

6. The article of footwear according to claim 3, wherein said superior spring element is affixed to said bottom side of said upper.

7. The article of footwear according to claim 3, further comprising a longitudinal axis and a transverse axis perpendicular to said longitudinal axis, wherein said at least one of said plurality of inferior spring elements projects from said superior spring element along said transverse axis.

8. The article of footwear according to claim 3, further comprising a longitudinal axis, a transverse axis perpendicular to said longitudinal axis, and a flexural axis deviated from said transverse axis less than 50 degrees, wherein at least one of said plurality of inferior spring elements projects from said superior spring element along said flexural axis.

9. The article of footwear according to claim 3, said plurality of inferior spring elements comprising an anterior inferior spring element located in said forefoot area comprising a third top surface comprising a third top curved configuration different from said top second curved configuration of said second inferior spring element located in at least one of said midfoot area and rearfoot area of said article of footwear.

10. The article of footwear according to claim 3, wherein said spring element comprises a V shape.

11. The article of footwear according to claim 3, wherein said bottom curved configuration of at least one of said plurality of inferior spring elements is substantially convex.

12. The article of footwear according to claim 3, said plurality of said inferior spring elements being located at least in said rearfoot area and said forefoot area.

13. The article of footwear according to claim 3, wherein at least one of said plurality of inferior spring elements comprising a different thickness on said medialmost side relative to said lateralmost side.

14. The article of footwear according to claim 3, wherein said spring element comprises a material selected from the group of materials consisting of thermoplastics, fiber composites, and metals.

15. The article of footwear according to claim 3, said spring element comprising a material capable of storing and returning at least 70 percent of the mechanical energy imparted thereto when measured using test method ASTM 790.

16. The article of footwear according to claim 3, at least one of said plurality of inferior spring elements comprising a tapered configuration.

17. The article of footwear according to claim 3, at least one of said plurality of inferior spring elements comprising an anterior curve comprising a fitted symmetrical radius of curvature extending downwardly between said anterior tangent point and a posterior tangent point, and a posterior curve extending upwardly between said posterior tangent point and said posteriormost side of said at least one of said plurality of inferior spring elements and comprising an angle between said posterior tangent point and said posteriormost side in the range between 1-15 degrees.

18. The article of footwear according to claim 3, wherein said at least one of said plurality of inferior spring elements comprises a length of said at least one of said plurality of inferior spring elements on said lateralmost side is different than on said medialmost side.

19. The article of footwear according to claim 3, at least one of said plurality of inferior spring elements further comprising an outsole.

20. The article of footwear according to claim 3, said heel counter being integral to said superior spring element.