Shock Absorbing Cushion Sole for Fishing Footwear

Abstract

A multi-layer shock absorbing cushion sole for footwear includes multiple layers of material, assembled in such a way that air pockets are created within the sole to provide a shock-absorbing, cushioning effect for a wearer's feet. The top layer of the sole is a hard rubber layer, preferably made from a thermoplastic rubber. The second layer is preferably positioned directly beneath the top layer, and includes air pockets formed therein by various structures, methods and techniques. The optional third layer, positioned below the cushion layer, is also preferably formed from a thermoplastic rubber. The bottom layer is preferably formed from natural rubber, and preferably includes a tread design on the bottom surface thereof. A multi-layer shock absorbing cushion insert for pre-existing footwear is also provided in another embodiment.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a continuation-in-part of U.S. application Ser. No. 18 / 953,317, entitled Shock Absorbing Cushion Sole For Fishing Footwear, filed on Nov. 19, 2024 which is a continuation-in-part of U.S. application Ser. No. 18 / 430,998, entitled Shock Absorbing Cushion Sole For Fishing Footwear, filed on Feb. 2, 2024. All of the foregoing applications are hereby incorporated by reference in their entireties.FIELD OF THE INVENTION

[0002] The present invention relates generally to footwear having shock-absorbing cushioned soles. More specifically, the present invention includes fishing shoes or boots having a multi-layer sole that provides shock absorbing properties, wherein one of the layers defines air pockets within the sole to provide additional comfort to a wearer.BACKGROUND OF THE INVENTION

[0003] Commercial fishermen and sport fishermen spend a significant amount of time on their feet while fishing, and are subjected to many adverse weather conditions. Boat decks can become slippery in bad weather, and the boat deck is often in constant motion when seas are choppy. Many fishermen wear rubber boots, which tend to be waterproof, and provide some protection to a fisherman's feet, but one common complaint about such rubber boots is that they do not provide enough padding in the soles, which makes them uncomfortable to wear for long periods of time under these types of adverse conditions.

[0004] Various attempts have been made to provide air or gas cushioned soles for shoes, and particularly for athletic footwear, but the fact remains that it is difficult to find fishing boots that include an air-cushioned sole. Providing a cushioned, shock-absorbing sole helps a wearer to operate in adverse weather conditions, including wet, slippery surfaces, and provides improved comfort while also reducing fatigue and the likelihood of injury. Such cushioned soles also serve to decrease the recovery time between days on the water, which is particularly important to commercial fishermen, boat captains, deck hands, and others who work on fishing boats day after day.

[0005] The following documents disclose some examples of cushioned soles, and these documents are hereby incorporated by reference herein, in their entireties:U.S. Pat. No. 4,223,455 Shoe Sole Containing Discrete Air-Chambers

[0006] A novel shoe incorporating a new sole and wedge-shaped arch support. The sole includes a plurality of sealed alveoli or air-chambers of different shapes which provide sufficient flexibility and resiliency to the shoe to reduce many of the common problems encountered by athletes. The alveoli are sealed in the sole by a mid-sole and an air-chamber member being sealed together in a simple and efficient manner.U.S. Pat. No. 4,991,317 Inflatable Sole Lining Shoes and Boots

[0007] There is disclosed an inflatable inner sole for a shoe or boot which is formed of upper and lower plastic sheets having the shape and size of a sole and bonded together in a continuous seam about their peripheral edges thereby forming a sealed interior. A plurality of this continuous seams are formed between the upper and lower sheets to create within the sealed interior a plurality of interconnecting tubular passageways. The inflatable inner sole is provided with an air pump that preferably is mounted at the heel of the inner sole. The air pump is a flexible bulb with an inlet valve and discharges into a flexible tube which extends to a pressure control valve and then to the interior chamber of the inflatable inner sole. The pressure relief valve is manually adjustable to control the pressure within the inflatable inner sole. Excess air from the pressure control valve is directed into channels formed on the undersurface of the inner sole where it discharges through sealed apertures in the inner sole thereby providing forced air circulation in the shoe. Alternatively a manually operated air pump can be provided and the inner sole can be provided with inflatable upper linings for the shoe or boot.U.S. Pat. No. 5,025,575 Inflatable Sole Lining for Shoes and Boots

[0008] There is disclosed the combination of an inflatable inner sole and a supporting underlayment for footwear, such as a shoe, boot or sandal. The inflatable inner sole is formed of upper and lower plastic sheets having the shape and size of a sole and bonded together in a continuous seam about their peripheral edges thereby forming a sealed interior. A plurality of this continuous seams are formed between the upper and lower sheets to create within the sealed interior a plurality of interconnecting tubular passageways. The inflatable inner sole is provided with an air pump that preferably is mounted at the heel of the inner sole. The air pump is a flexible bulb with an inlet valve and discharges into a flexible tube which extends to a pressure control valve and then to the interior chamber of the inflatable inner sole. The pressure relief valve is manually adjustable to control the pressure within the inflatable inner sole. Excess air from the pressure control valve is directed into channels formed on the undersurface of the inner sole where it discharges through sealed apertures in the inner sole thereby providing forced air circulation in the shoe. Alternatively a manually operated air pump can be provided and the inner sole can be provided with inflatable upper linings for the shoe or boot.U.S. Pat. No. 5,230,249 Shoe or Boot Provided with Tank Chambers

[0009] A footwear of the present invention is provided with tank chambers which are disposed to be in contact with an instep, sole and ankle of the user for applying pressure thereto to protect his foot from shocks. The tank chambers are filled with air and air pressure within the tank chambers can be adjusted. The footwear is further provided with a pressure sensor for measuring air pressure within the tank chambers to generate a pressure signal, and a pressure data displaying device for indicating pressure data on the basis of the pressure signal generated by the pressure sensor. Therefore, the user can make sure on the pressure data display device a pressure level at which the most suitable pressure for his foot is obtained. The user is also allowed to extremely easily adjust the air pressure at the above pressure level, watching an indication on the pressure data display device.U.S. Pat. No. 6,014,823 Inflatable Sole Lining for Shoes and Boots

[0010] There is disclosed an inflatable lining for selected inner surfaces of footwear, such as a shoe, boot or sandal. The inflatable lining is formed of first and second plastic sheets having the shape and size of the selected inner surfaces, e.g., a sole, or any portion of the upper surfaces of the footwear. The sheets are bonded together in a continuous seam about their peripheral edges thereby forming a sealed interior chamber. A plurality of discontinuous seams are formed between the first and second sheets to create within the sealed interior chamber a plurality of interconnecting tubular passageways, and at least one continuous seam can also be provided that subdivides the interior chamber into two or more subdivided interior chambers. The inflatable liner is provided with an air pump that preferably is a flexible bulb with an inlet valve which discharges into a flexible tube which extends to a pressure control valve and then to the interior chamber of the inflatable inner sole. Preferably the flexible bulb is mounted at the heel of the inner sole. The pressure relief valve is manually adjustable to control the pressure within the inflatable inner sole. Excess air from the pressure control valve can be directed into channels formed on the undersurface of the inner sole where it discharges through sealed apertures in the inner sole thereby providing forced air circulation in the footwear. Alternatively, manually operated air pumps can be provided.U.S. Pat. No. 6,505,420 Cushioning Member for an Article of Footwear

[0011] A cushioning member for an article of footwear is provided having a series of interconnected chambers filled with ambient or slightly pressurized air. An impedance is provided between selected chambers, in order to restrict the flow of air between the chambers. The shape and structure of the impedance determines the nature of the air flow between chambers, such that the cushioning member can be tailored for various types of activities and body weights, by offering varying degrees of cushioning.U.S. Pat. No. 6,796,056 Footwear Sole Component with a Single Sealed Chamber

[0012] A sole component for footwear formed as a single bladder chamber in contact with an elastomeric midsole, or a single chamber formed by a sealing a void in elastomeric material. The interface between the chamber and elastomeric material is sloped and gradual so that the shape of the chamber and its placement in a midsole determine the combination of response characteristics in the sole component. The chamber has one axis of symmetry with a rounded portion and a narrow portion. The chamber has a relatively large volume, is devoid of internal connections, and has an internal pressure within 5 psi of ambient pressure, and preferably at ambient pressure. Since air is used as the fluid, no specialized gases are required. No specialized films or bladder materials are required where the chamber is formed as a bladder, since the bladder is not highly pressurized.U.S. Pat. No. 6,931,764 Footwear Sole Structure Incorporating a Cushioning Component

[0013] A cushioning component for an article of footwear is disclosed that includes a fluid-filled chamber and a covering element extending over a portion of the chamber. The chamber is devoid of internal connections, and the fluid within the chamber may be at a pressure that is substantially equal to an ambient pressure. The chamber defines a plurality of lobes, and the cushioning element includes a plurality of inserts that extend between the lobes. The inserts are elongate structures that decrease the compressibility of peripheral portions of the cushioning component.U.S. Pat. No. 8,978,273 Article of Footwear with a Sole Structure Having Fluid-Filled Support Elements

[0014] An article of footwear is disclosed that includes an upper and a sole structure secured to the upper. The sole structure incorporates a support element that includes a fluid-filled chamber, The chamber may be bonded to other portions of the sole to secure the chamber within the sole. A surface of the chamber may also be angled to form a corresponding bevel in a lower surface of the sole structure, potentially in a rear-lateral area of the sole structure. A plate may also extend under a portion of the chamber.U.S. Pat. No. 9,289,030 Article of Footwear Having a Sole Structure with a Framework-Chamber Arrangement

[0015] A framework-chamber arrangement for an article of footwear, and an article of footwear having a sole structure including a framework-chamber arrangement, is provided that can cooperate to provide various advantageous features, such as multiple-stage cushioning and specialized attenuation of and reaction to ground contact forces. The framework-chamber arrangement can include a fluid-filled chamber forming laterally extending arms and a framework having corresponding recesses formed therein and receiving a lower portion of the chamber. The fluid-filled chamber can be retained within the framework without a bond being formed between lower regions of the chamber arms and the framework. Peripheral portions of some of the chamber arms can be spaced apart from adjacent portions of corresponding channels while in a relaxed state.U.S. Pat. No. 9,510,646 Article of Footwear Having a Flexible Fluid-Filled Chamber

[0016] An article of footwear may include an upper forming a void within the footwear, a sole structure secured to the upper, and a chamber that encloses a pressurized fluid. The sole structure includes a depression. The chamber is located within the void of the upper and located on the depression of the sole structure. The chamber may include a plurality of fluid-filled subchambers, a manifold, and a connection fluidically-connected at least one of the subchambers to the manifold. The subchambers may enclose the pressurized fluid at different pressures. The subchambers may be separated from one another by a bonded area in the direction extending between the heel and toe of the chamber.U.S. Pat. No. 11,259,596 Midsole System with Graded Response

[0017] A sole structure for an article of footwear comprises a midsole system with a plurality of cushioning units, each having multiple cushioning layers configured to work together as a system to absorb a compressive load, such as a dynamic compressive load due to impact with the ground, in stages of progressive cushioning according to the relative stiffness values of the layers. Various midsole systems disclosed include isolated cushioning units, linked cushioning units, sole layers having stanchions interfacing with the midsole system, midsole systems with sole layers having keyed and unkeyed portions overlying a bladder, and midsole systems with vertically-stacked cushioning units disposed in inverted relationship to one another.U.S. Pat. No. 11,272,755 Sole and Article of Footwear Having a Pod Assembly

[0018] A sole for an article of footwear includes: an upper sole portion; and a pod assembly having a plurality of pods fluidly connected in series disposed below the upper sole portion, wherein the pod assembly extends from a lateral heel portion of the sole to a medial forefoot portion of the sole such that the plurality of pods compress substantially in sequence through a gait cycle of a wearer.U.S. Patent Application Publication No. 20050011085 Footwear with a Sole Structure Incorporating a Lobed Fluid-Filled Chamber

[0019] A fluid-filled chamber for an article of footwear and a method for manufacturing the chamber are disclosed. The chamber may be incorporated into a sole structure of the footwear and includes a central area and a plurality of lobes extending outward from the central area. The lobes are in fluid communication with the central area and are formed from a first surface, a second surface, and a sidewall. The sidewall joins with the first surface with the second surface to seal the fluid within the chamber, but no internal connections are generally utilized to join interior portions of the first surface with interior portions of the second surface. The fluid within the chamber may be air at a pressure that is approximately equal to an ambient pressure.WIPO Patent Application No. WO1993012685 Outer Sole, in Particular for Hiking Shoes or Climbing Boots

[0020] An outer sole, in particular for hiking shoes or climbing boots, has two pads (7, 8) at least partially filled with a fluid medium and interconnected by a channel (9). The first pad (7) is arranged in the area of the heel (11) and the other pad (8) is arranged in the front area of the outer sole. The pads (7, 8) form together with the interconnecting channel (9) a single, flexible and in itself closed component that fits in a cavity (5) of matching dimensions in the outer sole. The length of the interconnecting channel (9) is set so that the second pad (8) arranged in the front area of the outer sole is located in the front area of the foot or in the area (13) of the ball of the foot.SUMMARY OF THE INVENTION

[0021] In one embodiment, a multi-layer shock absorbing cushion sole for footwear, and fishing shoes / boots in particular, includes four layers of material, assembled in such a way that air pockets are created within the sole to provide a shock-absorbing, cushioning effect for a wearer's feet. The top layer of the sole is a hard rubber layer, preferably made from a thermoplastic rubber. The second layer (also referred to herein as the ‘cushion layer’) is preferably positioned directly beneath the top layer, and includes shaped surfaces on a top and bottom portion thereof, wherein the shaped surfaces create air pockets within the sole. The cushion layer is preferably formed from a synthetic rubber, such as ethylene-vinyl acetate (EVA). The synthetic rubber cushion layer provides a balance of cushioning, durability, and is lightweight. The third layer, positioned below the cushion layer, is also preferably formed from a thermoplastic rubber. The bottom layer, positioned on a bottom surface of the sole, directly below the third layer, is preferably formed from natural rubber, and in a preferred embodiment, the bottom layer includes a tread design on the bottom surface of the sole.

[0022] The different layers are bonded together using any suitable adhesive or method for bonding the layers together. Once the layers are bonded together, the cushion layer provides air pockets between the top layer and the third layer, which is the primary source of the shock-absorbing, cushioning effect.

[0023] It should be understood that other types of materials may be used for the different layers, and the multi-layered soles may include layers adhered to one another in different configurations. Additionally, any suitable tread pattern may be used on the bottom layer, and the configuration of uneven surfaces on the upper and or lower sides of the cushioning layer may be modified without departing from the spirit and scope of the present invention.

[0024] In some embodiments, some of the air pockets may be constructed from different materials than materials used to construct other ridges and grooves that form air pockets, in order to tune or calibrate the soles to have more stiffness in desired places, such as the medial arch support region of the sole, and to maintain a softer, bouncier feel in other places, such as the lateral portions of the sole. For example, in order to provide additional arch support, the air pockets in the medial position of the sole may be made from a first, stiff material, while other air pockets on the lateral side of the sole may be formed from a second, more pliable and flexible material. Alternatively, the air pockets may all be made from the same material, but for areas that require additional support, such as arch support, the air pockets in the medial portion of the sole may be formed from thicker layers of the selected material than the layers forming laterally disposed air pockets, which may be made from a thinner layer of the same material.

[0025] Additionally, some embodiments of the present invention may include a cushion layer that is formed by a series of three-dimensional air pocket units, which are essentially tubular structures forming an air pocket therein. The cushion layer may include a series of individual air pocket units wherein each air pocket unit includes a single air pocket, or may include air pocket units that include multiple tubular structures that are connected together by support members that extend therebetween. In this embodiment, the sole structure is preferably constructed of three layers: a top layer, the cushion layer comprising the air pocket units, and a bottom layer. The underside of the top layer preferably includes complementary grooves to receive the air pocket units, and similarly, the top side of the bottom layer may also include such complementary grooves to receive the air pocket units of the cushion layer.

[0026] Further, in another embodiment, the present invention includes an insert for shoes, which is preferably made from the top three layers as set forth herein, but which does not include the bottom layer with tread. In this embodiment, the insert may be placed into an existing shoe, boot, or other type of footwear, in order to provide a shock-absorbing cushion for added comfort.

[0027] This multi-layer sole may be used in conjunction with any suitable shoe or boot, and although the present invention is described in terms of a cushioned sole for fishing boots, shoes, and other types of fishing footwear, it should be understood that the novel multi-layer sole disclosed herein may be used in connection with other types of footwear, or for footwear used for other types of activities.DESCRIPTION OF THE DRAWINGS

[0028] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description and accompanying drawings where:

[0029] FIG. 1A is a side view of one embodiment of a top layer of a multi-layer shock absorbing cushion sole, wherein the top layer is preferably manufactured from a hard thermoplastic rubber material;

[0030] FIG. 1B is a perspective view of the embodiment of a top layer of a multi-layer shock absorbing cushion sole, as shown in FIG. 1A;

[0031] FIG. 2A is a side view of one embodiment of a second layer of a multi-layer shock absorbing cushion sole, which is preferably positioned below a top layer, and includes shaped surfaces on a top and bottom portion thereof, wherein the shaped surfaces create air pockets within the sole;

[0032] FIG. 2B is a perspective view of the embodiment of a second layer of a multi-layer shock absorbing cushion sole, as shown in FIG. 2A;

[0033] FIG. 3A is a side view of one embodiment of a third layer of a multi-layer shock absorbing cushion sole, which is preferably positioned below the second layer, and is preferably formed from a thermoplastic rubber material;

[0034] FIG. 3B is a perspective view of the embodiment of a third layer of a multi-layer shock absorbing cushion sole, as shown in FIG. 3A;

[0035] FIG. 4A is a side view of one embodiment of a bottom layer of a multi-layer shock absorbing cushion sole, wherein the bottom layer positioned on a bottom surface of the sole, directly below the third layer, and is preferably formed from natural rubber and includes a tread design on the bottom surface of the sole, which provides enhanced traction, particularly on wet boat decks and other potentially slippery surfaces;

[0036] FIG. 4B is a perspective view of the embodiment of a bottom layer of a multi-layer shock absorbing cushion sole, illustrating one example of a tread for providing enhanced traction;

[0037] FIG. 5 is a bottom view of one embodiment of the bottom layer of a multi-layer shock absorbing cushion sole, illustrating one example of a tread for providing enhanced traction;

[0038] FIG. 6 is a side view of one embodiment of a multi-layer shock absorbing cushion sole, showing multiple layers in an assembled state to form the sole;

[0039] FIG. 7 is a perspective view of one embodiment of a multi-layer shock absorbing cushion sole, showing multiple layers in an assembled state to form the sole;

[0040] FIG. 8 is a perspective view of one embodiment of a boot having a multi-layer shock absorbing cushion sole;

[0041] FIG. 9 is a perspective view of another embodiment of a boot having a multi-layer shock absorbing cushion sole;

[0042] FIG. 10 is a side view of another embodiment of the present invention illustrating an insert that may be placed into existing footwear to provide a shock-absorbing cushion, wherein the insert includes a top layer, a second cushioning layer below the top layer, and a third layer below the cushion layer;

[0043] FIG. 11 is a perspective view of the embodiment of an insert as shown in FIG. 10;

[0044] FIG. 12 is a side view of one embodiment of air pocket units, showing a first shape of air pocket that is used in the medial portion of the sole, wherein the first shape is formed of a stiffer material, and a pair of air pocket units having a second shape formed on the lateral portions of the sole, wherein these lateral air pocket units are preferably formed from a second material that is more flexible and pliant than the first material;

[0045] FIG. 13 is a side view of a second embodiment of air pocket units showing a first shape of air pocket that is used in the medial portion of the sole, and a pair of air pockets having a second shape formed on the lateral portions of the sole; and

[0046] FIG. 14 is a perspective exploded view of one embodiment of a multi-layer shock absorbing cushion sole, including a top layer, a bottom layer, and a cushion layer, wherein the cushion layer is constructed of air pocket units that are connected together by generally parallel, spaced apart support members.DESCRIPTION OF THE INVENTION

[0047] As shown in FIGS. 1-9, the present invention includes, in one embodiment, a multi-layer shock-absorbing cushion sole 10 that is primarily used in connection with fishing footwear, including fishing boots, shoes, sandals, and the like. The top layer 12 of the sole 10 in this embodiment, as shown in FIGS. 1A and 1B, is preferably a hard rubber layer, more preferably made from a thermoplastic rubber. Thermoplastic rubber is the preferred material for some of the layers incorporated into the multi-layer sole 10 because it provides the combined benefits of plastic and rubber, which provides a layer having durability, flexibility, strength, resistance to abrasion, and enough rigidity to maintain its shape and dimensional stability.

[0048] The second layer 14 (also referred to herein as the ‘cushion layer’) is preferably positioned directly beneath the top layer, and includes shaped surfaces on a top and bottom portion thereof, wherein the shaped surfaces create air pockets 16 within the sole. In one particular embodiment, as shown in FIGS. 2A and 2B, the upper and lower surfaces of the cushion layer may include wave-like shapes, including ridges 18 and grooves 20, that form air pockets 16 within the multi-layer sole. In the embodiment shown herein, the wave shapes lean forward on an upper portion of the cushion layer 14, and lean in a rearward direction on an underside thereof. It should be noted that other shapes and configurations may be used for the upper and / or lower surfaces of the cushion layer 14, so long as the shapes provide air pockets 16 within the sole 10 to create the air-cushioned shock absorbing effect against absorb impact forces and provide enhanced comfort to a wearer. The cushion layer 14 is preferably formed from a synthetic rubber, such as ethylene-vinyl acetate (EVA). The synthetic rubber cushion layer 14 provides a balance of cushioning, durability, and is lightweight.

[0049] The third layer 22, positioned below the cushion layer 14, is also preferably formed from a thermoplastic rubber, as shown in FIGS. 3A and 3B. The bottom layer 24, positioned on a bottom surface of the sole 10, directly below the third layer 22, is preferably formed from natural rubber, and in a preferred embodiment, the bottom layer 24 includes a tread design 26 on the bottom surface of the sole 10 as shown in FIGS. 5-7, which provides enhanced traction, particularly on wet boat decks and other potentially slippery surfaces.

[0050] The different layers are bonded together using any suitable adhesive or method for bonding the layers together. Once the layers are bonded together, the cushion layer 14 provides and defines air pockets 16 between the top layer 12 and the third layer 22, which is the primary source of the shock-absorbing, cushioning effect. In one preferred embodiment, the sides of the soles are open, so that the air pockets 16 are open to ambient air, as shown in FIGS. 8-9, so that air may flow freely through the air pockets 16. In other words, in this embodiment, air is not trapped within the air pockets 16, which allows the sole to be slightly compressed upon hard impacts, but resilient enough to retain its original shape and dimensional stability when the sole 10 is not absorbing force from such impact.

[0051] In some embodiments, the ridges and grooves that form some of the air pockets 16 may be constructed from different materials than materials used to construct other ridges and grooves that form air pockets, in order to tune or calibrate the soles to have more stiffness in desired places, and to maintain a softer, bouncier feel in other places. For example, air pockets 16 in the medial area that supports the arch of the foot may be made from ridges and grooves (or may be independently constructed into air pocket units and inserted into the sole), and are preferably formed from nylon thermoplastic polyurethane (TPU), rubber, or any other suitable stiffer material to increase stiffness in the arch area of the foot for increased support, while air pockets 16 in the lateral side of the sole may be made from other softer or more flexible materials, such as ethyl vinyl acetate (EVA), polyurethane (PU) or a softer type of rubber to provide a softer, less rigid feel along the lateral side of the sole.

[0052] Similarly, air pockets may be tuned or calibrated to provide additional stiffness in some areas of the sole (medial arch support, for instance) by providing that the layers of material forming ridges and grooves defining the air pockets are thicker than the layers of material forming air pockets in other areas (lateral side of the sole, for instance). In a preferred embodiment, the air pockets in the medial portion of the sole may have a wider cross-section in a generally horizontal direction than air pockets in the lateral portion of the sole, as shown in FIGS. 12 and 13. The air pockets are preferably formed to have a generally horizontal, linear top portion, while the lower portions of the air pockets are curved or angled, as shown.

[0053] It should also be noted that the medial air pockets 16 may be made by forming three-dimensionally constructed, independent air pocket units 100, as shown in FIGS. 12-14, that form and define the air pockets 16, rather than being formed by ridges and grooves, and these air pocket units 100 may be injection molded, compression molded or 3-D printed and added or inserted in any suitable fashion to the sole during the manufacturing process. Similarly, the more flexible air pockets may also be formed of independent air pocket units as described above, and are preferably formed via injection molding, pouring, compression molding, or they may be 3-D printed. Other suitable manufacturing techniques for forming the free-standing, independent air pocket units may be employed, as well. It should be understood that the materials used to form the air pockets and air pocket units in these embodiments may be any suitable materials that offer the ability to fine-tune or calibrate the stiffness in some areas while maintaining the softer, bouncier characteristics in other areas, as discussed herein. As used herein, the term ‘air pocket unit’ may be used to indicate a three-dimensional structure that forms a single air pocket, as shown in FIGS. 12-13, and may also be used to indicate a three dimensional structure that forms multiple air pockets, as shown in FIG. 14, as discussed hereinbelow.

[0054] In another embodiment, as shown in FIG. 14, the air pocket units 100 may be formed so that multiple air pockets 16 are connected to one another by support members 102 that are spaced apart from one another. FIG. 14 shows, for example one air pocket unit 100 that forms three air pockets 16 that are each connected by a pair of generally parallel, spaced apart support members 102, and further shows a second air pocket unit 100 that forms two air pockets 16 connected by the support members 102. These air pocket units 100 may be made from any suitable material, which can be the same material or different material than the material used to form the other layers within the cushioned sole. It is contemplated that the air pocket units 100 may form a series of air pockets that are all connected to one another by support members, and that in an alternate embodiment, clusters of air pockets may be connected by support members (as shown in FIG. 14) in any desired arrangement. In these embodiments, the underside of the top layer preferably includes a series of complementary grooves for receiving the air pocket units 100. Similarly, the top side of the bottom layer may also include grooves for receiving the air pocket units 100, as shown in FIG. 14.

[0055] It should be understood that the multi-layer sole 10 may be used in connection with any types of shoes, boots or footwear. For example, the multi-layer shock-absorbing soles 10 may be used in connection with rubber or neoprene boots or shoes, sandals, hiking boots, rain boots, and athletic footwear of all types.

[0056] It is also contemplated that a similar multi-layer shock absorbing construction may be used for inserts into fishing boots, shoes, or other types of footwear, as shown in FIGS. 10-11. In the insert embodiment, it may not be necessary to include the bottom layer having a tread, but may instead be formed by the top layer 12, the cushion layer 14, and the third layer 22. This arrangement allows a wearer to simply slide the inserts into their own footwear, in order to provide the shock-absorbing cushion effect to footwear that otherwise may not have such features. It should be noted that the cushion layer of the insert may be formed in any suitable manner, including all embodiments of the cushion layer that are described herein.

[0057] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. All features disclosed in this specification may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

Claims

1. A multi-layer shock-absorbing cushion sole comprising:a top layer;a cushion layer attached to an underside of said top layer; anda bottom layer positioned on an underside of said third layer, said bottom layer including a tread pattern on an underside thereof; andwherein said cushion layer is formed by at least two independent air pocket units so that each air pocket unit includes at least two air pockets connected to one another by support members;2. The multi-layer shock absorbing cushion sole set forth in claim 1, wherein at least one of said air pockets is formed by a layer of material having a first thickness, while other air pockets are formed by a layer of material having a second thickness that is less than said first thickness.

3. The multi-layer shock-absorbing cushion sole set forth in claim 2, wherein said air pocket having said first thickness is positioned in a medial portion of said cushion layer to provide additional support for an arch of a wearer's foot.

4. The multi-layer shock-absorbing cushion sole set forth in claim 1, wherein said top layer is formed from a thermoplastic rubber material.

5. The multi-layer shock-absorbing cushion sole set forth in claim 1, wherein said cushion layer is formed from a synthetic rubber material.

6. The multi-layer shock-absorbing cushion sole set forth in claim 5, wherein said synthetic rubber material is ethylene-vinyl acetate.

7. The multi-layer shock-absorbing cushion sole set forth in claim 1, wherein said bottom layer is formed from natural rubber.

8. The multi-layer shock-absorbing cushion sole set forth in claim 1, wherein said air pockets are open on either side of said multi-layer shock-absorbing cushion sole, so that air may freely flow into and out of said air pockets from surrounding atmosphere.

9. A multi-layer shock-absorbing cushion sole comprising:a top layer;a cushion layer attached to an underside of said top layer; anda bottom layer positioned on an underside of said third layer, said bottom layer including a tread pattern on an underside thereof;wherein said cushion layer comprises at least one air pocket unit that forms least two air pockets that are connected together by support members.

10. The multi-layer shock-absorbing cushion sole set forth in claim 9, wherein said top layer is formed from a thermoplastic rubber material.

11. The multi-layer shock-absorbing cushion insert set forth in claim 9, wherein said third layer is formed from a thermoplastic rubber material.

12. The multi-layer shock-absorbing cushion insert set forth in claim 9, wherein said bottom layer is formed from natural rubber.

13. The multi-layer shock-absorbing cushion insert set forth in claim 9, wherein a bottom surface of said top layer includes a series of grooves that are positioned therein to receive said air pocket unit.

14. The multi-layer shock-absorbing cushion insert set forth in claim 9, wherein a top surface of said bottom layer includes a series of grooves that are positioned therein to receive said air pocket unit.

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