Article of footwear with midsole having variable hardness

Abstract

To provide an article of footwear having a midsole that provides both stability during the swing and comfort and flexibility while walking and standing.SOLUTION: The article of footwear includes an upper, a heel region having a heel core and a heel perimeter, a forefoot region, a medial side, a lateral side, an outsole, and a midsole. The medial side extends from the forefoot region to the heel region. The lateral side extends from the forefoot region to the heel region, and is opposite to and generally parallel to the medial side. The midsole is a dual durometer midsole and includes a soft durometer positioned between the heel region and the forefoot region, and a firm durometer positioned around the heel perimeter.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure generally relates to the field of footwear. More specifically, the present disclosure relates to the field of footwear having an improved midsole structure.

Background Art

[0002] The game of golf includes long stretches of walking and short moments of swinging a golf club to hit a ball. As a result, golf shoes have evolved to provide the wearer with excellent traction on grass, comfort during walking, and a stable platform for hitting the ball. Thus, golf shoes typically comprise a relatively hard sole with metal spikes or plastic cleats. Some golf shoes also include gels that cushion the impact of so-called "ground reaction forces" on the foot. From Newton's third law of motion, i.e., the law of action-reaction, it is known that the ground pushes on the foot with the same force in the direction opposite to the direction in which the foot pushes on the ground. These are known as ground reaction forces.

[0003] The midsole of footwear is known to strongly influence the sense of cushioning / comfort by redistributing the magnitude and rate of load on the bone's load-bearing structure and the foot's soft tissue. A single-density foam of a particular Asker C hardness is most commonly used as a midsole to provide a structure that compresses under walking loads. However, since single-density foams have a uniform hardness, one must choose between using a hard sole for support or a soft sole for comfort. Thus, current midsoles cannot simultaneously provide adequate support in areas of the foot under high loads and / or comfort in areas of the foot under low loads.

[0004] There remains a need for footwear having an improved midsole that provides sufficient rigidity without sacrificing flexibility and comfort. The footwear needs to provide stability when a golfer's weight shifts during a golf swing while allowing the golfer to walk comfortably between holes.

[0005] Patent Document 1 discloses making the sole structures of the midsole and outsole suitable for a golf swing.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

[0007] The present disclosure provides a footwear product having a midsole that provides both stability during a swing and comfort and flexibility during walking and standing.

[0008] The following presents a simplified summary of the present disclosure in order to provide a basic understanding of some aspects of the present disclosure. This summary is not an extensive overview of the disclosure. It is not intended to identify key elements of the disclosure or to delineate the scope of the disclosure. Its sole purpose is to present some concepts of the disclosure in a simplified form as a prelude to a more detailed description presented elsewhere.

[0009] One aspect of the present disclosure relates to a footwear product configured to provide stability, comfort, and flexibility. The footwear product may include an upper, a heel region having a heel core and around the heel, a forefoot region, an inner side (medial side: the side closer to the midline), an outer side (lateral side: the side farther from the midline), an outsole, and a midsole. The inner side may extend from the forefoot region to the heel region. The outer side extends from the forefoot region to the heel region, is on the opposite side of the inner side, and may be substantially parallel. The midsole may be a dual durometer midsole and may include a soft durometer positioned from the heel region to the forefoot region and a hard durometer positioned around the heel.

[0010] These and other aspects will become apparent to those skilled in the art after reading the following description in view of the drawings.

Brief Description of the Drawings

[0011] Non-limiting and non-exhaustive examples are described with reference to the following figures.

[0012] Exemplary embodiments of the present disclosure are described in detail below with reference to the accompanying drawings.

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[0013] With reference to the accompanying drawings, several embodiments are described more fully. However, this disclosure should not be construed as limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like numerals refer to like elements throughout. The thicknesses and dimensions of some of the components may be exaggerated for clarity.

[0014] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms (''a'', ''an'', and ''the'') include plural references unless the context clearly dictates otherwise.

[0015] As used herein, the description that two or more parts or components are ''coupled'' means that the parts are directly or indirectly joined or operate together, i.e., through one or more intermediate parts or components, as long as a link occurs. As used herein, ''directly coupled'' means that two elements are in direct contact with each other.

[0016] All patents, patent applications, and publications referred to herein are incorporated by reference in their entirety. In case of any conflict in terms, this specification shall prevail.

[0017] It should be noted that any one or more aspects or features described with respect to one embodiment may be incorporated into different embodiments even if not specifically described in relation thereto. That is, all embodiments and / or all features of any embodiment can be combined in any manner and / or combination. The applicant reserves the right to amend the originally filed claims or to file new claims accordingly, which includes the right to correct the originally filed claims to depend on any other claims and / or to incorporate any features of any other claims, even if not originally so claimed in that manner. These and other objects and / or aspects of this invention are described in detail in the specification set forth below.

[0018] Referring now to FIG. 1, a footwear product 10 according to one embodiment is provided. The footwear product 10 may, in some embodiments, include an upper 15, a midsole 20 coupled to the upper 15, and an outsole 25 coupled to the midsole 20. The footwear product may also include a gill strip 23.

[0019] The footwear product 10 may further include a heel region 30, a midfoot region 40, and a forefoot region 45. The heel region 30 may generally correspond to the rear portion of the foot, i.e., the Achilles tendon, the area behind the heel, and the area around and below the talus and calcaneus bones. The midfoot region 40 may generally correspond to the center of the foot, i.e., the arch and the navicular, cuboid, and cuneiform bones. The forefoot region 45 may generally correspond to the front portion of the foot, i.e., the toes and the metatarsal, phalangeal, and sesamoid bones. It should be noted that the heel region 30, the midfoot region 40, and the forefoot region 45 are intended to represent general regions of the footwear product and are not intended to distinguish exact regions.

[0020] In some embodiments, the upper 15 may comprise an inner surface 60 (see FIG. 2) and an outer surface 65. The inner surface 60 may partially form an area configured to receive a human foot. The upper 15 may be configured to extend over a human foot, along the inner (medial) side and the outer (lateral) side of the foot, and around the forefoot region and the heel region of the foot. The area configured to receive a human foot may be accessed from an ankle opening formed by the collar 70.

[0021] The upper 15 may be constructed from any suitable material known currently or developed later, including but not limited to leather, synthetic leather, polyurethane composites, polyvinyl chloride composites, hot melt composites (thermoplastic polymers laminated to another substrate), suede, cloth, canvas, woven, knit, artificial polymer fibers, nylon, polyester, or cotton. The upper 15 may be elastic. Alternatively, at least a portion of the upper 15 may be elastic. In other embodiments, the upper 15 may be inelastic. The upper 15 may include those that are at least partially non - flexible, rigid or semi - rigid.

[0022] The upper 15 may further include an external heel counter 85 in the heel region 30. The heel counter 85 may reinforce the upper 15 and reduce or limit the movement of a human heel. The heel counter 85 may be formed from a rigid thermoplastic polymer such as thermoplastic polyurethane (“TPU”). The external heel counter 85 may wrap around the heel region 30 and extend forward along both the outer side and the inner side. The heel counter 85 may also include a ridge 87 or the like to provide rigidity while reducing overall weight.

[0023] In some embodiments, the lace 90 may be on top of the upper 15 and may be configured to interact with the outer surface of the upper 15. The lace 90 may be wholly or partially visible. The footwear may include one or more closure systems for securing the user's foot, the selection of which is within the skill of those in the art. Examples of closure systems include the lace, the lace tightening system described in U.S. Patent No. 10,070,695, which is hereby incorporated by reference in its entirety, and the closure system described in U.S. Serial No. 17 / 355,390, filed June 23, 2021, which is hereby incorporated by reference in its entirety. It will be understood that any suitable lace system or closure system can be used to secure the wearer's foot to the upper 15 of the footwear product 10. In some embodiments, the footwear product 10 may comprise an inner side 50 extending from the forefoot region 45 to the heel region 30 and an outer side 55 extending from the forefoot region 45 to the heel region 30. The inner side and the outer side may be on opposite sides of each other. In some embodiments, the outer side 55 and the inner side 50 may generally be parallel to each other. The outer side 55 may generally correspond to the outer region of the foot and the surface facing away from the other foot of the person. The inner side 50 may generally correspond to the inner region of the foot and the surface facing the other foot of the person.

[0024] In some embodiments, the outsole may include a traction element 95. The traction element 95 may be made of any suitable material such as rubber or plastic and combinations thereof. Thermoplastic plastics such as nylon, polyester, polyolefin, polyurethane may be used. Suitable rubber materials that can be used include, but are not limited to, polybutadiene, polyisoprene, ethylene propylene rubber ("EPR"), ethylene-propylene-diene ("EPDM") rubber, styrene-butadiene rubber, styrene block copolymer rubber, butyl rubber, nitrile rubber, and blends of two or more of these.

[0025] Referring to FIGS. 2 and 3, various embodiments of the midsole 20 and outsole 25 are shown. The support frame 110 may be molded onto the outsole or may be part of the outsole. In various embodiments, the support frame 110 may be provided as a solid predetermined shape / geometry or as a predetermined shape / geometry with openings. In one embodiment, the support frame 110 may extend from the heel region 30 to the midfoot region 40. As shown in FIGS. 2 and 3, a portion of the support frame 110 may be the predetermined shape / geometry of the A-frame 113. Other shape / geometry selections are within the skill of those in the art and the particular shape / geometry may be selected to provide support, aesthetics, or both in the preferred embodiment. As shown in FIG. 3, the hard durometer portion 130 may include a recess 114 shaped like the top portion of the A-frame to position the support frame 110 with the hard durometer portion 130. The support frame 110 may also include outer side legs 115a and inner side legs 115b. The outer side / inner side legs 115a, 115b may extend from the hard durometer portion 130 side and may engage corresponding outer side / inner side recesses 117a, 117b of the midsole 20.

[0026] The stability insert 120 may be in the midfoot region 40 of the outer side 55. As shown in FIG. 2, the midsole 20 may include a stability insert recess 140 for receiving the stability insert 120. The stability insert 120 may be molded from ethylene vinyl acetate (“EVA”) copolymer, polyurethane, and blends thereof. The stability insert 120 may be a harder material and thus may achieve stability by reducing the movement of the sidewall of the footwear product during a golf swing.

[0027] As shown in FIG. 4, the midsole 20 may include a soft durometer portion 125 disposed from the heel region 30 to the forefoot region 45 of the midsole 20. The dual durometer midsole 20 further includes a hard durometer portion 130 disposed around the heel circumference. In one embodiment, the preferred shape of the hard durometer portion is a U-shape or a horseshoe shape for wrapping around the heel. The soft durometer portion 125 may be manufactured from an ethylene vinyl acetate (“EVA”) copolymer. The soft durometer portion 125 may have a Shore C hardness between about 50 and 85, preferably between about 60 and 65. The hard durometer portion 130 may also be formed from an ethylene-vinyl acetate (“EVA”) copolymer, polyurethane, etc., and may be injection molded. In one embodiment, the hard durometer portion 130 and the stability insert may be of different materials, of the same material, or may be molded together. The hard durometer portion may have a Shore C hardness between about 60 and 95, preferably between about 70 and 75.

[0028] Referring to FIGS. 5 and 6, examples of the support frame 110 and the hard durometer portion 130 are shown. The hard durometer portion 130 may be horseshoe-shaped or U-shaped, may overlap the outer heel counter 85 of the heel region 30, and may be partially under the heel counter 85, i.e., the heel counter 85 is molded over the hard durometer portion 130. The hard durometer portion 130 may be in contact with the support frame 110. In one embodiment, the support frame 110 may have a slanted, i.e., angled, sidewall shape as opposed to a straight sidewall. The hard durometer portion may also be in contact with the soft durometer portion 125.

[0029] Referring now to FIGS. 7 - 9, alternative embodiments of the orientation of the stability insert 120 and the rigid durometer portion 130 are shown in some embodiments of the present invention. In FIG. 7, one embodiment is shown, in which there may be two stability inserts, namely, an outer side stability insert 120a and an inner side stability insert 120b, and the inserts 120a, 120b may be spaced apart from the rigid durometer portion 130.

[0030] In FIG. 8, the outer side and inner side stability inserts 120a, 120b may be connected to the rigid durometer portion 130 by an internal bridge section 150 or may be molded together. The internal bridge section 150 may be disposed in the corresponding outsole inner outer side and inner side portions 163a, 163b of the outsole 25.

[0031] In FIG. 9, the outer side and inner side stability inserts 120a, 120b may be connected to the hard durometer portion 130 by an external bridge section 165 or may be molded together. The external bridge section 165 may be disposed in the corresponding insole outer outer side and inner side portions 167a, 167b. FIGS. 8 and 9 show embodiments in which both outer side and inner side stability inserts 120a, 120b are present. Alternatively, embodiments are contemplated in which there is only one outer side (lateral) stability insert connected to or molded together with the rigid durometer portion.

[0032] Components not shown may be provided without departing from the spirit and scope of the present disclosure. It should be noted that the embodiments of the present disclosure have been described by way of illustration and not limitation. Alternative embodiments will be apparent to those skilled in the art that do not depart from its scope. Those skilled in the art can develop alternative means for implementing the improvements described above without departing from the scope of the present disclosure.

[0033] Certain features and sub - combinations are useful and can be used without reference to other features and sub - combinations, as will be understood to be contemplated within the scope of the claims.

[0034] The following lists the technical features described herein. [Technical Feature 1] In a footwear product, an upper, a heel region having a heel core and a heel circumference, a forefoot region, an inner side extending from the forefoot region to the heel region, an outer side extending from the forefoot region to the heel region, opposite the inner side and substantially parallel thereto, an outsole, and a dual - durometer midsole comprising a soft durometer portion positioned from the heel region to the forefoot region and a hard durometer portion positioned around the heel circumference. A footwear product characterized by having the above. [Technical Feature 2] The footwear product according to Technical Feature 1, further comprising an external heel counter molded on the hard durometer portion. [Technical Feature 3] The footwear product according to Technical Feature 2, wherein the external heel counter further includes a ridge. [Technical Feature 4] The footwear product according to Technical Feature 1, further comprising at least one stability insert positioned in the midfoot region on the outer side, inner side, or an intermediate of both sides of the footwear product. [Technical Feature 5] The footwear product according to Technical Feature 1, further comprising a support frame positioned between the heel region and the midfoot region. [Technical Feature 6] The footwear product according to technical feature 5, wherein the soft durometer part, the hard durometer part, the support frame, and the stability insert have thermoplastic materials of various hardnesses selected from the group consisting of ethylene vinyl acetate, polyurethane, and blends thereof. [Technical Feature 7] The footwear product according to technical feature 5, wherein the support frame forms an A shape. [Technical Feature 8] The footwear product according to technical feature 1, wherein the soft durometer part has a Shore C hardness between about 50 and 85. [Technical Feature 9] The footwear product according to technical feature 1, wherein the soft durometer part has an ethylene-vinyl acetate copolymer. [Technical Feature 10] The footwear product according to technical feature 1, wherein the hard durometer part has a Shore C hardness between about 60 and 95. [Technical Feature 11] The footwear product according to technical feature 1, wherein the hard durometer part has an ethylene vinyl acetate copolymer. [Technical Feature 12] The footwear product according to technical feature 12, wherein the stability insert is connected to the hard durometer part. [Technical Feature 13] In a footwear product, an upper, a heel region having a heel core and around the heel, a forefoot region, an inner side extending from the forefoot region to the heel region, an outer side extending from the forefoot region to the heel region, opposite the inner side and substantially parallel, an outsole, a dual durometer midsole comprising a soft durometer part positioned from the heel region to the forefoot region and a hard durometer part positioned around the heel circumference, A support frame positioned between the heel region and the midfoot region, and a stability insert positioned on the outer side, inner side, or both sides, characterized by a footwear product. [Technical Feature 14] The footwear product according to Technical Feature 13, wherein the soft durometer portion, the hard durometer portion, the support frame, and the stability insert are made of thermoplastic materials of various hardnesses selected from the group consisting of ethylene vinyl acetate, polyurethane, and blends thereof. [Technical Feature 15] The footwear product according to Technical Feature 13, wherein the soft durometer portion has a Shore C hardness between about 50 and 85. [Technical Feature 16] The footwear product according to Technical Feature 13, wherein the hard durometer portion has a Shore C hardness between about 60 and 95.

Explanation of Reference Signs

[0035] 10 Footwear product 15 Upper 20 Midsole 23 Gusset strip 25 Outsole 30 Heel region 40 Midfoot region 45 Forefoot region 50 Inner side 55 Outer side 60 Inner surface 65 Outer surface 70 Collar 85 External heel counter 87 Ridge 90 Lace 95 Traction element 110 Support frame 113 A-frame 114 Depression 115a Outer side leg 115b Inner side leg 117a Outer side depression 117b Inner side depression 120 Stability insert 120a Outer side stability insert 120b Inner side stability insert 125 Soft durometer portion 130 Hard durometer portion 140 Stability insert depression 150 Internal bridge section

Claims

1. In footwear products, Upper and a sole assembly coupled to the upper; The sole assembly is (i) a midsole including a soft durometer portion extending between a forefoot region and a heel region of the article of footwear and a hard durometer portion positioned in the heel region of the article of footwear, the midsole having a first recess extending in the hard durometer portion and a second recess extending in the soft durometer portion; (ii) an outsole attached or secured to the midsole, the outsole having an A-frame configured to support the heel and / or midfoot region of the footwear article, the A-frame having a set of lateral or medial side legs, the set of lateral or medial side legs having a first leg portion extending toward the heel region and a second leg portion extending away from the heel region, the first leg portion configured to extend along the first recess and the second leg portion configured to extend along the second recess.

2. The article of footwear of claim 1 , wherein the second recess is configured to extend through both the hard durometer portion and the soft durometer portion of the midsole.

3. The article of footwear of claim 1 , wherein the second recess is configured to extend along a portion of the hard durometer portion that contacts the soft durometer portion.

4. 2. The article of footwear of claim 1, wherein the second leg is configured to extend along or across both the hard durometer portion and the soft durometer portion of the midsole.

5. 10. The article of footwear of claim 1, wherein the A-frame is configured as a support frame having predetermined shape and geometric characteristics.

6. 2. The article of footwear of claim 1, wherein the A-frame is molded into or integrally formed as part of the outsole.

7. The article of footwear of claim 1 , wherein the A-frame is configured to extend along at least a portion of the midsole and / or the upper.

8. 2. The article of footwear of claim 1, wherein the A-frame is configured to extend upwardly from the outsole toward the midsole.

9. 2. The article of footwear of claim 1, wherein the A-frame is configured to extend upwardly from the midsole toward the upper.

10. 2. The article of footwear of claim 1, wherein the A-frame is configured to extend across both a medial side and a lateral side of the upper.

11. 10. The article of footwear of claim 1, wherein the A-frame has one or more sloping or angled sidewalls extending along the medial and lateral sides of the midsole and / or upper.

12. 2. The article of footwear of claim 1, wherein said first leg and said second leg are angled to form an opening in said A-frame.

13. 13. The article of footwear of claim 12, wherein the opening has a predetermined shape having fixed geometric characteristics.

14. 13. The article of footwear of claim 12, wherein the opening is positioned beneath an exterior heel counter of the article of footwear.

15. 15. The article of footwear of claim 14, wherein the A-frame is configured to extend beyond the lateral heel counter.

16. 10. The article of footwear of claim 1, further comprising a stability insert disposed along a medial side and / or a lateral side of the midfoot region.

17. 17. The article of footwear of claim 16, wherein the stability insert is positioned along the soft durometer portion of the midsole to reduce sidewall movement of the article of footwear during a golf swing.

18. 17. The article of footwear of claim 16, wherein the stability insert is bonded to at least one of the soft durometer portion and the hard durometer portion.

19. 17. The article of footwear of claim 16, wherein the stability insert comprises a lateral side stability insert and / or a medial side stability insert molded with a hard durometer portion.

20. 20. The article of footwear of claim 19, further comprising an interior or exterior bridge section connecting the lateral side stability insert, the medial side stability insert, and the hard durometer portion.

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