Adjustable shoe sole system and methods of use

Abstract

Embodiments disclosed herein relate to an adjustable footwear sole. The adjustable footwear sole may include a forefoot region with a length adjustable region and a width adjustable region. The adjustable footwear may include a heel portion having a length adjustable region. The forefoot portion may be configured to interlock with the heel portion.

Description

ADJUSTABLE SHOE SOLE SYSTEM AND METHODS OF USECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims benefit under 35 U.S.C. § 119(e) of U.S. provisional application serial number 63 / 465,538, filed May 11, 2023, the disclosure of which is incorporated herein by reference in its entirety.FIELD

[0002] The technical field relates to footwear soles and methods of construction of footwear soles.BACKGROUND

[0003] Shoe soles have been deployed in a wide array of designs to help provide foot protection, energy return, comfort, slip resistance, grip, safety, protection, aesthetics, and many other reasons. Creating soles that meet the needs of different foot shapes, lengths, widths and sizing is important.SUMMARY

[0004] In one embodiment, an adjustable footwear sole is provided, the adjustable footwear sole comprising: a forefoot portion with a length adjustable region and a width adjustable region, and a heel portion with a length adjustable region. The forefoot portion is configured to interlock with the heel portion, and the heel portion is configured to interlock with the forefoot portion to create a footwear sole of adjustable length, width, and outline shape.

[0005] In some embodiments, a method of fabricating an adjustable footwear sole, the footwear sole comprising a forefoot portion with a length adjustable region and a width adjustable region configured to interlock with a heel portion, and the heel portion with a length adjustable region configured to interlock with the forefoot portion is provided. The method comprising adjusting the forefoot portion in length, width, and / or outline shape by altering of the forefoot adjustable region through removal of material to make the region smaller or creation of a gap to expand the region; and interlocking the forefoot portion andthe heel portion together to create a sole adjusted in length, width and shape that is ready for use in footwear fabrication.

[0006] An adjustable shoe sole is provided, the adjustable shoe sole comprising a forefoot portion and a heel portion which may be assembled together to provide custom sole length, width, last bottom shape, water drainage, and medial / lateral heel cushion support levels.

[0007] A method of fabricating an adjustable shoe sole to meet the requirements of sole length, width, last bottom shape, water drainage, and medial lateral heel cushion support levels is provided. The method comprising the alteration in width, length, and last bottom shape of the forefoot portion, the alteration in width, length, and last bottom shape of the heel portion, assembly of the forefoot portion to the heel portion, election of a closed or open water drain port, and election of filled or open heel cushion medial and lateral cavities.

[0008] A method of customizing a shoe sole to the length, width, and shape of an individual user’s foot, while also adjusting to meet their personal needs for water drainage and heel cushion characteristics is provided.

[0009] It should be appreciated that the foregoing concepts, and additional concepts discussed below, may be arranged in any suitable combination, as the present disclosure is not limited in this respect. Further, other advantages and novel features of the present disclosure will become apparent from the following detailed description of various nonlimiting embodiments when considered in conjunction with the accompanying figures.BRIEF DESCRIPTION OF DRAWINGS

[0010] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:

[0011] Figure 1 A shows a bottom view of an adjustable sole unit in an assembled state;

[0012] Figure IB shows a top view of an adjustable sole unit in an assembled state;

[0013] Figure 1C shows a cross-section view along the midline of a water drain port;

[0014] Figure ID is a side view of an adjustable sole unit in an assembled state;

[0015] Figure IE is a cross-section view of an adjustable sole unit down the long midline;

[0016] Figure 2 shows an overlapping silhouette top view of the perimeter of adjustable sole;

[0017] Figure 3A shows an adjustable sole with a trim outline in top view;

[0018] Figure 3B shows an adjustable sole with a trim outline in top view;

[0019] Figure 4A shows an adjustable sole in perspective view;

[0020] Figure 4B shows an adjustable sole in an exploded perspective view;

[0021] Figure 5A shows a top exploded view of a heel portion of an adjustable sole;

[0022] Figure 5B shows a top exploded view of a forefoot portion of an adjustable sole;

[0023] Figure 5C shows a side view of an assembled adjustable sole;

[0024] Figure 5D shows a top view of an adjustable sole;

[0025] Figure 5E shows a side view of an assembled adjustable sole;

[0026] Figure 5F shows a top view of an adjustable sole;

[0027] Figure 6 shows an exemplary method of forming a footwear using an adjustable sole; and

[0028] Figure 7 shows an exemplary method of forming a footwear using an adjustable sole.DETAIEED DESCRIPTION

[0029] Footwear Sizing: Feet have a wide range of morphologies and represent a continuum of shapes and sizes from small children’s feet to larger adult feet. It is common for commercial shoe makers to include a broad number of sizes in their production and inventory for each of their shoe styles. For example, common athletic shoes for women cover size 5 through 11 in half sizes and sizes 12 to 14 in whole sizes; and for men in halfsizes from 7 to 12 and whole sizes in 13 through 16. This implies approximately 12 to 17 sizes each for men’s and women’s shoes. If shoe brands offer multiple widths, it requires proportionately more sizes. Thus if the shoes are offered in standard width (D), Narrow (C), and one or more sizes of Wide (E, EE, 4E, 6E, 8E) - this multiplies the number of sizes more than 3-fold to 45+. This represents a financial burden for tooling, returns and inventory for the manufacturer as well as the distributor and retailer.

[0030] The limits of shoe sizing: Even shoes offered in multiple sizes and multiple widths do not address variations in foot shape - such as arch height, instep height, toe length difference medial / lateral, foot deformities such as calluses, bunions, Charco Marie Tooth deformities and amputations. Nor do the multiple sizes reflect variations in the flexibility of the foot, foot pain areas, edema, changes in edema throughout the day, foot ulcers, partial foot amputations, ankle stability / instability and requirements for managing these differences in how feet move within footwear. The consumer is therefore forced to compare different brands and different models of shoes in hopes of using trial and error to find a brand, model, and size that best fits their foot size, shape, flexibility and other needs.

[0031] Footwear Last and Sole Size Grading: Footwear bodies are designed around the shape of a shoe last. Uppers are attached to the sole to create a volume for the foot. To establish a range of sizes - a process and method called “grading” enables a footwear manufacturer to establish a range of last sizes and sole dimensions. “Grading” is often done by a relatively few number of people worldwide. This use of a limited number of grading specialists creates an artificial standard-like environment to help make sizing more predictable and to ensure consumers who purchase shoes have the highest likelihood of a predictable purchase with minimal returns because the shoe “ran large” or “ran small”. There is no generally accepted shoe size standards, though, because length and width do not have the ability to clarify the three-dimensional shape. At best, some brands develop a reputation for their fit. Some brands are known to be narrow versus some more wide.

[0032] Quarter Sizing and Similar Techniques: To help minimize the tooling requirement and mold cost and inventory, while at the same time offer a broad range of shoe sizes and widths, shoe makers sometimes use a technique called quarter sizing to enable a single last and sole to service both a whole size and half size. This technique is also commonly used in shoe widths, in which one sole is paired with two uppers to enable different volumes of the shoe to get two or more widths from each sole. These techniques, however, are emblematic of a key problem in the industry, footwear sizes rarely fit any one person’s foot shape perfectly, they are an attempt to cover a range of foot sizes and morphologies such that as many sizes and shapes can fit within a given number of inventoried sizes and widths.

[0033] Custom Footwear: There are several methods of creating ‘custom’ footwear. 1) “Custom Material Choices” is a new approach that leverages e-commerce to enable consumers to choose or create graphic styles for the materials that will be used to constructtheir footwear. In this way, standard patterns are used to create a known and pre-established design, but with a consumer’s preferred footwear body materials. For example, if a consumer wanted a blue toe box and a purple heel counter - the e-commerce system would facilitate that, the materials would be cut to the pre-established pattern, the shoes made and shipped to the user. There is no custom fit - only custom material choices. 2) “Custom Made- Simple” is another approach where the manufacturer invites precise foot length and width measures, and then chooses a last that is the best fit. This approach can be combined with a (1) above to also offer custom material choices. This approach, however, does not create a new set of lasts or patterns - and simply uses conventional lasts and patterns. This approach is limited to the variety of lasts available to the purveyor. In evaluating such companies, however, their response to a request for a custom shoe for an individual with a size 10 Extra Wide feet was to ship a size 12 shoe - because they did not choose to make or find a last that matched the 10 Extra Wide. 3) “Custom Made - Complex” is an approach in which a user’s foot is translated to create a custom last to represent the foot. In this approach, well-trained cobblers make each component separately and assemble them by hand. This often results in wellfitting shoes or boots, but because of the manufacturing technique, these often result in shoes that have an old-fashioned appearance and often cost 2 to 10 times more than conventional shoes.

[0034] Key Problems and Unmet Needs: There are many variables in foot size, shape, flexibility, movement and deformity. Looking at the practice of the largest global footwear manufacturers, they frequently offer 15 sizes in a single width for mens and the same for womens sizes. Such conventional shoe making does not accommodate all the spectrum of people and their needs. Companies that choose to offer multiple widths create augmented costs of tooling, fabrication, inventory, logistics, shelf-space, and management - driving up costs and still do not address the complex and varied range of foot shapes, dynamic movements, and needs. Because of these facts, approximately 1 in 5 shoes purchased at various retailers is returned because of poor fit and many consumers complain that their foot pain is hurting them.

[0035] Diabetic shoes are often offered in 18+ sizes and 4+ widths for men and the same for women’s sizes. This leads to an inventory of 60 or more sizes.

[0036] Differences in ambulation: People have different morphologies, and they also have different gait characteristics. Two people with identically shaped feet can require different performance soles.

[0037] Differences in terrain, weather and wetness. People who walk in dry arid climates will have different needs than those in wet jungle climates.

[0038] 3D printing concerns: There is a new trend toward using 3D printing for the creation of shoe soles and uppers. These techniques have the opportunity to create precisely sized components to optimize fit. Unfortunately, these methods have a high cost, the polyurethanes employed are frequently heavy and weigh more than a similar EVA foam sole. The manufacturing process can also have a high demand for energy consumption and can drive a higher carbon footprint.

[0039] Opportunities for Innovation: Conventional footwear design is linked to the shoe last. The last shape drives the sole shape and footwear body (upper) shape. It is possible to design footwear for multiple size feet.

[0040] Conventional shoe making techniques are typically limited to 15 sizes for men and women each. While some companies offer multiple widths, it requires trial and error to find footwear that fits. This approach has a high cost of tooling, inventory, management, and logistical planning. Lack of cross-brand size standards leads to frequent returns of purchased footwear, often cited as high as 1 in 5 pairs being returned. The current state of 3D printing limits its ability to help, because the available materials often create soles that are much heavier and expensive than their foam counterparts. There is significant room for innovation. A preferred embodiment is described that uses multi-component soles to enable precise fit with lower tooling, lower inventory, lower logistics, and lower return requirements.

[0041] Applicability to Exoskeleton Footwear: Such a configurable sized shoe can also be an excellent candidate for integration with semi-rigid support elements. This includes the ability to build-in ankle braces, ankle-foot orthoses, lower limb exoskeletons and other elements.

[0042] Inclusion of Carbon Plates: Carbon fiber or similar semi-rigid elastic plates may be incorporated into the footwear in order to improve energy return during ambulation. In some embodiments, a single carbon fiber or similar semi-rigid elastic plate for the smallest of the size range may be used across an whole size range of a given set of sole tooling. In some embodiments, multiple sizes of carbon fiber or similar semi-rigid elastic plate.

[0043] Combination of Carbon Plates with Exoskeletons: Carbon fiber or similar semi-rigid elastic midsole plates can offer improved energy return to users. Lower limb passive exoskeletons can also improve energy return. Combining a carbon fiber plate with apassive lower limb exoskeleton is believed to have synergistic benefits. This is because a lower limb exoskeleton can induce torque into the base of the exoskeleton during dorsiflexion. That torque is delivered to the ground through the sole. Including a carbon fiber plate extends the moment arm of the exoskeleton and allows the energy return to be delivered over a longer time of the gait, improving energy delivery during ambulation.

[0044] Makers of footwear may desire to create footwear to provide their customers with a wide assortment of shoe lengths and widths for men and for women while also desiring to limit the amount of manufacturing equipment, molds, tools, inventory, bill-of- material items, and other expenses that drive the initial and variable costs of producing a line of footwear.

[0045] Makers of footwear may desire to create footwear to provide their customers with a shoe that matches the length, width, and last shape of that particular customer’s foot while also minimizing the time, effort and expense of making something from scratch, or sacrificing comfort by not having the exact sole length, width and last bottom shape required for that customer.

[0046] Makers of footwear may desire to offer a line of shoes with a given characteristic of heel cushioning while also desiring to avoid the cost and complexity of stocking different molds, tools, inventory and equipment for each variation of performance.

[0047] Makers of footwear may desire to create footwear to provide their customers with a shoe that has heel cushioning available in different levels of support and different bias between medial and lateral firmness to match customers ambulation performance and activity type while also minimizing the time, effort and expense of making something from scratch, or sacrificing comfort by not having the exact sole heel cushion required for that customer.

[0048] Makers of footwear may wish to provide their customers with an option for a water drain port from the shoe sole while not mandating that every user have that drain port, and while minimizing costs. Customers of footwear may wish to purchase footwear that has an optional drain port that would provide them with the ability through the use of a drill, awl, needle, hot nail or other such device to create a drain port when they know that the environment, they will be traveling in has significant risk for water coming over the tops of their shoes which must escape.

[0049] In view of the above, an adjustable shoe sole is provided. In some embodiments, physical characteristics of the sole, such as length, width, and last shape of thesole, may be modifiable to fit a specific user’s foot. In some embodiments, and adjustable shoe sole may include a variety of heel cushion options. In some embodiments, the adjustable sole may include a water port to allow for draining of water from the shoe. In some embodiments, the water port may be selectively openable by the user. In some embodiments, the water port may be selectively openable and closeable by the user.

[0050] In some embodiments, the adjustable sole may include a forefoot portion, a heel portion, regions for material removal to adjust length, width and shape. Additionally, or in the alternative, the adjustable sole may include regions for in-fill to adjust heel cushion. Additionally, or in the alternative, the adjustable sole may include regions for penetration by a user for water drainage.

[0051] The term Last refers to a device to help footwear designers and manufacturers to specify the shape of the empty volume so that it fits a given range of foot sizes or the foot of a particular user. The same shape last is typically used in design and manufacturing. The shape of the last drives the shape of the uppers as well as the shape of the top of the sole. Thus, it is hard to find a footwear manufacturing process that does not rely upon lasts.

[0052] The term Last Bottom Shape refers to the process of shoe making where the bottom of the last creates a silhouette shape with contours of the bottom of the last. This is called the last-bottom shape. In the industry, this is commonly provided as a last bottom paper for tracing. Insoles are often designed to the last bottom shape.

[0053] The term Footwear Body refers to the aspect of footwear for holding the foot, while maintaining the proximity of the sole to the foot. It may also provide many other features - including more aggressive heel lock-down and forefoot lockdown, abrasion protection, stabilization, aesthetics, energy return, aesthetics, branding, and comfort management of temperature, softness and moisture. In sandals - the footwear body may consist only of a strap or two. In boots and hightops - the footwear body may cover the whole foot as well as part of the lower leg.

[0054] Soles are generally disposed along the bottom surface of the foot and may sometimes wrap around and up the vertical aspects of footwear as well as the toe cap. Soles are designed to match the size and shape of a given shoe last. Soles typically include ground contact surface, typically known as an outsole, a foot contact surface, typically known as an insole, and a middle layer to provide cushion, foot positioning, dynamic gait stability, energy return, and shock isolation, known as a midsole. Soles are therefore a system of multipledesign aspects, typically comprising multiple components. Collectively, they are designed and manufactured to optimize performance for a given use case.

[0055] Turning to the figures, specific non-limiting embodiments are described in further detail. It should be understood that the various systems, components, features, and methods described relative to these embodiments may be used either individually and / or in any desired combination as the disclosure is not limited to only the specific embodiments described herein.

[0056] Figures 1A-E show an adjustable sole system according to an embodiment. The adjustable sole may be adjusted for length, width, last bottom shape, and heel cushion quality. In some embodiments, a user may elect to open a drain port for their own situational requirements. Each adjustable sole unit can span a variety of shoe sizes. For example, an adjustable sole unit may be configured such that when it is assembled, without any material removal, it would be equivalent to a US men’s shoe size of 10.5 with EE width. By material removal, that same unit may be trimmed down and assembled to a US men’s shoe size of 9 with D width. The heel cushion may be altered by filling-in the adjustable cushion cavities to provide augmented stiffness beyond the stiffness created by the empty cavities. In-fill material may include foam, solid materials, metal, or any other suitable material or combination of materials. In some embodiments, the infill material may be inserts pre-shaped reciprocally to the shape of the open volume. In some embodiments, the infill material may be fluid in nature and injected into the cavities and allowed to harden. In-fill can be done symmetric between medial and lateral, or it can augment one more than the other to provide improved dynamics for the user.

[0057] An adjustable sole unit 100 is shown assembled. Forefoot portion 101 may be assembled to a heel portion 102. A parting line 103 becomes visible between the two components. In some embodiments, indicia may be included on forefoot portion 101 and / or heel portion 102 to identify length adjustable regions 112. In some embodiments, the length adjustable regions may be left untouched. When left untouched, the sole may be assembled at a baseline size, for example a Men’s 10.5 with EE width.

[0058] Forefoot portion 101 may be assembled to heel portion 102 using any suitable fastener. Such a suitable fastener may include adhesives, glues, bonding agents and other similar approaches. These agents could be applied between the components and or applied to a layered material such as a rubber outsole below them as yet another means of strengthening the bond. The agents could be applied on top of the components, for example to a carbonfiber plate that spans both objects, further strengthening the assembly strength. Forefoot portion 101 may interlock with heel portion 102.

[0059] In some embodiments, material may be removed from the length adjustable regions 112 prior to assembly. When the unit 100 is assembled with shortened length adjustable regions, the unit 100 may have a different length after assembly. If a gap is left between length adjustable regions on the forefoot portion and length adjustable regions on the heel region, or material is added to the length adjustable regions prior to assembly, the unit 100 may have a different length after assembly.

[0060] In some embodiments, material may be removed from the width adjustable region 113 prior to assembly. When the unit is assembled with narrowed adjustable width region 113, it may have a different width and contour shape after assembly. If a gap is created or material is added to the width adjustable region 113 prior to assembly, the unit 100 may have a different width and contour shape after assembly.

[0061] In some embodiments, heel cushion cavities 111 may be provided allow for adjustment of heel cushion properties of the sole. The heel cushion cavities 111 may be filled with materials to alter the cushion characteristics of the heel. In some embodiments, different filling materials may be used to alter stiffness of the heel cushioning. For instance, filling the cavities with harder durometer materials may increase the stiffness of the heel cushioning experienced by a user when the user is wearing the footwear and walking. Leaving the heel cushion cavities empty may maintain the same stiffness. Filling the medial and lateral cavities with different materials, or filling one cavity and not the other may create a difference in medial / lateral cushion qualities to a user who is wearing the footwear and walking or otherwise ambulating in them.

[0062] In some embodiments, flex grooves 105 are provided. Flex grooves 105 may be connected via a connector 106 to provide an opportunity for water to move between the flex grooves. The adjustable sole unit 100 may include a water receiving area 107 to provide a volume of space for water to be held if a user of the footwear gets their footwear wet. The adjustable sole unit 100 may include a detent 109 on the exterior portion of the sole adjacent to the water receiving area 107 to provide a guide for a user to penetrate the sidewall of the sole unit 100. The user may use a drill, needle, knife, hot nail or other suitable tool to penetrate between the detent 109 and the water receiving area 107. Such a configuration may allow for a user to configure their shoes for very wet environments.

[0063] Figure 2 shows an overlapping silhouette top view of a perimeter of an adjustable sole 200 according to an embodiment. When no material is removed from the adjustable regions 112, the adjustable sole stays larger than when material is removed from the adjustable regions 112. This is shown by larger size rendering 201 compared to smaller size rendering 202.

[0064] Figure 3 A shows an adjustable sole forefoot portion 301 according to an embodiment. In some embodiments, material may be removed from adjustable region 305 by trimming along a portion of the adjustable region, such as along trim outline 302. Removal of material is depicted by removed volume 303. This results in an outline width and shape of the width being altered to the post-trim outline 304 represented by a dashed line. This can be compared to other approaches to removing material in Figure 3B from adjustable region 305. In Figure 3B, the adjustable region 305 is trimmed along trim outline 306 to remove more material as depicted in removed material 307. This results in a sole forefoot outline width and shape being altered to the post-trim outline 308 represented by dashed line.

[0065] Figure 4A shows an adjustable sole in perspective view with the adjustable sole in an assembled configuration according to an embodiment. Adjustable sole 400 may include forefoot portion 401 and heel portion 402. A spring plate 405 may be positioned in forefoot portion 401. Spring plate 405 may be of stiff materials of plastic, carbon fiber, urethane or a broad array of other suitable materials that have an ability to store elastic potential energy when bent. Spring plate 405 may be disposed within forefoot portion or it may span across forefoot portion 401 and heel portion 402.

[0066] Figure 4B shows an adjustable sole in an exploded perspective view identifying how forefoot portion 401 is able to interlock with heel portion 402. An outward tab 403 of forefoot portion 401 may be assembled by fitting within an inward recess 404 of heel portion 402. Outward tab 403 may be assembled to inward recess 404. Each of forefoot portion 401 and heel portion 402 have adjustable regions 407. Adjustable regions 407 may be marked by indicia lines 406. Material may be removed from the adjustable regions 407 to change the length of the sole 400 when assembled.

[0067] Figure 5A shows a top exploded view of a heel portion 502 of an adjustable sole according to an embodiment. Figure 5B shows a top exploded view of a forefoot portion 501 of an adjustable sole according to an embodiment. In some embodiments, indicia 503 may be included for denoting trimming guidance for length adjustable area 504. Width and shape adjustable portion region may be created in this embodiment with an existing gap to simplify the choice of reducing width by trimming, or augmenting width by augmenting thegap between medial and lateral sides of the gap, or adding material to augment the gap between medial and lateral sides of the gap. These processes of trimming and augmenting may also vary the outline shape of the width.

[0068] Figure 5C shows a side view of assembled adjustable sole 500 according to an embodiment. Forefoot portion 501 may be assembled to heel portion 502 to create a shortened length. Heel outward tab 515 may be inserted into reciprocal volume 516 in forefoot 501 shown in Figure 5D.

[0069] Figure 5E shows a side view of assembled adjustable sole 509. Forefoot portion 501 may be assembled to heel portion 502 without trimming to maintain a longer length as compared to adjustable sole 500. Heel outward tab 515 inserts into reciprocal volume 516 in forefoot 50, as shown in Figure 5F.

[0070] Figure 6 is a description of a method that may be used to manufacture a footwear. This may include measuring a foot of a user at 600. Measuring the foot may be done using any suitable measuring device, such as a 3D image scanner or a Brannock device.

[0071] This method may also include procuring the various footwear components at 602. Such components may include adjustable sole elements and / or a footwear upper. In some embodiments, the components may also include an exoskeleton, a heel cup, footwear closures, footwear stiffeners, and / or logos.

[0072] This method may also include setting the length and width of the sole elements at 604. Setting the length and width of sole elements may include arranging the components to the size of the intended user’ s feet. This may be facilitated by the foot measurements, foot scan, a model of the user’s foot, or even the user’s fee. This may require the components being trimmed to fit, and / or may require to add gap filler.

[0073] This method may also include securing the sole elements in the desired locations relative to each other at 606. Securing the sole elements may be accomplished using any suitable fastening means, such as adhesive between the sole element, hook and loop between the elements, adhering a Strobel across the elements, adhering a heel cup or exoskeleton across the elements, adhering outsole patches across the sole elements, and / or any other fastening means or combination of fastening means between or across the sole elements.

[0074] This method may also include securing additional components to the sole elements at 608. Such additional components may include a heel cup, a sole shank, an exoskeleton, and / or any other suitable additional component.

[0075] This method may also include securing an upper of the footwear to the sole elements at 610. The upper may be secured using any suitable fastening means, such as adhesive, hook and loop, chemical bonding, welding, fasteners and / or other fastening means or combination of fastening means. In some embodiments, the upper may be selected at a matching size to the sole elements. In some embodiments, an adjustable upper may be employed. Such an adjustable upper may be prepared to attain proper length and width as part of securement to lock in a given size.

[0076] This method may also include allowing for additional adjustment and / or detaching of sole elements and / or upper sizing at 612. Such additional adjustment and / or detaching may be accomplished via the use of any suitable adjustable and or removable fastening means (e.g., hook and loop fasteners). Such additional adjustment and / or detaching may allow for resizing of the footwear (e.g. for a new user, or as a user grow), and / or may allow for separation of footwear components for reuse or recycling.

[0077] Figure 7 is a description of a method that may be used to adjust an adjustable sole unit.

[0078] One step may include establishing the target shoe length, width and last bottom shape at 700. - For example by referring to a last bottom paper or for a bespoke fitting, or by measuring a user’ s foot with a measuring instrument, a 3D image scanner or a Brannock device.

[0079] One step may include establishing whether the heel cushion is desired to be made more stiff in medial, lateral, or both sides, and, if so, how much more stiff at 702.

[0080] One step may include trimming the length of the forefoot portion and heel portion to match the desired length of the sole elements at 704.

[0081] One step may include trimming the width of the forefoot portion according to the desired forefoot shape to match the desired width and shape of the last bottom paper or user’s foot measurements at 706.

[0082] One step may include securing the forefoot portion to the heel portion using any suitable means, such as an adhesive to bond mating surfaces at 708.

[0083] One step may include to filling-in medial and lateral heel cavities as desired to achieve the desired stiffness on medial and or lateral sides of the heel at 710.

[0084] One step may include further securing the sole through the remaining fabrication of the footwear, in which the attachment of the outsole to the bottom surface of the adjustable sole and the footwear upper to the top surface of the sole creates additional securement of the forefoot portion to the heel portion 712.

[0085] One step may include opening the drain port of the footwear if so desired by creating an orifice at the water drain detent at 714.

[0086] The embodiments described herein may be embodied as a method. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments.

[0087] While the present teachings have been described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments or examples. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art. Accordingly, the foregoing description and drawings are by way of example only.

Claims

CLAIMSWhat is claimed is:

1. An adjustable footwear sole comprising: a forefoot portion with a length adjustable region and a width adjustable region; and a heel portion with a length adjustable region; wherein the forefoot portion is configured to interlock with the heel portion, and the heel portion is configured to interlock with the forefoot portion to create a footwear sole of adjustable length, width, and outline shape.

2. The adjustable footwear sole of claim 1, wherein the heel portion has a medial and a lateral cavity, amenable for receiving materials of various stiffness to alter the stiffness characteristics and symmetry of the cushion characteristics of the heel portion.

3. A method of fabricating an adjustable footwear sole, wherein the footwear sole comprises a forefoot portion with a length adjustable region and a width adjustable region configured to interlock with a heel portion, and the heel portion with a length adjustable region configured to interlock with the forefoot portion, the method comprising: adjusting the forefoot portion in length, width, and / or outline shape by altering of the forefoot adjustable region through removal of material to make the region smaller or creation of a gap to expand the region; and interlocking the forefoot portion and the heel portion together to create a sole adjusted in length, width and shape that is ready for use in footwear fabrication.

4. The method of claim 3, further comprising adjusting the heel portion in length, width, and outline shape by altering of the heel adjustable region through removal of material to make the region smaller or creation of a gap to expand the region.

5. A footwear sole with an exterior detent on the sidewall of a sole adjacent to an internal empty volume to enable a user of the footwear to selectively create an orifice through the detent to breach the sidewall of the sole and provide a water drain.

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