Multilayer midsole structure for footwear

Abstract

A footwear, particularly a sports, hiking, mountaineering, hunting, and / or work footwear, comprising an upper (20) and a sole assembly (12), wherein the sole assembly (12) comprises a tread (14), configured to be in contact with the ground while the footwear is in use, and a midsole assembly (10), placed superior to the tread (14). The midsole assembly (10) has an inner shaped layer (11), made of plastic material, fiberglass, and / or carbon fiber, and two outer layers (120, 121), placed on opposite sides of the inner shaped layer (11) and made of cushioning materials, such as polyurethane, polyurethane foam, and / or EVA.

Description

[0001] MULTILAYER MIDSOLE STRUCTURE FOR FOOTWEAR

[0002] The present invention generally relates to footwear comprising a sole assembly that comprises a tread or outsole, a midsole assembly, and an insole.

[0003] In particular, the midsole assembly comprises a central shaped layer made of plastic material, such as a polypropylene copolymer and / or glass fibers and / or carbon fibers, along with additional upper and lower layers made of polyurethane or EVA. This configuration enhances both the rigidity effect and the cushioning effect of the footwear.

[0004] Field of the invention

[0005] The invention falls within the technical field of footwear, specifically in the field of components that make up the midsole assemblies of footwear.

[0006] More particularly, the invention relates to a midsole assembly that can be used, for example, in sports or trekking footwears, hunting or mountain boots, and work and / or safety footwear.

[0007] Prior art

[0008] Footwear generally presents soles or sole assemblies with different characteristics depending on their use, cost, and type.

[0009] It is well known that a sole assembly, particularly one for sports, trekking, mountain, hunting, or work footwear, consists of one or more components. Each individual component may, in turn, be composed of one or more layers.

[0010] As previously mentioned, a traditional sole assembly for sports, trekking, mountain, hunting, and / or work footwear typically includes a tread or outsole, a midsole assembly, and an insole.

[0011] More specifically, the tread is the outermost component of the sole, which comes into contact with the ground during use, while the insole is the innermost component, which comes into contact with the wearer's foot or with removable cleaning insoles (commonly known as "fussbett"). The midsole assembly is the component positioned between the tread and the insole.

[0012] The various components of the midsole assembly can be connected in different ways, depending on the type of footwear and the manufacturing process used. In some embodiments, certain components of the midsole assembly are irreversibly connected to each other and may be integrated into the rest of the footwear.

[0013] In other embodiments, the tread and midsole assembly may be irreversibly connected, while the cleaning insole can be inserted and removed from the footwear as needed, depending on the preferences of the user and / or manufacturer.

[0014] In some cases, the tread and midsole assembly can also be manufactured as a single piece using the latest molding technologies, such as 3D printing. In this case, an insole is then attached or simply placed on top. Regardless of the specific configuration, the upper is subsequently mounted onto the insole, and the midsole assembly is then attached to the upper, which is already fitted with the insole.

[0015] Some existing insoles are designed to enhance specific functionalities of the footwear, such as cushioning and / or rigidity while various types of connections can be used between the upper and the insole, as well as between the upper, the midsole assembly, and the tread, depending on the shape and characteristics of the footwear.

[0016] In particular, attached figure 1 shows an exploded view of a traditional trekking footwear.

[0017] In this figure 1 , it can be seen how the upper 20 of the footwear is mounted directly onto the sole assembly 12, which in turn includes a tread 14 and a midsole assembly 10.

[0018] The tread 14 is assembled with the midsole assembly 10, and the upper 20 is mounted directly onto the sole assembly 12. In the case of the trekking footwear in figure 1 , there is also a heel insert 17 as support for the crampon lever, which is glued, at a rear portion of the footwear, on top of the sole assembly 12.

[0019] However, market demands require footwear with increasingly better characteristics and functionalities, offering greater comfort and safety for users while ensuring high performance.

[0020] For these reasons, all footwear components are subject to continuous research and improvements to provide users with ever-better products.

[0021] In this perspective, especially for sports, trekking, mountain, hunting, and work footwear, it is necessary to find solutions that enhance certain structural features of the footwear, particularly those of the sole assembly and / or the midsole assembly. In fact, it is now well known how analyses and studies are continually carried out to improve the characteristics of sole and midsole assemblies, through modification or improvement of each of their components, in order to achieve greater rigidity, cushioning, waterproofing, etc.

[0022] Consider, for example, a user who has the intention of purchasing sports and, in particular, hiking footwear.

[0023] Such a user will compare different footwear so as to identify the one that is the most comfortable, durable, long-lasting, and has the best shock-absorbing characteristics, so as to maintain optimal comfort at all times, even after long use of the footwear.

[0024] Therefore, it is likely to buy the footwear that has better features of the sole and midsole assembly, particularly with respect to waterproofing and cushioning.

[0025] Therefore, there is a need to realize footwear having a sole assembly and midsole assembly with increasingly better features and functionality, especially from the point of view of stiffness, cushioning, and shock absorption during walking.

[0026] In the following description, reference will be made to a sole assembly and a midsole assembly of a generic footwear, with a focus on sports footwear, particularly hiking, mountain, hunting, and / or working footwear.

[0027] Aim of the invention

[0028] Thus, the aim of the present invention is to provide a sole and midsole assembly for footwear that can overcome the above-mentioned limitations.

[0029] Another aim of the present invention is to make a midsole assembly for footwear that increases the functionality, comfort, and cushioning of footwear, particularly sports, hiking, mountaineering, hunting, and working footwear.

[0030] Another aim of the present invention is to make a midsole assembly for footwear that increases comfort, stiffness and anti-shock function in certain parts of the user's foot, such as at the heel and / or metatarsal.

[0031] Further aim of the present invention is to make a footwear midsole assembly that increases the stability of the footwear.

[0032] Further aim of the present invention is to provide a sole and midsole assembly for footwear that is economical and simple to make by virtue of the advantages achieved. These and other aims are achieved by a footwear, particularly sports, hiking, mountaineering, hunting and / or working footwear, comprising a midsole assembly according to the attached independent claim.

[0033] Further detailed technical characteristics are given in the attached dependent claims.

[0034] Brief description of the figures

[0035] The present invention will now be described, by way of illustration but not limitation, according to some of its preferred forms of embodiment, and with the aid of the appended figures, in which:

[0036] - figure 1 is an exploded view of a footwear according to the prior known art;

[0037] - figure 2 is a side view of a first embodiment form of a footwear sole assembly according to the present invention;

[0038] - figure 2A is a cross-sectional view of the sole assembly referred to in figure 2, according to the present invention;

[0039] - figure 3 is a side view of another embodiment form of the footwear sole assembly, according to the present invention;

[0040] - figure 4 is an exploded view of a further embodiment shape of a footwear sole assembly, according to the present invention;

[0041] - figure 4A is a cross-sectional view of the sole assembly in figure 4, according to the present invention;

[0042] - figures 5 and 6 are side views of further realizable shapes of a sole assembly for footwear, according to the present invention.

[0043] Detailed description

[0044] The attached figures show preferred embodiments of a midsole assembly 10 to be assembled on an upper and forming part of a sole assembly 12 of a footwear, particularly a sports, hiking, mountaineering, hunting, and / or work footwear.

[0045] Sole assembly 12 comprises a tread 14, intended to contact the ground, an eventual shaped insert 16, placed in contact with tread 14 at the heel of the user of the footwear, a midsole assembly 10, placed superior to tread 14 and to the eventual insert 16 and on the opposite side with respect to the ground, and an eventual insole 19, placed superior to midsole assembly 10 i.e., toward the sole of the user's foot.

[0046] The midsole assembly 10 presents an inner layer 11 appropriately shaped to follow the shapes of the midsole assembly 10 of which it is a part; the inner layer 11 is responsible for the rigidity of the midsole assembly 10 and includes an upper surface 101 (that facing the user's foot) and a lower surface 102 (that facing the tread 14 and thus toward the ground).

[0047] In a particular embodiment, the inner layer 11 is configured to be totally or partially present along the entire extent of the midsole assembly 10 and, appropriately, the inner layer 11 is visible at least along the lateral portions of the midsole assembly 10.

[0048] In particular embodiments, the inner layer 11 is visible, on the outside of the footwear, along the entire perimeter of the midsole assembly 10 or along the entire perimeter of the midsole assembly 10 excluding a front area, corresponding to the tip of the footwear, and / or a back area, corresponding to the heel of the footwear.

[0049] The perimeter of midsole assembly 10 is defined as the entire outer contour of midsole assembly 10.

[0050] Advantageously, the inner layer 11 is arranged to partially or totally follow the shapes of the layers 120, 121 of the midsole assembly 10.

[0051] The aforesaid layers 120, 121 are placed, immediately and in contact, in upper and lower positions namely on either side, with respect to the inner layer 11 .

[0052] Advantageously, the layers 120 and 121 are suitable for improving the cushioning function of the footwear, and the inner layer 11 rests on the entire surface of at least one of the said layers 120, 121 .

[0053] Advantageously, layers 120, 121 are made from the same material while layer 11 is made from a different material, and the material from which inner layer 11 is made has greater stiffness than the material from which layers 120, 121 are made.

[0054] The material of layers 120, 121 is a shock-absorbing material and still more shock-absorbing than layer 11 and allows for complete cushioning of the entire footwear as well as the adaptation of the tread caps with respect to the ground during walking.

[0055] Advantageously, with the embodiments described above, it is therefore possible to make footwear having greater stability than conventional footwear.

[0056] Moreover, such realization forms allow for greater stiffness over the entire midsole and sole assembly (including near the perimeter) and not only over the central portion as is the case in some solutions of the prior art.

[0057] These aspects are remarkably relevant, particularly referring to trekking and / or mountain footwear, as the sole assembly demonstrates excellent performance and results even in those cases where walking takes place on slopes or steep terrain.

[0058] In fact, since stiffness and stability are equally present at every point of the sole assembly, these characteristics confer the aforementioned advantages to the footwear for any type of ground and terrain.

[0059] Advantageously, the increased stability of the sole assembly is also ensured by the fact that the inner layer 11 has greater contact with the ground and a center of gravity closer to the ground than known solutions.

[0060] In particular, unlike the known solutions in which a rigid layer can be interposed between the upper and the midsole, according to the present invention, the more rigid layer 11 is included within the midsole assembly 10 and particularly between layers 120 and 121.

[0061] In this way, the rigid layer 11 is obviously placed closer to the ground, lowering the footwear's center of gravity and increasing its contact with the ground.

[0062] Similarly, according to the invention, user comfort is also increased because there is a cushioning layer between the foot and the inner layer 11 that is not present in traditional footwear.

[0063] Appropriately, rigid layer 11 has a higher stiffness than layers 120 and 121 .

[0064] In a preferred embodiment, rigid layer 11 presents stiffness between values 80-100 on the Shore D scale, while layers 120 and 121 present stiffness between values 40-70 on the Shore A scale.

[0065] In a further preferred embodiment form, rigid layer 11 has a stiffness of, for example, a value of 90 on the Shore D scale while layers 120 and 121 have stiffnesses between values 50-55 on the Shore A scale.

[0066] In a particular embodiment, the inner layer 11 has a differentiated thickness from one area to another of the midsole assembly 10 and may have a portion with a greater thickness than the others, preferably at the heel of the footwear; this aspect allows the stability and structure of the entire sole assembly 12 to be increased in the rear portion of the footwear.

[0067] Analogously, insert 16, which is present in a position immediately below layer 120, can either consist of a single element (made of a material having a higher density than the material of which layer 120 is made) or it can be incorporated into layer 120, which then, in the latter case, is appropriately shaped. In particular, inner layer 11 can be reversibly or irreversibly connected to layers 120, 121 , so as to impart additional cushioning characteristics to the footwear in which it is embedded.

[0068] Inner layer 11 has a first surface or upper surface 101 and a second surface or lower surface 102; the first surface or upper surface 101 is configured to contact layer 121 , while the second surface or lower surface 102 is configured to contact layer 120.

[0069] Advantageously, the inner layer 11 can be made of different materials depending on the requirements and characteristics to be achieved for the footwear and, in particular, can be made, for example, of plastic materials, such as copolymer of polypropylene, nylon, pebax®, glass fibers, and / or carbon fibers, in order to achieve adequate stiffness of the midsole assembly 10 and the entire footwear.

[0070] Still advantageously, the inner layer 11 of the midsole assembly 10 can be coupled to respective surface layers deposited on the surfaces 101 , 102 and made of felt or other clinging materials, by fastening or bonding means, in order to increase the ease of bonding between the surfaces and thus the ease of assembly of the entire footwear.

[0071] In other embodiments of the invention, the tread 14 has a toe-board or spike 141 , made singly or made in one piece with the tread 14, that partially wraps around the midsole assembly 10.

[0072] Such wrapping occurs, in particular, at the tip of the footwear and involves the toe toe-board141 wrapping a portion of the lateral surface of midsole assembly 10.

[0073] In other embodiments illustrative, but not limiting, of the invention, superior to the layer 121 is disposed an insole 19, which is placed in place by means of fastening and / or bonding means.

[0074] Advantageously, at least one cleaning insole may also be employed within the midsole assembly 10 of the footwear.

[0075] Advantageously, layers 120 and 121 can be made of rubbery material and / or polyurethane materials and / or polyurethane foam materials, such as EVA or similar materials, to increase the cushioning effect of midsole assembly 10.

[0076] In other forms of construction, particularly suitable for those footwear in which the sole assembly 12 includes a heel insert 17 for crampons, layer 11 is inserted into that heel insert 17. In particular, the heel insert 17 has a through-opening in which said layer 11 is inserted so that it passes through it, while in traditional footwear the heel insert 17 for crampons is disadvantageously glued to the components of the sole assembly 12; this aspect entails a lower resistance to the repeated actions of hooking and unhooking of the crampons to the footwear.

[0077] Indeed, the actions of hooking and unhooking the crampons from the footwear cause a series of forces and movements which tend to detach the heel insert 17 from the remaining components of the sole assembly 12 (rolling phenomenon).

[0078] Furthermore, the heel insert 17 is often subject to breaking phenomena due to the stresses to which it is subjected.

[0079] In particular, according to the invention, it is possible to achieve the assembly of the heel insert 17 by means of an injection phase of the inner layer 11 on the heel insert 17.

[0080] In particular, the inner layer 11 is injected or embedded in the heel insert 17 and, in this way, the heel insert 17 can grip the inner layer 11 giving greater strength to the entire sole assembly 12.

[0081] Advantageously, with such a design, it is less likely that the heel insert 17 will detach from the sole assembly 12 or that it will break.

[0082] In fact, heel inserts according to the prior art, which are normally bonded to the components of the sole assembly 12, tend to break or detach in the vicinity of the heel and in particular in the bonding areas.

[0083] This problem is not present in the footwear according to the invention as the heel insert 17 are made by injection on the inner layer 11 which is then embedded in the heel insert 17 itself.

[0084] This coupling ensures greater strength of the heel insert 17 and prevents detachment of the heel insert 17 from the sole assembly 12.

[0085] The necessary rigidity that the heel insert 17 must have is appropriately conferred by the inner layer 11 passing through it.

[0086] In a preferred embodiment, the heel insert 17 is made of soft material so as to absorb impacts due to the presence of the crampon lever.

[0087] Advantageously, the user perceives the presence of the crampon lever less, compared to known solutions, particularly in hard terrain such as frozen ground. Still advantageously, the heel insert 17 is made of soft material, so as to ensure a greater grip or grip of the footwear with the crampon lever.

[0088] In such embodiments, in which the sole assembly 12 is provided with the heel insert 17, the inner layer 11 is not totally visible externally at the heel insert 17 itself.

[0089] In further exemplifying, but not limiting, embodiments of the invention, the inner layer 11 of the midsole assembly 10 has one or more holes or through- openings 15, which may be adapt to accommodate one or more respective inserts 13 for enhanced cushioning function. Alternatively, the through-openings 15 can be filled with polyurethane or EVA from mold.

[0090] In preferred embodiments, the through-openings 15 are made in the portions of the inner layer 11 of the midsole assembly 10 corresponding to the heel and / or metatarsal of the footwear user.

[0091] Advantageously, the inserts 13 are made of anti-shock material that confers this feature to the midsole assembly 10 and the entire footwear.

[0092] In a particular embodiment of the present invention, the inserts 13 can be realized in EVA, particularly low density EVA.

[0093] In a further embodiment, the inserts 13 may be made of polyurethane foam by casting or injection.

[0094] In an embodiment, the inserts 13 may be inserted into the through-openings 15 of the shaped layer 11 of the midsole assembly 10 by bonding and / or casting and / or injection on the perimeter.

[0095] The inserts 13 can also be attached or glued to the inner layer 11 of the midsole assembly 10 at the perimeter of the through-opening 15, so that they do not protrude during manufacture of the footwear or during use by the user.

[0096] Advantageously, the use of the inserts 13 allows the cushioning characteristics of the midsole assembly 10 and the entire footwear to be increased, while the inner layer 11 provides adequate rigidity.

[0097] From the foregoing description, the characteristics of the midsole assembly for footwear, which is the object of the invention, are clear, as well as the advantages it offers.

[0098] It is also evident that numerous variations can be made to the object in question without departing from the principles of novelty inherent in the inventive concept. Furthermore, in the practical implementation of the invention, the materials, shapes, and dimensions of the illustrated details may vary according to specific needs and may be replaced with equivalent alternatives.

[0099] Wherever features and techniques mentioned in any claim are followed by reference signs, such reference signs have been included solely to enhance the clarity of the claims. Consequently, such reference signs have no limiting effect on the interpretation of each element identified as an example by those reference signs.

Claims

CLAIMS1. Footwear, in particular sports, trekking, hiking, hunting or working footwear, comprising an upper (20) and a sole assembly (12), wherein said sole assembly (12) comprises a tread (14), configured to be in contact with the ground during use of the footwear, and a midsole assembly (10), placed superiorly to said tread (14), characterised by the fact that said midsole assembly (10) has an inner shaped layer (11 ), made of plastic material or glass fibre or carbon fibre, and two outer layers (120, 121 ), placed on opposite sides with respect to said inner shaped layer (11 ) and made of shock-absorbing materials, wherein the inner shaped layer (11 ) is made of a material having a higher stiffness than the material of the outer layers (120, 121 ) and wherein the inner shaped layer (11 ) rests on the entire surface of at least one of said two outer layers (120, 121 ) and is visible, for at least a lateral portion of the midsole assembly (10), on the outside of the footwear and along the perimeter of the midsole assembly (10).

2. Footwear according to claim 1 , characterised by the fact that said tread (14) has a toe-board or spike (141 ), which partially wraps said midsole assembly (10) at the tip of the footwear.

3. Footwear according to one or more of the preceding claims, characterised by the fact that said sole assembly (12) comprises a heel insert (17) connected to said internal shaped layer (11 ) of said midsole assembly (10).

4. Footwear according to claim 3 characterised by the fact that said inner shaped layer (11 ) is inserted in a through-opening of said heel insert (17).

5. Footwear according to claim 3 characterised by the fact that said midsole assembly (10) is injected into said heel insert (17).

6. Footwear according to one or more of the preceding claims characterised by the fact that said internal shaped layer (11 ) has different thicknesses along the entire length of said midsole assembly (10) and has a greater thickness at the heel of the footwear.

7. Footwear according to claim 1 , characterised by the fact that between said tread (14) and said midsole assembly (10) is present a cushioning insert (16) positioned at the heel of the footwear.

8. Footwear according to claim 1 , characterised by the fact that said inner shaped layer (11 ) has one or more holes or through-openings (15) adapted to accommodateone or more respective inserts (13), realised in low density EVA and / or polyurethane foam, with a cushioning function.

9. Footwear according to claim 8, characterised in that said one or more through- openings (15) are realised in the portions of said inner shaped layer (11 ) of the midsole assembly (10) corresponding to the heel and / or the metatarsal of the user of the footwear.

10. Footwear according to claim 8, characterised by the fact that said one or more inserts (13) are attached or bonded or cast or injected to said inner shaped layer (11 ) of the midsole assembly (10) in correspondence with the perimeter of each through-opening (15).

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