Self-cooling shoe with control and automation system

Abstract

A self-cooling footwear system, including a shoe having an interior cavity, a forefoot region, and a heel region, a heel housing integrated into the heel region, a fan module disposed within the heel housing and including a fan operable to generate forced airflow from an air inlet located at the forefoot region of the shoe toward an air outlet in the heel region, the forced airflow configured to cool the interior of the shoe, an airflow enabled insole positioned within the shoe, an electronic control system disposed in electrical communication with the fan module, the electronic control system including one or more sensors configured to detect an environmental condition within the shoe and generate sensor data, a control unit configured to receive and analyze the sensor data and to adjust operation of the fan, and a wireless communication module configured to communicate with an external device.

Description

[0001] SELF-COOLING SHOE WITH CONTROL AND AUTOMATION SYSTEM

[0002] CROSS REFERENCE TO RELATED APPLICATION

[0003] This application is related to and claims the benefit of U.S. Provisional Patent Application Serial Number 63 / 660,518 filed on June 16, 2024, the entire contents of which are incorporated herein by reference.

[0004] TECHNICAL FIELD

[0005] The present disclosure pertains to footwear technology, specifically to self- cooling systems integrated into enclosed shoes, employing electronic components, sensors, airflow mechanisms, and mobile application interfaces to improve user comfort, adaptability to environmental conditions, and system control.

[0006] BACKGROUND

[0007] In the realm of footwear design, achieving consistent and effective cooling airflow within a shoe presents significant challenges.

[0008] Traditional approaches to cooling rely on passive ventilation methods, such as perforations in the shoe material or the use of breathable fabrics. While these methods can provide some degree of airflow, they are inherently limited in their ability to actively manage heat and moisture buildup, particularly in fully enclosed footwear such as men’s dress shoes. The lack of active airflow mechanisms often results in uneven and / or ineffective cooling, with certain areas of the foot — such as the sole and heel — retaining heat and encouraging sweat accumulation. Furthermore, passive systems are highly dependent on external environmental conditions, such as ambient temperature and humidity, and cannot adapt dynamically to changes in these conditions or to the wearer’s activity level.

[0009] Active footwear cooling systems have been attempted but have been largely unsuccessful due to innate physical design constraints. The compact and confined space of a shoe makes it difficult to integrate components such as fans, ducts, and airflow channels without compromising the shoe’s structural integrity, comfort, or aesthetic appeal. Additionally, ensuring that airflow is directed to the areas of the foot most in need of cooling, such as the sole, requires careful design of internal airflow pathways. These pathways must balance the need for effective cooling with the need to maintain the shoe’s durability and comfort. Also, the formation of such internal pathways within a shoe requires extensive tooling, complex manufacture, and increased costs. The integration of such systems in a shoe is further complicated by the need to minimize noise and vibration, which could otherwise detract from the user experience.

[0010] In addition to the challenges of creating consistent airflow, the automation and user control of internal footwear cooling systems pose their own set of difficulties. Existing solutions often lack the ability to dynamically adjust cooling based on realtime environmental and user-specific conditions. For example, many systems rely on manual controls, requiring the user to actively adjust settings such as fan speed or cooling intensity. This approach not only places a burden on the user but also fails to provide an optimal cooling experience, as it does not account for variations in temperature, humidity, or activity level throughout the day.

[0011] Automation of cooling systems within footwear requires the integration of sensors, such as temperature and humidity sensors, to monitor internal and external conditions. However, designing a control system that can effectively interpret sensor data and make real-time adjustments to the cooling mechanism, is a complex task. Such systems must balance competing priorities, such as maximizing cooling efficiency, minimizing power consumption, and ensuring user comfort. Furthermore, the inclusion of user control features, such as a mobile app interface, adds another layer of complexity. These interfaces must be intuitive and user-friendly while providing sufficient customization options to meet individual preferences.

[0012] U.S. Patent No. 12,016,434 to Nedelcu provides an active footwear cooling system including a complex internal array of airflow tubes including a main airflow tube 23 that extends from a main air inlet at the front of the shoe longitudinally down the middle of the interior of the shoe 11 , and first and second secondary air flow tubes 25 and 27 which extend from auxiliary inlets 17, 19 at the front of the shoe and curve inwardly slightly to join the main air flow channel 23 at respective acute angles. Col. 2, lines 42-61. “The first and second secondary air flow channels 25, 27 have rows 33, 35; 37, 39 of equally spaced perforations formed on opposite sides thereof, which act as air ducts, as does a front portion 31 of the main tube 23.” Id. See also, FIG. 4. Nedelcu further discloses: “In operation, air is sucked in through air inlets 15, 17, 19 and exits out the turbo fan 13. At the same time, a vacuum effect is created at the rear of the shoe 11 causing air drawn in through the free air inlets 29, 31 to flow outside of the main tube 15 forward through the perforations 33, 35, 37, 39 and into the first and second auxiliary channels 25, 27.” Col. 3, lines 25-37.

[0013] Nedelcu requires a complex tubing arrangement to be installed in a shoe, complicating manufacture and increasing costs. Moreover the operating principle is based upon a technical vacuum arrangement relying upon alleged Venturi and Coanda effects, which in practice are difficult to establish and maintain at the interior of a shoe in view of the movement of a foot within the shoe during normal use, the different sizes and shape of feet to be inserted into the shoe, the presence or absence of socks, etc. Thus, not only is the disclosed system complex and expensive, but also unreliable and largely ineffective at cooling the foot.

[0014] Lastly, Nedelcu provides only the most rudimentary control system where a user can manually or remotely power the fan on and off and adjust speed. There is no automation, nor is any sensing arrangement provided to determine real time conditions with the shoe.

[0015] Korean Patent Application Publication No. 101451719 provides a shoe insole with a heating and cooling function. Here again, the disclosed system requires a complex airflow network (see, e.g., FIG. 2) which complicates manufacture, increases costs, and can affect foot comfort. Additionally, control and automation functions are limited.

[0016] The combination of several challenges — achieving consistent and effective airflow with a simple, cost-effective design, and implementing robust automation and user control — highlights the limitations of current technologies in addressing the needs of modern footwear users. Thus, there remains a need for innovative solutions that can overcome these obstacles, providing a seamless and adaptive cooling experience without compromising on comfort, aesthetics, or usability.

[0017] BRIEF SUMMARY

[0018] A self-cooling footwear system is described herein as including a shoe having an interior cavity, a forefoot region, and a heel region, a heel housing integrated into the heel region, a fan module disposed within the heel housing and including a fan operable to generate forced airflow from an air inlet located at the forefoot region of the shoe toward an air outlet in the heel region, the forced airflow configured to cool the interior of the shoe, an insole positioned within the shoe and comprising a three-dimensional periodic cellular structure configured to provide ventilation and cushioning beneath a wearer’s foot, an electronic control system disposed in electrical communication with the fan module, the electronic control system including a sensor configured to detect an environmental condition within the shoe and generate sensor data, a control unit configured to receive and analyze the sensor data and to adjust operation of the fan, and a wireless communication module configured to communicate with an external device, where the control unit is configured to adjust an operation of the fan module based on at least one of the sensor data and commands received wirelessly from the external device.

[0019] Also provided herein is a shoe configured for self-cooling, the shoe including a shoe body having an interior cavity, a forefoot region, and a heel region, a heel housing integrated into the heel region and configured to house electronic components, a fan module disposed within the heel housing, the fan module including a fan operable to generate forced airflow from an air inlet located at the forefoot region of the shoe toward an air outlet in the heel region, an insole positioned within the interior cavity of the shoe, the insole comprising a three-dimensional periodic cellular structure configured to provide ventilation and cushioning beneath a wearer’s foot, at least one sensor disposed within the shoe body, the sensor configured to detect environmental conditions within the interior cavity, an electronic control unit disposed within the heel housing and operatively coupled to the fan module and the at least one sensor, the electronic control unit configured to adjust operation of the fan based on sensor data, a wireless communication module disposed within the heel housing and configured to communicate with an external device, and a rechargeable battery disposed within the heel housing and electrically coupled to the electronic control unit, the rechargeable battery configured to power the fan module and electronic control unit.

[0020] The disclosure also concerns a mobile application for operating a self-cooling footwear system, the mobile application including a user interface configured to display operational parameters of the self-cooling footwear system, including at least one of internal temperature, internal humidity, fan speed, and battery level, a control module configured to allow a user to adjust operational settings of the self-cooling footwear system, including at least one of fan speed, temperature thresholds, and humidity thresholds, a communication module configured to transmit user-defined operational settings to the self-cooling footwear system via a wireless communication protocol, and receive sensor data from the self-cooling footwear system, including at least one of temperature data and humidity data, and a self-learning module configured to analyze user preferences and operational data to automatically adjust the operational settings of the self-cooling footwear system based on user behavior and environmental conditions.

[0021] BRIEF DESCRIPTION OF THE DRAWINGS

[0022] For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts. The pictures from a prototype version, vs. full production version, and some details may vary. Nonetheless, in the Figures, in which:

[0023] FIG. 1 shows a shoe having a self-cooling footwear system in one embodiment of the present disclosure;

[0024] FIG. 2 shows a partial enlarged view of a forefoot region of the shoe of FIG. 1 ;

[0025] FIG. 3 shows a partial enlarged bottom view thereof;

[0026] FIG. 4 shows a top view thereof;

[0027] FIG. 5 is a top view of a heel plate;

[0028] FIG. 6 is a bottom view thereof; FIG. 7 is a top perspective view of a heel housing;

[0029] FIG. 8 is schematic of an electronic control system;

[0030] FIG. 9 is a top perspective view of a fan module;

[0031] FIG. 10 is a bottom perspective view thereof;

[0032] FIG. 11 shows top and bottom plan views of an insole having a three- dimensional periodic cellular structure;

[0033] FIGS. 12-14 show additional views of the insole and an enlarged view of a gyroid unit cell which, when repeated, forms the structure of the insole; and

[0034] FIGS. 15-19 show graphic user interfaces of a control application for a mobile device, graphic display, or other computing device.

[0035] DETAILED DESCRIPTION

[0036] FIG. 1 illustrates an exemplary shoe 10 comprising a self-cooling footwear system in one embodiment according to the present disclosure. The shoe 10 includes an upper 12 and an outsole 14, which together create an interior cavity 16. The shoe 10 has a forefoot region 18 encompassing a toe and arch area, and a heel region 20 disposed rearward of the forefoot region 16.

[0037] An air inlet 22 is disposed in the forefoot region 16 of the shoe 10. As discussed further herein, the air inlet 22 is configured to allow inflow of air when the self-cooling footwear system is in operation. The air inlet 22 may include a cover in order to conceal the inlet 22 and / or to prevent entry into the interior cavity 16 of water and debris. Such cover may be formed of a mesh material, a water repellant material such as a waterproof breathable fabric, a microporous membrane, or any material suitable to provide the described functionality thereof. Additionally and / or alternatively, the air inlet 22 may include a circuitous air duct or a baffled air duct, again for the purpose of concealing the air inlet 22 and / or to prevent entry into the interior cavity 16 of water and debris. A single air inlet 22 may be provided at the forefoot region 18 of the shoe 10, for example at the front of a toe box 24, as shown in the example of FIG. 1. Alternatively, the air inlet 22 may be disposed on a side of the forefoot region 18 or on a vamp area 26 of the shoe 10 which extends from the toe box 24 to a lace region. The air inlet 22 may be formed into the upper, as illustrated in the example of FIG. 1, or may be formed into the outsole 14 and / or into a midsole of the shoe 10. The shoe 10 may include a single air inlet 22 or multiple air inlets 22. For example, an air inlet may be formed on both sides of the forefoot region 18. Alternatively, multiple air inlets 22 may be formed in the vamp area 26 as the only air inlets of the shoe 10, or these may be disposed along with one or more air inlets 22 at the toe box 24 and / or in the forefoot region 18. For example, a plurality of air inlets 22 may be disposed on one or both sides of the forefoot region. This configuration may further include an additional plurality of air inlets at other locations on the upper 12, such as at the top of the toe box 24 and / or in the vamp area 26 and / or proximate to the eyelet and lace area of the shoe 10.

[0038] FIG. 2 shows a preferred embodiment in which a plurality of air inlets 22 are arranged in the forefoot region 18 in the upper 12 essentially at the interface of the upper 12 and the outsole 14. In this configuration, the air inlets 22 each comprise a small hole which passes from an exterior of the shoe 10, through the upper 12 and / or the outsole 14, to the interior cavity 16. Here, the air inlets 22 may be formed of a sufficiently small size so as to occlude passage of water and debris into the interior cavity 16. Alternatively, the air inlets 22 of FIG. 2 may include one or more of the cover, the circuitous air duct, and the baffled air duct described above with regard to FIG. 1.

[0039] FIG. 3 shows an underside view of the shoe 10. The heel region 20 comprises a heel housing 28 which, as further described herein, contains components of the self- cooling footwear system. The heel housing 28 also includes an air outlet 30 disposed on a forward side 23. The air outlet 30 is configured to allow outflow of air during operation of the self-cooling footwear system. To conceal the air outlet 30 and / or to prevent ingress of unwanted substances, the air outlet 30 may include one or more of the cover, the circuitous air duct, and the baffled air duct described above with regard to the air inlet 22. As illustrated in FIG. 3, the air outlet 30 includes a mesh cover.

[0040] The forward side 32 of the heel housing 28 extends generally vertically from a ground contact surface 34 of the heel housing 28. The ground contact surface 34 is generally coplanar with a ground contact surface 36 of the forefoot region 18. The vertical arrangement of the forward side 32 of the heel housing 28 relative to the lower disposition of the ground contact surfaces 34, 36 creates a clearance gap 38 beneath the outsole 14 when the shoe 10 is in contact with the ground. The air outlet 30 is disposed in this clearance gap 38 which allows for effective evacuation of air from the interior cavity 16 of the shoe 10 during operation of the self-cooling footwear system, while keeping the air outlet 30 out of view during normal use of the shoe 10. The forward side 32 of the heel housing 28 may further include an interface 40 integrated into the heel housing 28 and configured to allow the wearer to manually control operation of the self-cooling footwear system. For example, the interface 40 may comprise a button, a switch, a touch screen, or similar, which is manually actuated by the wearer to power on and off the fan and to adjust fan speed, as further disclosed herein. The interface 40 may be disposed in the clearance gap 38 on the vertical forward side 32 of the heel housing 28 as shown in FIG. 3, or alternatively may be disposed on other side surfaces of the heel housing 28, or elsewhere on the shoe, for example, on the side of the outsole at the forefoot region 18 or at any desired location on the upper 12. In another embodiment, the interface 40 may comprise a toggle switch disposed at the interior cavity 16 of the shoe 10, beneath an insole. Such disposition of the interface 40 would allow the wearer to manually control the self-cooling footwear system in rare or necessary circumstances, e.g., during a wireless communication failure, while concealing the interface 40 within the shoe 10 so as not to effect the overall aesthetic appearance.

[0041] FIG. 4 shows a view of the top of the shoe 10 in which a portion of the interior cavity 16 can be seen. A footbed 42 is disposed in the interior cavity 16 to form a lower boundary thereof. The footbed 42 includes a pass through hole 44 formed therethrough located in the heel region 20 above the heel housing 28. The pass through hole 44 is essentially a conduit which extends from the interior cavity 16 to an interior of the heel housing 28 to allow airflow from the from the former to the latter. In the illustrated embodiment, a ventilated support structure 46 is disposed in the pass through hole 44 in order to support the downward force of the foot of a wearer upon the footbed 42, while still allowing air to pass from the interior cavity 16 to the interior of the heel housing 28. In this exemplary embodiment, the ventilated support structure 46 includes structural members which extend across a width of the plate 46 in a honey-comb-like arrangement, creating a plurality of openings in the plate 46. The structural members support the load created by the foot of a wearer, the openings allow airflow between the interior cavity 16 and the interior of the heel housing 28. The broad scope of the disclosure contemplates other arrangements of the structural members in order to accomplish the two-fold purpose of the ventilated support structure 46, i.e., load support and promotion of airflow. For example, the structural members may be linear and extend from one side of the ventilated support structure 46 to an opposite side to form a vent arrangement. Or, the structural members may again be linear but arranged in a cross hatching pattern, at right angles to one another or angled with respect to one another. The structural members may be formed as concentric circles of decreasing diameter with spokes extending from a center of the ventilated support structure 46 to a circumference in order to support the circular structural members, etc. Of course, the ventilated support structure 46 need not be circular, but could instead be oval, elliptical, square, rectangular, or abstractly shaped. The shoe 10 may include a single ventilated support structure 46, as illustrated, or a plurality thereof.

[0042] Referring to FIGS. 5-7, the heel housing 28 is formed by the ground contact surface 34, the forward side 32, peripheral sides 48, and a heel cap 50. The peripheral sides 48 extend in a vertical direction upward from the ground contact surface 34 to the heel cap 50. The peripheral sides 48 further wrap an exterior of the heel housing 38, from a lateral end of the forward side 32, around a rearmost portion of the heel region 20, to a medial end of the forward side 32. These various surfaces delimit the interior of the heel housing 28 which contains a fan module 52, an electronic control system 54, and a power source 56 such as a battery.

[0043] The heel cap, best seen in FIGS. 5-6, is essentially a planar member which contains the pass through hole 44 and ventilated support structure 46, and which forms the upper boundary of the heel housing 28 to support the downward load on the housing 28 applied by a wearer of the shoe 10. The heel cap 50 may include attachment means 51 to facilitate connection of the heel cap 50 with the heel housing 28. The attachment means 51 may be screws, rivets, dowel pins, or the like, with corresponding receiving means at the interior of the heel housing 28. Alternatively, the heel cap 50 may be secured to the heel housing 28 by adhesive, welding, or by other means know in the art. As can be seen in FIG. 5, the ventilated support structure 46 may be concave in shape so as to be recessed beneath a top surface of the heel cap 50. Alternatively, the ventilated support structure 46 may be planar or convex, or have a varying topography including a plurality of concave and / or convex portions.

[0044] Returning to FIG. 7, the fan module 52 includes a fan inlet 58 and a fan exit 60 disposed in communication, respectively, with the pass through hole 44 of the heel cap 50 and with the and the air outlet 30. Located between the fan inlet 58 and fan exit 60 is a fan element driven by a motor to force air through the fan exit 60, through the air outlet 30, and to an exterior of the shoe 10. This creates a negative pressure at the fan inlet 58. As a result, air is drawn from the interior cavity 16 of the shoe 10, through the pass through hole 44, into the fan inlet 58, and is expelled through the fan exit 60, and air outlet 30 to the external environment. As air is drawn in this manner from the interior cavity 16, a negative pressure is created at the air inlet 22. Accordingly, fresh cooling air is drawn into the interior cavity 16 from outside of the shoe 10 and is circulated around the foot of a wearer toward, and ultimately through, the pass through hole 44, to then be evacuated from the shoe 10 as described. This provides a significant cooling and drying effect within the interior cavity 16 of the shoe 10.

[0045] Interface electronics 62 are disposed in communication with the user interface 40 located on the front side 32 of the heel housing 28, and with the fan module 52. The interface electronics 62 are configured to communicate the manual actuation of the interface 40 to the fan module 52 or to control elements of the electronic control system 54, as further described below, in order to alter operation of the fan. For example, the user may toggle the interface 40 which directs the interface electronics 62 to turn on or off the fan or to adjust the speed thereof, or which said toggling directs the interface electronics 62 to communicate the same to the electronic control system 54 which then executes the user’s instructions.

[0046] Also in the example of FIG. 7, a charging port 63 is disposed on the front side 32 of the heel housing 28. The charging port 63 may be for example a USB port, particularly a USB-C port, which is disposed in electrical communication with the power source 56 to enable rapid charging thereof. In other embodiments, the charging port 63 may be positioned in different locations about the shoe 10. For example, the charging port 63 may be disposed on the peripheral sides 48 of the heel housing 28, at other locations on the outsole or on the upper, within the interior cavity 16 of the shoe 10 such as beneath the insole or integrated into the tongue structure of the shoe 10. Of course, the charging port 63 may include a connectivity structure other than USB-C. For example, the charging port 63 may comprise USB-A, Micro USB, Lightning, standard DC jack, etc.

[0047] In one exemplary embodiment, as illustrated in FIG. 8, the electronic control system 54 includes one or more sensors 64, a control unit 66, and a wireless communication module 68. The sensor 64 is configured to detect an environmental condition in the interior cavity 16 of the shoe 10, to generate respective sensor data, and to communicate said data to the control unit 66. The environmental condition may be, for example, temperature and / or humidity. The control unit 66 is configured to receive and analyze the sensor data and to adjust operation of the fan accordingly, and also to receive and act upon external instructions received from the wireless communication module 68. The wireless communication module 68 is configured to communicate with the control unit 66 in a wired or wireless manner and with an external device 70, such as a smart phone, and / or with an external database and / or with the internet and respective cloud services. The control unit 66 is disposed in communication with the fan module 52 and is configured to adjust an operation of the fan based on at least one of the sensor data and external commands received by the wireless communication module 68.

[0048] The sensor 64 may be located proximate to the fan inlet 58. See, FIG. 7. A secondary sensor 64 may be located upstream from this primary sensor 64 with regard to the airflow pathway through the shoe. For example, such a secondary sensor 64 may be located in the arch area of the shoe 10, in the toe box 24, or elsewhere within the interior cavity 16. Each sensor 64 may detect temperature and / or humidity of the air within the interior cavity 16 of the shoe 10. Where a secondary upstream sensor 64 is utilized, a temperature and / or humidity gradient within the interior cavity 16 may be determined.

[0049] In a further embodiment, the self-cooling footwear system may additionally include an external sensor 65 disposed on an external surface of the shoe 10, for example, on the peripheral sides 48 of the heel housing 25, at other locations on the outsole 14 or on the upper 12. The external sensor 65 may be configured to detect temperature and / or humidity of the air external to the shoe 10. The sensor 65 may communicate in a wired or wireless manner with the control unit 66 in order to provide real time external environmental conditions. The control unit 66 may correspondingly be configured to receiving and analyze this data and to accordingly adjust operation of the self-cooling footwear system and / or communicate such data via the wireless communication module 68 to a mobile device of the wearer, to the cloud, etc.

[0050] FIGS. 9-10 show another exemplary embodiment of the fan module 52 including a blower fan 53 with a temperature and / or humidity sensor 64 disposed upstream thereof, a push button switch serving as the previously described manual user interface 40, the charging port 63, the battery 56, a connector 57 for the battery 56, a micro-controller serving as the control unit 66, and a wireless antenna 69 forming a part of the wireless communication module 68. Here, the push button switch 40 extends upward from the heel housing 28 into the interior cavity 16 of the shoe 10, and preferably at a location disposed generally at the footbed 42, beneath an insole. As explained above, this allows the wearer to manually operate the self-cooling footwear system when necessary without effecting the outward appearance of the shoe 10. In the present embodiment, the charging port 63 also extends in the upward direction into the interior cavity 16 to facilitate plug-in charging when desired. That is, an opening of the charging port 63 may be accessible at the footbed 42 beneath the insole, or elsewhere within the interior cavity 16 of the shoe 10. The embodiment of the fan module 52 of FIGS. 9-10 further includes an inductive charging coil 72 disposed on a lower side of the module 52 and arranged toward a bottom of the heel housing 28 to allow for wireless charging of the battery 56. This embodiment may further include a connector 74 for an external sensor 65. This allows the external sensor 65, described above, to make a wired connection to the fan module 52. Similarly, the exemplary module 52 may include a connector 76 for a secondary internal sensor 64 disposed upstream of the primary sensor 64 disposed adjacent to the blower fan 53, in the manner as described previously. This connector 76 allows the secondary upstream internal sensor 64 to make a wired connection to the fan module 52. FIG. 11 shows top and bottom plan views of an airflow enabled insole 70 shaped and configured to extend across the entirety of the footbed 42, from the forward extent of the forefoot region 18, to the rear of the heel region 20, and from the lateral edge of the interior cavity 16 to the medial edge. The insole 70 has a construction which permits airflow in the horizontal and vertical directions within the interior cavity 16. Particularly, during operation of the fan module 52, air is directed in a horizontal direction from the air inlet 22, through a body of the insole 70, toward the pass through hole 44 at which the air is drawn in a vertical downward direction to the fan inlet 58. Across the longitudinal extent of insole 70, the structure thereof permits air to move in the vertical downward direction toward the footbed 42 and / or in the vertical upward direction into interior cavity 16 of the shoe 10.

[0051] In one exemplary embodiment, the airflow enabled insole 70 includes a three- dimensional periodic cellular structure construction formed by additive manufacturing. In this example, the cellular structure is formed of 95A TPU at -15% gyroid infill. The gyroid infill is exposed on all surfaces of the insole 70, i.e., top, bottom, and all side edges. There are no walls or other surfaces obstructing the gyroid infill. This construction forms a multitude of airflow pathways that extend through the insole 70 in both the horizontal and vertical directions, i.e., the x, y, and z directions.

[0052] FIG. 12 shows another view of the insole. FIG. 13 shows an enlarged view of a gyroid unit cell which is repeated in a periodic manner to form the structure of the insole 70. FIG. 14 shows an enlarged partial view of the insole of FIG. 12 illustrating the cellular geometry formed by the repeating gyroid unit cell.

[0053] In other embodiments, the airflow enabled insole 70 may have a lattice, mesh or woven construction that similarly delimits multi-directional airflow pathways through the insole to allow air circulation during fan operation.

[0054] The insole 70 is configured to comfortably support the foot of a wearer and to enable the described airflow patterns. The insole is disposed directly on top of the footbed 42 which need not be modified in any manner to effect the desired airflow. That is, channels, grooves, tubes or other special modifications are not required of the footbed to induce airflow through the shoe 10 due to the unique airflow enabling design of the inventive insole 70. In a further exemplary embodiment of the self-cooling footwear system, the shoe 10 may additionally include a heating element, such as a heating coil or the like, which is disposed in electrical communication with, and controlled by, the electronic control system 54. The heating element may be disposed in the heel region 20 and / or the forefoot region 18, for example, in or beneath the footbed 42, or in a portion of the outsole 14 or upper 12. In this embodiment, the heating element may be activated by the control unit 66 in response to detection of a threshold external temperature by the external sensor 64. For example, at detected external temperature of 20F, the heating element may be activated to bring warmth to the interior cavity and comfort to the wearer. This feature can counter the inflow of cold external air through the air inlets 22 and enable comfortable use of the shoe 10 during cooler seasons. The heating element may also be activated manually by the wearer in the manner described above with regard to the fan module, and further may be fully controllable by the mobile application as now described below 52.

[0055] Hereinabove, the self-cooling footwear system is described as including the air outlet 30 at the front side 32 of the heel housing 28. This location of the air outlet 30 is merely exemplary, other dispositions thereof are contemplated by the broad scope of the disclosure. In additional embodiments, one or more of the air outlets 30 may be located on a side of the shoe 10, for example, at the peripheral side 48 of the heel housing 28, or at other locations on the sides of the outsole 14 or upper 12.

[0056] A mobile application is provided to operate and enhance the functionality of the self-cooling footwear system. The application provides a seamless interface between the user and the footwear system, enabling real-time monitoring, control, and customization of the system’s operational parameters. The mobile application is compatible with a variety of mobile devices, including smartphones and tablets, and communicates with the footwear system via a wireless communication protocol, such as Bluetooth.

[0057] The mobile application comprises an intuitive and user-friendly interface, various optional embodiment examples of which are shown in FIGS. 15-19. The user interface displays key operational parameters of the self-cooling footwear system. These parameters include, but are not limited to: internal and / or external temperature of the shoe; internal and / or external humidity levels; current fan speed; and battery level of the footwear system. Also likely to be included, is information on motion detected from any embedded accelerometers in each shoe.

[0058] The user interface is designed to provide real-time feedback, allowing the user to monitor the effectiveness of the cooling system. Additionally, the interface includes graphical representations, such as trend charts, to display historical data on temperature and humidity levels over time. This feature enables users to analyze the performance of the system under various conditions.

[0059] The mobile application further includes a control module configured to allow users to adjust the operational settings of the self-cooling footwear system. The operation settings of the system include but are not limited to:

[0060] • Fan speed: Users can manually increase or decrease the fan speed to suit their comfort preferences.

[0061] • Temperature thresholds: Users can set specific temperature levels at which the fan will activate or deactivate.

[0062] • Humidity thresholds: Users can define humidity levels that trigger the fan operation.

[0063] • Predefined operational modes: The mobile application offers multiple modes, such as the following: o Manual Mode: Allows the user to control all settings directly. o Automatic Mode: Adjusts fan operation based on real-time sensor data. o Self-Learning Mode: Adapts to user preferences over time based on historical usage patterns.

[0064] The control module also includes an option to set a maximum fan speed to minimize noise during operation, ensuring the system remains discreet in quiet environments. The mobile application further includes a communication module which facilitates wireless data exchange between the mobile application and the self-cooling footwear system.

[0065] The communication module enables transmission of user-defined settings. For example, the mobile application can send operational parameters, such as fan speed and thresholds, to the footwear system.

[0066] The communication module also facilities reception of sensor data. The application can receive real-time data from the footwear system, including internal and / or external temperature, internal and / or external humidity, battery status, and any motion information from accelerometers.

[0067] The communication module further allows synchronization with a cloud-based database. For example, the communication module enables the application to store operational settings and sensor data in the cloud, allowing users to access their data across multiple devices.

[0068] The communication module also supports pairing of multiple footwear systems, enabling synchronized operation of a pair of shoes. For example, one shoe can act as a "server" while the other operates as a "client," ensuring coordinated cooling performance.

[0069] The mobile application further comprises a self-learning module configured to leverage machine learning algorithms to analyze user behavior, environmental conditions, and historical data. Based on this analysis, the self-learning module automatically adjusts the operational settings of the footwear system to optimize comfort and efficiency. Key features of the self-learning module include:

[0070] • Preference adaptation: The system learns user preferences for hotter or cooler conditions and adjusts fan operation accordingly.

[0071] • Environmental adaptation: The module considers external factors, such as ambient temperature and humidity, to fine-tune the system’s performance. • Usage recommendations: The application provides personalized recommendations to the user, such as suggested fan speeds or operational modes, based on historical usage patterns.

[0072] The mobile application also includes a notification system to keep users informed about the status of the footwear system. Such notifications may include: low battery alerts when the battery level falls below a predetermined threshold; maintenance reminders, such as when to clean air inlets / outlets, replace inlet / outlet covers, etc.; connectivity troubleshooting guidance for resolving issues with the wireless connection.

[0073] In an exemplary embodiment, the application is configured to allow users to customize operational parameters based on their activity level. For example, a Walking Mode may be provided which optimizes cooling for moderate activity. A Running Mode increases airflow to manage higher heat and moisture levels. Stationary Mode reduces fan speed to conserve battery life when the user is inactive.

[0074] The mobile application supports remote operation of the self-cooling footwear system. Users can control the system from a secondary device, such as a tablet or another smartphone, providing flexibility and convenience.

[0075] The application includes a dedicated troubleshooting section to assist users in resolving common issues. This section provides step-by-step guidance for addressing connectivity problems, operational errors, or other technical difficulties. Additionally, the application can log error data and transmit it to a support team for further assistance.

[0076] The mobile application incorporates robust security measures to protect user data and ensure secure communication with the footwear system. All data transmissions can be encrypted, and users have the option to manage their privacy settings, including the ability to disable cloud synchronization if desired.

[0077] The mobile application is designed to support future updates and additional features. For example, future versions may include integration with voice assistants for hands-free control; advanced analytics for deeper insights into system performance; and / or compatibility with other wearable devices, such as fitness trackers, to provide a holistic view of the user’s activity and comfort.

[0078] In summary, the mobile application serves as a comprehensive control and monitoring platform for the self-cooling footwear system. By combining real-time data visualization, customizable settings, and intelligent automation, the application enhances the user experience and ensures optimal performance of the footwear system.

[0079] As described herein, the self-cooling footwear system provides effective cooling to a shoe with a simple and cost-efficient construction and provides the user with an expansive range of operational control without compromising on comfort, aesthetics, or usability.

[0080] Various embodiments of the present invention are described herein with reference to the related drawings. Alternative embodiments can be devised without departing from the scope of this invention. It is noted that various connections and positional relationships (e.g., over, below, adjacent, etc.) are set forth between elements in the following description and in the drawings. These connections and / or positional relationships, unless specified otherwise, can be direct or indirect, and the present invention is not intended to be limiting in this respect. Accordingly, a coupling of entities can refer to either a direct or an indirect coupling, and a positional relationship between entities can be a direct or indirect positional relationship.

[0081] The term "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or design described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments or designs. The terms "at least one" and "one or more" are understood to include any integer number greater than or equal to one, i.e. one, two, three, four, etc. The terms "a plurality" are understood to include any integer number greater than or equal to two, i.e. two, three, four, five, etc. Terms such as "connected to", “affixed to”, etc., can include both an indirect "connection" and a direct "connection."

[0082] The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.

Claims

CLAIMS:

1. A self-cooling footwear system, comprising: a shoe having an interior cavity, a forefoot region, and a heel region; a heel housing integrated into the heel region; a fan module disposed within the heel housing and including a fan operable to generate forced airflow from an air inlet located at the forefoot region of the shoe toward an air outlet in the heel region, the forced airflow configured to cool the interior of the shoe; an insole positioned within the shoe and comprising a three-dimensional periodic cellular structure configured to provide ventilation and cushioning beneath a wearer’s foot; an electronic control system disposed in electrical communication with the fan module, the electronic control system including: a sensor configured to detect an environmental condition within the shoe and generate sensor data; and a control unit configured to receive and analyze the sensor data and to adjust operation of the fan; wherein the control unit is configured to adjust an operation of the fan module based on the sensor data.

2. The self-cooling footwear system of the preceding claim, wherein the sensor comprises at least one of: a temperature sensor, a humidity sensor, an acceleration sensor for detecting movement of the shoe, and a capacitive touch sensor for detection of a foot within the shoe.

3. The self-cooling footwear system of any one of the preceding claims, wherein the sensor comprises two of said temperature sensors, one disposed internally and one disposed externally relative to the shoe, and two of said humidity sensors, one disposed internally and one disposed externally relative to the shoe .

4. The self-cooling footwear system of any one of the preceding claims, wherein the sensor is positioned near the air outlet in the heal region of the shoe.

5. The self-cooling footwear system of any one of the preceding claims, further comprising an interface integrated into the heel housing and configured to allow the wearer to control operation of the fan.

6. The self-cooling footwear system of any one of the preceding claims, wherein the interface is a button or switch manually actuated by the wearer to power on and off the fan and to adjust fan speed.

7. The self-cooling footwear system of any one of the preceding claims, further comprising a wireless communication module configured to communicate with an external device, wherein the control unit is configured to adjust an operation of the fan module based on commands received wirelessly from the external device.

8. The self-cooling footwear system of the preceding claim, wherein the external device comprises a mobile device executing a control application.

9. The self-cooling footwear system of any one of the preceding claims, wherein the insole is configured as a replaceable insert having the three-dimensional periodic cellular structure. The cellular structure may have variation in the spacing based on the needs of cooling and pressure support in the region.

10. The self-cooling footwear system of any one of the preceding claims, wherein the three-dimensional periodic cellular structure is formed of structural elements which delimit airflow pathways in a horizontal direction from the forefoot region to the heal region and from a lateral edge to a medial edge of the shoe, and in a direction generally perpendicular thereto.

11. The self-cooling footwear system of any one of the preceding claims, wherein the three-dimensional periodic cellular structure, or an elongated air flow enabler, iscovered by a highly perforated insole designed to provide increased surface area to be in contact with the foot for comfort, while enabling air exchange, reducing temperature and / or humidity.

12. The self-cooling footwear system of any one of the preceding claims, wherein the structural elements comprise approximately 15% gyroid infill, wherein the three- dimensional periodic cellular structure is shaped to extend over an entirety of a bottom of the interior cavity such that the wearer’s foot rests thereupon when disposed in the interior cavity, and wherein outer edges of the three-dimensional periodic cellular structure are unbounded such that the gyroid infill is exposed at the edges.

13. The self-cooling footwear system of any one of the preceding claims, wherein the fan module is configured to direct the forced airflow substantially parallel to a longitudinal axis of the shoe.

14. The self-cooling footwear system of any one of the preceding claims, further comprising a rechargeable battery disposed within the heel housing electrically coupled to the electronic control system.

15. The self-cooling footwear system of any one of the preceding claims, further comprising a wireless charging coil embedded in the shoe, preferably in the heel region, for inductive charging of the rechargeable battery.

16. The self-cooling footwear system of any one of the preceding claims, wherein the electronic control system is further configured to communicate with a mobile device executing the control application via the wireless communication module; and receive user-defined operational settings including a self-learning mode.

17. The self-cooling footwear system of any one of the preceding claims, wherein the fan module further comprises a cover, a circuitous air duct, and a baffled air duct disposed on at least one of the air inlet and air outlet, the cover and air ducts configuredto conceal the respective outlet, prevent entry of debris, and reduce noise during operation of the fan.

18. The self-cooling footwear system of any one of the preceding claims, wherein at least one sensor comprises a first sensor positioned near an inlet of the fan and a second sensor positioned forward of the first sensor toward the forefoot region, the first and second sensors configured to monitor spatial variations in at least one of temperature and humidity, or both temperature and humidity.

19. The self-cooling footwear system of any one of the preceding claims, wherein the air outlet is disposed at a forward terminal edge of the heel housing in a gap delimited between the heel housing and a sole of the forefoot region.

20. A pair of shoes comprising a first shoe and a second shoe, the first and second shoes both comprising the self-cooling footwear system of any one of the preceding claims, wherein the first shoe communicates wirelessly with the second shoe and vice versa, and the second shoe communicates wirelessly with the external device, the control unit of the second shoe configured to receive the sensor data from both the first and second shoes and further configured to control fan operation of both the first and second shoes based on based on at least one of the sensor data and commands received wirelessly from the external device.

21. The self-cooling footwear system of any one of the preceding claims, wherein the environmental condition is at least one of temperature and humidity, wherein the control unit is configured to automatically regulate fan speed based on the sensed temperature and humidity in the shoe, and / or the difference between those readings and the readings of temperature and humidity external to the shoe.

22. The self-cooling footwear system of any one of the preceding claims, wherein the control unit is configured to increase airflow when the sensed temperature or humidity within the interior cavity exceeds a predetermined threshold, preferably relative to thetemperature and / or humidity external to the shoe, and to decrease airflow when the sensed temperature or humidity is below the predetermined threshold.

23. The self-cooling footwear system of any one of the preceding claims, wherein the predetermined threshold can be stored within the control unit and / or set by the wearer via a mobile device executing a control application.

24. The self-cooling footwear system of any one of the preceding claims, further comprising an odor-absorbing or particulate filter positioned at one or more of the air inlet or air outlet.

25. The self-cooling footwear system of any one of the preceding claims, wherein the shoe is a men’s dress shoe having a formal upper composed of leather or leather-like material and an outsole where the heel region is elevated relative to a ground contact surface at the forefoot region.

26. The self-cooling footwear system of any one of the preceding claims, wherein the shoe is a men’s or women’s shoe and is an athletic shoe, a casual shoe, a dress shoe, a work boot, or a hiking boot.

27. A mobile application for operating the self-cooling footwear system according to any of the preceding claims, the mobile application comprising any mix of: a user interface configured to display operational parameters of the self- cooling footwear system, including at least one of internal temperature, internal humidity, external temperature, external humidity, fan speed, and battery level; a control module configured to allow a user to adjust operational settings of the self-cooling footwear system, including at least one of fan speed, temperature thresholds, and humidity thresholds; where the thresholds are set in absolute value, preferably over 90 deg F, or adaptively relative to a value and a difference with readings revealing an environment external to the shoe a communication module configured to transmit user-defined operational settings to the self-cooling footwear system via a wirelesscommunication protocol, and receive sensor data from the self-cooling footwear system, including at least one of temperature data and humidity data; and a self-learning module configured to analyze user preferences and operational data to automatically adjust the operational settings of the self- cooling footwear system based on user behavior and environmental conditions.

28. The mobile application according to any of the preceding claims, wherein the wireless communication protocol comprises Bluetooth.

29. The mobile application according to any of the preceding claims, wherein the user interface further displays historical data of operational parameters, including trends in internal temperature and humidity over time.

30. The mobile application according to any of the preceding claims, wherein the control module is further configured to enable the user to select predefined operational modes, including at least one of a manual mode, an automatic mode, and a self-learning mode.

31. The mobile application according to any of the preceding claims, wherein the selflearning module is configured to adjust operational settings based external temperature and humidity.

32. The mobile application according to any of the preceding claims, wherein the communication module is further configured to synchronize operational settings and sensor data with a cloud-based database.

33. The mobile application according to any of the preceding claims, wherein the user interface includes notifications to alert the user when the battery level of the self- cooling footwear system falls below a predetermined threshold.

34. The mobile application according to any of the preceding claims, wherein the control module is further configured to allow the user to set a maximum fan speed, especially to minimize noise during operation.

35. The mobile application according to any of the preceding claims, wherein the selflearning module is configured to provide recommendations to the user based on historical usage patterns.

36. The mobile application according to any of the preceding claims, wherein the communication module is further configured to enable pairing of multiple self-cooling footwear systems, allowing synchronized operation of a pair of the shoes.

37. The mobile application according to any of the preceding claims, wherein the user interface is configured to provide real-time feedback on the effectiveness of cooling based on sensor data.

38. The mobile application according to any of the preceding claims, wherein the control module is further configured to allow the user to set operational parameters based on activity level, including walking, running, or stationary modes.

39. The mobile application according to any of the preceding claims, wherein the communication module is further configured to enable remote operation of the self- cooling footwear system from a secondary device.

40. The mobile application according to any of the preceding claims, wherein the user interface is configured to provide troubleshooting guidance for connectivity or operational issues with the self-cooling footwear system.

41. A shoe configured for self-cooling, comprising: a shoe body having an interior cavity, a forefoot region, and a heel region;a heel housing integrated into the heel region and configured to house electronic components; a fan module disposed within the heel housing, the fan module including a fan operable to generate forced airflow from an air inlet located at the forefoot region of the shoe toward an air outlet in the heel region; an insole positioned within the interior cavity of the shoe, the insole comprising a three-dimensional periodic cellular structure configured to provide ventilation and cushioning beneath a wearer’s foot; at least one sensor disposed within the shoe body, the sensor configured to detect environmental conditions within the interior cavity; an electronic control unit disposed within the heel housing and operatively coupled to the fan module and the at least one sensor, the electronic control unit configured to adjust operation of the fan based on sensor data; a wireless communication module disposed within the heel housing and configured to communicate with an external device; and a rechargeable battery disposed within the heel housing and electrically coupled to the electronic control unit, the rechargeable battery configured to power the fan module and electronic control unit.

42. A method for operating a self-cooling footwear system, comprising: detecting environmental conditions within an interior cavity of a shoe using at least one sensor, the environmental conditions including at least one of temperature and humidity; generating sensor data based on the detected environmental conditions; analyzing the sensor data using an electronic control unit operatively coupled to a fan module; adjusting operation of the fan module based on the analyzed sensor data to generate forced airflow from an air inlet located at a forefoot region of the shoe toward an air outlet in a heel region of the shoe; transmitting the sensor data to a mobile device executing a control application via a wireless communication module;receiving user-defined operational settings from the mobile device via the wireless communication module; and modifying operation of the fan module based on the user-defined operational settings.

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