Footwear with internally connected strapping system

Abstract

A footwear article can include: an upper sole including a bottom surface; a lower sole including a top surface coupled to the bottom surface, at least one of the bottom surface or the top surface defining a strap channel; a toe strap including an upper connection portion positioned above the upper sole and a lower connection portion fixedly positioned in the strap channel and between the upper sole and the lower sole; and a foot strap including opposing end portions fixedly positioned in the strap channel between the upper sole and the lower sole.

Description

Attorney Docket No P326774.W0.01 700137-46FOOTWEAR WITH INTERNALLY CONNECTED STRAPPING SYSTEMRELATED APPLICATIONS

[0001] This application claims the benefit of pending U.S. Provisional Patent Application No. 63 / 666,020 filed on 28 June 2024, the contents of which are incorporated herein by reference in their entirety.FIELD

[0002] The described examples relate generally to footwear.BACKGROUND

[0003] People ubiquitously use footwear for protection and comfort of their feet, improved grip or traction on terrain, and / or a desired support or stability of a user’s foot during an activity. Some footwear (e.g., sandals, flip-flops, dress heels, wedges, water shoes, thongs, etc.) can include straps that can engage a user’s foot or otherwise secure the footwear to the user. These straps are commonly integrated with the footwear in ways that lend to strap failure. For example, straps of traditional footwear that include points of attachment to the exterior of the sole sidewall are prone to ripping free of stitching and / or adhesive. As another example, straps of traditional footwear that include pass-through couplings extending to the bottom-most surface of the outer sole — bounded often via an interference fit — are notorious for tearing and / or pulling free from the pass-through attachment. Example activities like walking downhill or on uneven terrain, walking in sand or mud, running, traversing rocks or ground debris, etc. can exacerbate strap weaknesses just mentioned (e.g., by inducing higher stresses and strains on the straps and their points of attachment) that can lead to strap failures. Accordingly, there is a need for improved footwear with straps that are more comfortable and can withstand greater active loads (and sudden, acute loads)14916-6658-8735'1over a longer life of the footwear — thus increasing footwear usability and cross-functionality in some examples.

[0004] The subject matter claimed herein is not limited to examples that solve any disadvantages or that operate only in environments such as those described above. Rather, this background is only provided to illustrate one example technology area where some examples described herein may be practiced.SUMMARY

[0005] An aspect of the present disclosure relates to a footwear article. The footwear article can include: an upper sole including a bottom surface; a lower sole including a top surface coupled to the bottom surface, at least one of the bottom surface or the top surface defining a strap channel; a toe strap comprising an upper connection portion positioned above the upper sole and a lower connection portion fixedly positioned in the strap channel and between the upper sole and the lower sole; and a foot strap comprising opposing end portions fixedly positioned in the strap channel between the upper sole and the lower sole.

[0006] In some examples, the upper sole is a midsole and the lower sole is an outsole, and the footwear article further comprises an insole positioned above midsole. In at least one example, the opposing end portions of the foot strap are coupled to the lower connection portion of the toe strap. In particular examples, the opposing end portions of the foot strap are coupled to each other. In specific implementations, the foot strap comprises a mid-portion between the opposing end portions, the mid-portion being coupled to the upper connection portion of the toe strap above the upper sole. In one example, the lower connection portion of the toe strap extends a majority of a length of the footwear article. In one or more examples, the lower connection portion of the toe strap is coupled to a reinforcement member, the reinforcement member secured to at least one of the bottom surface or the top surface.

[0007] Another aspect of the present disclosure relates to a footwear article. The footwear article can include: a first footwear layer and a second footwear layer defining an interface; an internal track defined by at least one of the first footwear layer or the second footwear layer, the internal track being concealed from an exterior view and positioned along the interface; and aplurality of foot engagement members comprising retained portions statically retained in place inside the internal track.

[0008] In some examples, the retained portions are tactilely imperceivable when the footwear article is donned. In particular examples, in response to a compression load from a user’s weight, at least the first footwear layer is compressible such that one or more segments of the retained portions are compressed against one or both of the first and second footwear layers. In at least one example, a depth of an entirety of the internal track is greater than or equal to a thickness of the retained portions. In specific implementations, the first footwear layer comprises a foam material and the second footwear layer comprises a rubber material.

[0009] Yet another aspect of the present disclosure relates to a method of manufacturing a footwear article. The method can include: providing a first footwear layer including a first mating surface and a second footwear layer including a second mating surface; forming a strap channel in at least one of the first mating surface or the second mating surface; positioning a first strap and a second strap inside the strap channel; and coupling the first mating surface and the second mating surface together, thereby affixing the first strap and the second strap relative to the first mating surface and the second mating surface.

[0010] In some examples, the first strap and the second strap are coupled together. In particular examples, an end portion of the first strap is coupled to each end portion of the second strap. In at least one example, the first strap extends through a toe post hole defined in the first footwear layer, and from the toe post hole the first strap extends longitudinally within the strap channel in a heelward direction. In specific implementations, the method can further include coupling an anchor strip to the first strap, the anchor strip extending longitudinally from the toe post hole in a toeward direction opposite the heelward direction. In one example, forming the strap channelcomprises forming an elongate channel portion in a longitudinal direction for the first strap and forming at least one flank channel portion to each side of the elongate channel portion for the second strap. In some examples, forming the strap channel comprises forming the strap channel with a variable depth, a greatest depth being positioned where the elongate channel portion intersects the flank channel portions. In at least one example, the method can further include lining the second strap with a liner, end portions of the liner extending into the strap channel and secured in place between the first mating surface and the second mating surface.

[0011] Other technical features may be apparent to one skilled in the art, having the benefit of this disclosure, in connection with the following figures, descriptions, and claims. Further, the subject matter claimed herein is not limited to embodiments that solve any disadvantages or that operate only in environments such as those described above. Rather, this summary section is only provided to illustrate certain feature and embodiments.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:

[0013] FIG. 1 illustrates a schematic diagram of a footwear article in accordance with one or more examples of the present disclosure;

[0014] FIG. 2 illustrates a cross-sectional schematic diagram of a footwear article in accordance with one or more examples of the present disclosure;

[0015] FIG. 3 illustrates a cross-sectional schematic diagram of another footwear article in accordance with one or more examples of the present disclosure;

[0016] FIG. 4 illustrates a plan view of a first embodiment of a footwear layer in accordance with one or more examples of the present disclosure;

[0017] FIG. 5 illustrates a plan view of a second embodiment of a footwear layer in accordance with one or more examples of the present disclosure;

[0018] FIG. 6 illustrates a plan view of a third embodiment of a footwear layer in accordance with one or more examples of the present disclosure;

[0019] FIG. 7 illustrates a plan view of a fourth embodiment of a footwear layer in accordance with one or more examples of the present disclosure;

[0020] FIG. 8 illustrates a top perspective view of a midsole in accordance with one or more examples of the present disclosure;

[0021] FIG. 9 illustrates another top perspective view of the midsole of FIG. 8, in accordance with one or more examples of the present disclosure;

[0022] FIG. 10 illustrates a bottom perspective view of the midsole of FIG. 8, in accordance with one or more examples of the present disclosure;

[0023] FIG. 11 illustrates another bottom perspective view of the midsole of FIG. 8, in accordance with one or more examples of the present disclosure;

[0024] FIG. 12 illustrates a detail view of the midsole shown in FIG. 11, in accordance with one or more examples of the present disclosure;

[0025] FIG. 13 illustrates a top perspective view of an outsole in accordance with one or more examples of the present disclosure;

[0026] FIG. 14 illustrates a bottom perspective view of the outsole shown in FIG. 13, in accordance with one or more examples of the present disclosure;

[0027] FIG. 15A illustrates an exploded view of a footwear article in accordance with one or more examples of the present disclosure;

[0028] FIG. 15B illustrates an assembled view of the footwear article shown in FIG. 15 A, in accordance with one or more examples of the present disclosure;

[0029] FIG. 15C illustrates a cross-sectional assembled view of the footwear article shown in FIG. 15B, in accordance with one or more examples of the present disclosure; and

[0030] FIG. 16 illustrates a flowchart of a series of acts for manufacturing a footwear article in accordance with one or more examples of the present disclosure.DETAILED DESCRIPTION

[0031] Reference will now be made in detail to representative examples illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the examples to one preferred example. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described examples as defined by the appended claims.

[0032] The following disclosure relates to a footwear article that includes an internal strapping system. The internal strapping system can include an internally anchored toe strap and an internally anchored foot strap. These straps can extend from an above-sole positioning — where engageable with a user’s foot — to an inter-sole positioning where internal strap portions are fixedly anchored to each other and / or to one or more interior sole surfaces. In particular examples, internal strap portions are routed through strap channels, lending to comfort, tactile imperceptibility of the housed straps, and lower stack heights for the footwear article. In some examples, the internal strapping system imparts to a footwear article superior durability, enhanced cross-functionality, and / or improved tearing resistance relative to conventional designs.

[0033] These and other examples are discussed below with reference to FIGS. 1-16. However, a person of ordinary skill in the art — having the benefit of this disclosure — will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. Furthermore, as used herein, a system, a method, an article, a component, a feature, or a sub-feature including at least one of a first option, a second option, or a third option should be understood as referring to a system, a method, an article, a component, a feature, or a sub-feature that can include one of each listed option (e.g., only one ofthe first option, only one of the second option, or only one of the third option), multiple of a single listed option (e.g., two or more of the first option), two options simultaneously (e.g., one of the first option and one of the second option), or combination thereof e.g., two of the first option and one of the second option).

[0034] FIG. 1 illustrates a schematic diagram of a footwear article 100 in accordance with one or more examples of the present disclosure. As shown, the footwear article 100 can include a first footwear layer 102, a second footwear layer 104, internal track(s) 106, and foot engagement members 108. These elements are described in detail below. As used herein, the term “footwear article” can refer to a foot covering, foot slip-on, foot protector, foot-traction aid, foot insulator, foot gear, and the like. Examples of a footwear article can include shoes, sneakers, slippers, boots, cleats, clogs, sandals, sport sandals, moccasins, flip-flops, loafers, flats, slides, stilettos, high heels, wedges, lace-ups, thongs, buckled shoes, strapped shoes, latchet shoes, open-toe shoes, water shoes, etc. In some examples, a footwear article of the present disclosure does not include an enclosed upper (e.g., an upper enclosed with each of a vamp, quarters, tongue, heel counter, toe box, and lace guard). Rather, a footwear article of the present disclosure can include an at least partially open upper (e. ., that omits at least one of a vamp, quarters, tongue, heel counter, toe box, or lace guard). These and / or other examples of the footwear article 100 can be adapted to implement the new and novel elements of the present disclosure.

[0035] In some examples, the footwear article 100 can include a first footwear layer 102 and a second footwear layer 104. Additional footwear layers can also be implemented in specific examples (e.g., as discussed below in relation to FIG. 3). As used herein, the term “footwear layer” can refer to a section or segment of material composing a footwear article. In some examples, afootwear layer describes a particular stratum or level of material in a material stack. In particular examples, a footwear layer is a discrete portion in an ordered tier comprising a footwear article. Additionally or alternatively, a footwear layer can include an insert, cushion, orthopedic inlay, removable pad, etc. In at least some examples, a footwear layer comprises a sole (e.g., an insole, a midsole, or an outsole). In one implementation, the first footwear layer 102 can thus include an insole, and the second footwear layer 104 can include an outsole. In another implementation, the first footwear layer 102 can include a midsole, and the second footwear layer 104 can include an outsole. In yet another implementation, the first footwear layer 102 can include an insole, and the second footwear layer 104 can include a midsole. In these or other examples, the first footwear layer 102 and the second footwear layer 104 can be positioned adjacent to one another. For instance, the first footwear layer 102 and the second footwear layer 104 can be in intimate contact with each other and / or coupled to one another. The term “coupled” can be interpreted as glued, bonded, fastened, thermally welded, stitched, nailed, adhered, etc. The term “coupled” can also be interpreted as including portions ( .g., footwear layers) that are integrally formed together as a single piece — such as via a molding process.

[0036] The footwear layer 102 and the footwear layer 104 can include a variety of materials and material properties. In some examples, the footwear layer 102 and the footwear layer 104 comprise a same material. In other examples, the footwear layer 102 and the footwear layer 104 comprise different materials. For example, the first footwear layer 102 can include a foam material, plastic material, cushioning material, shock absorption material, formable material, etc. (e.g., ethylene vinyl acetate, known as EVA). In addition, the second footwear layer 104 can include a rubber material. Additionally or alternatively, the first footwear layer 102 can include a foam material comprising a first density, and the second footwear layer 104 can include a foam materialcomprising a second density greater than the first density (e.g., to provide a comfort layer in immediate contact with a user’s foot and a denser layer below the comfort layer for support). In certain examples, at least one of the first layer 102 or the second layer 104 can include a bio-based material, an environmentally friendly material, a petroleum-alternative material, etc. In specific implementations, at least one of the first layer 102 or the second layer 104 can include an algae- based foam and / or rubber material. Additionally or alternatively, at least one of the first layer 102 or the second layer 104 can include a leather material, wood material, canvas material, nylon material, neoprene material, and / or a composite material.

[0037] The footwear article 100 can additionally include the internal track(s) 106. As used herein, the terms “internal track,” “channel,” or “strap channel” can refer to an interior groove, cutaway, or depression defined by at least one of the first footwear layer 102 or the second footwear layer 104. In some examples, the internal track(s) 106 are sized and shaped to receive one or more portions of the foot engagement members 108 (particularly retained portions 110 and, in some cases, end portions of a liner 112), as will be discussed below. For instance, the internal track(s) 106 can include permanent receptacles or elongate holding slots for the retained portions 110. In these or other examples, the internal track(s) 106 can be positioned along the interface (e. ., a mating interface) between the first footwear layer 102 and the second footwear layer 104 where the first footwear layer 102 and the second footwear layer 104 are abutted and / or joined together. Thus, in some embodiments, the internal track(s) 106 can be concealed from an exterior view. That is, the first footwear layer 102 and the second footwear layer 104 (when coupled together or positioned adjacent to each other) can visually obscure the internal track(s) 106, which can be exclusively positioned between exterior surfaces formed by the combination of the first footwear layer 102 and the second footwear layer 104.

[0038] The footwear article 100 can further include the foot engagement members 108. As used herein, the term “foot engagement member” refers to a portion of the footwear article 100 that can help secure the footwear article 100 to a user’s foot. In some examples, the foot engagement members 108 can engage (e.g., contact, secure, abut, support, brace, hold, overlay, wrap around, or at least partially cover) portions of a user’s foot — such as a toe region, forefoot region, midfoot region, hindfoot region, top foot region, back foot / heel region, ankle region, etc. In particular examples, the foot engagement members 108 can engage the user’ s foot when the foot is in motion, thereby preventing the footwear article 100 from inadvertently falling off of the user’s foot. Examples of a foot engagement member can include a strap, webbing, band, cord, rope, lace, weave, tie, elastic member, adjustable connector, etc. More specific examples of a foot engagement member can include a sandal bridge, toe strap (also referred to as a toe post), foot strap, ankle strap, lateral and medial straps, heel strap, etc. In these or other examples, the foot engagement members 108 can include various materials (e.g., leather, polypropylene, polyester, nylon, tubular nylon, rubber, silicone, plant-based materials, composite materials, braided or twisted materials, ripstop material, neoprene, etc ).

[0039] In one or more examples, the foot engagement members 108 can include the retained portions 110. The retained portions 110 can include the portions of the foot engagement members 108 that are statically retained (e.g. , permanently set and immovably positioned) within the internal track(s) 106. The retained portions 110 can be concealed portions of the foot engagement members 108 that positionally anchor or brace the foot engagement members 108. For example, the retained portions 110 can reinforce the foot engagement members 108 to more easily withstand stresses and strains of casual wear, as well as the greater, acute stresses and strains that can accompany active wear / use of the footwear article 100. Unlike traditional footwear, and as will be discussedmore below in relation to subsequent figures, the retained portions 110 can leverage an increased surface area (e.g., along a substantial portion or length of the footwear article 100) to create a stronger coupling of the foot engagement members 108 to the footwear article 100 itself. Because of the retained portions 110, more surface area of the foot engagement members 108 can be utilized to counter the active — and often sudden peak — forces that a user can impart to the foot engagement members 108 when, for instance, walking downhill or on uneven terrain, walking in sand or mud, running, traversing rocks or ground debris, catching a toe edge, etc. With an increased surface area afforded by the retained portions 110, the foot engagement members 108 can include a significantly higher durability rating (e.g., maximum force load), a longer footwear life, and / or increased useability / cross-functionality in comparison to traditional sandals, flip-flops, etc. prone to strap failure.

[0040] In certain examples, the added strength and durability provided by the retained portions 110 does not sacrifice or detract from user comfort. In particular examples, the retained portions 110 can be tactilely imperceivable (e.g., unfelt, too subtle or slight to be perceived or sensed by the user, no noticeable bump or protrusion, no perceived foot pressure, etc.) when the footwear article 100 is donned by a user. Indeed, despite being positioned underneath the user’s foot, the retained portions 110 can be positioned within the internal track(s) 106 such that a thickness of the retained portions 110 does not perceivably add to the local profile height or stack-up of the footwear article 100. For example, inside the internal track(s) 106, the retained portions 110 can be positioned flush with (or even slightly recessed relative to) the adjacent surface portions of the first footwear layer 102 and the second footwear layer 104.

[0041] In some examples, the foot engagement members 108 can optionally include a liner 112.The liner 112 can include a shell, cover, wrapping, coating, envelope, or padding that at least partially encompasses the foot engagement members 108, particularly portions (other than the retained portions 110) that can contact the user’s foot. In one or more examples, the liner 112 can include a comfort liner. In these or other examples, the liner 112 can include various materials (e.g., foam, leather, polyester, nylon, rubber, silicone, plant-based materials, composite materials, cushion materials, deformable materials, neoprene, soft (non-rigid) materials, woven materials, knitted materials, gels, textiles, etc.). In particular implementations, end portions of the liner 112 can be retained inside the internal track(s) 106, as will be discussed below.

[0042] Any of the features, components, and / or parts, including the arrangements and configurations thereof shown in FIG. 1 can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and / or parts, including the arrangements and configurations thereof shown and described with reference to the other FIGS, can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIG. 1.

[0043] FIG. 2 illustrates a cross-sectional schematic diagram of a footwear article 200 in accordance with one or more examples of the present disclosure. The footwear article 200 can be the same as or similar to the footwear article 100 discussed above in relation to FIG. 1. As shown, the footwear article 200 can include an upper sole 202 and a lower sole 206 (e.g., first and second footwear layers 102, 104). In these or other examples, the upper sole 202 can include an insole,and the lower sole 206 can include an outsole. However, other two-sole or two-layer implementations are herein contemplated.

[0044] As depicted in FIG. 2, the upper sole 202 can include a concealed bottom surface 204 (e.g., a first mating surface), and the lower sole 206 can include a concealed top surface 208 (e.g., a second mating surface). The lower sole 206 and the concealed top surface 208 are positionable adjacent to each other and coupled together (e.g., in intimate contact one with another along an interface) — thereby concealing the lower sole 206 and the concealed top surface 208 from external view.

[0045] Further depicted, a strap channel 210 is defined by the concealed bottom surface 204 of the upper sole 202. Additionally or alternatively, the strap channel 210 can be defined by the concealed top surface 208 of the lower sole 206, as represented via the dashed line segment. In these or other examples, foot engagement members can be positioned inside the strap channel 210. For example, a toe strap 212 can be routed through the upper sole 202, where a lower connection portion 216 of the toe strap 212 can be statically retained (e.g., the retained portions 110 discussed above) inside the strap channel 210. In specific examples, the lower connection portion 216 can be coupled (e.g., adhered) to the concealed bottom surface 204 defining the walls of the strap channel 210. Additionally or alternatively, the lower connection portion 216 can couple to a foot strap 218 (e.g., an ankle strap, lateral / medial strap, heel strap, midfoot strap, hindfoot strap, etc.) at opposing end portions 220 of the foot strap 218 also routed into the strap channel 210. In one or more examples, coupling the lower connection portion 216 and the opposing end portions 220 to each other can impart additional strength to one or both of the foot strap 218 and the toe strap 212 than if independently coupled to the upper sole 202 (or the lower sole 206). Still further, at leastone of the lower connection portion 216 or the opposing end portions 220 can be additionally or alternatively coupled to the concealed top surface 208. In some examples, the lower connection portion 216 and the opposing end portions 220 are coupled to each other, coupled to the concealed bottom surface 204 defining the strap channel 210, and coupled to the concealed top surface 208 — thus providing a three-form coupling for superior strength and improved resistance to wear and tear over sustained active loads and sudden acute loads.

[0046] In one or more examples, a mid-portion 222 of the foot strap 218 can be coupled to an upper connection portion 214 of the toe strap 212. In these or other examples, the mid-portion 222 of the foot strap 218 and the upper connection portion 214 of the toe strap 212 can refer to the portions of the foot engagement members that are positioned exterior to (or above) the upper sole 202 and the lower sole 206.

[0047] Although FIG. 2 illustrates two discrete foot engagement members (i.e., the toe strap 212 and the foot strap 218), those of ordinary skill in the art — having the benefit of this disclosure — will recognize that other configurations of foot engagement members can be adapted with the strap channel 210. For example, a single-piece foot engagement member may be arranged to form both the foot strap and the toe strap with end portions thereof coupled together within the strap channel 210. As another example, three or more foot engagement members can be coupled together and / or otherwise retained within the strap channel 210. For instance, a heel strap (not shown) or any other foot strap can be added, and end portions thereof can be retained within the strap channel 210 and / or coupled to at least one of the opposing end portions 220 or the lower connection portion 216.

[0048] Any of the features, components, and / or parts, including the arrangements and configurations thereof shown in FIG. 2 can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and / or parts, including the arrangements and configurations thereof shown and described with reference to the other FIGS, can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIG. 2.

[0049] As mentioned above, a footwear article of the present disclosure can include three or more footwear layers. In accordance with one or more such examples, FIG. 3 illustrates a cross- sectional schematic diagram of a footwear article 300. As shown, the footwear article 300 can include an insole 302, a midsole 304, and an outsole 306. In the depicted example, the strap channel 210 is defined by the midsole 304 (like the upper sole 202 in FIG. 2). Additionally or alternatively, however, the strap channel 210 can be defined by the top surface of the outsole 306. In other examples, the strap channel 210 can be defined by the bottom surface of the insole 302 and / or the top surface of the midsole 304. All other aspects of the footwear article 300 can be the same as or similar to the footwear article 100 and / or the footwear article 200 discussed above.

[0050] Any of the features, components, and / or parts, including the arrangements and configurations thereof shown in FIG. 3 can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and / or parts, including the arrangements and configurations thereof shown and described with reference to the other FIGS.can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIG. 3.

[0051] FIGS. 4-7illustrate schematic plan views of various embodiments of a footwear layer or sole in accordance with one or more examples of the present disclosure. FIG. 4, for example, illustrates a sole 400, which can be the same as or similar to any of the footwear layers or soles discussed herein. In some examples, the sole 400 can include a mating surface 402. The mating surface 402 can be a coupling surface positionable against (and coupled to) another sole or footwear layer. The mating surface 402 can define various features now discussed in turn.

[0052] In some examples, the mating surface 402 defines a strap channel 404. The strap channel 404 can include various portions for receiving various straps or strap portions. In particular examples, the strap channel 404 can include an elongate channel portion 406 extending longitudinally along at least a portion of the length 418 of the sole 400. In some examples, the elongate channel portion 406 extends a majority i.e., at least 50%) of the length 418. In other examples, the elongate channel portion 406 can extend between about 5% and about 50% of the length 418, between about 10% and about 40% of the length 418, between about 15% and about 30% of the length 418, or between about 20% and 25% of the length 418.

[0053] The longitudinal direction of the elongate channel portion 406 can generally extend in the toeward and heelward directions. However, the elongate channel portion 406 is not limited to be parallel to the toeward or heelward directions. Likewise, the elongate channel portion 406 is not limited to being centrally positioned (e.g., positioned equidistant between lateral and medial sides of the sole 400) along the mating surface 402. In some examples, the elongate channel portion 406 can be oblique to the toeward and heelward directions while still extending in a generallylongitudinal fashion at least partially between toe and heel regions. Additionally or alternatively, the elongate channel portion 406 can include curved segments, shaped segments, non-linear segments, serpentine segments, etc. In some examples, the elongate channel portion 406 can include multiple linear segments that form a bend, corner, or turn to create a non-straight (or angled) relationship therebetween.

[0054] As shown, the elongate channel portion 406 can extend at least from a toe post hole 412 (e.g., a through-hole defined in the mating surface 402 and an opposing surface to the mating surface 402) and longitudinally in the heelward direction. A toe strap above the mating surface 402 (e.g., into the page) can extend through the toe post hole 412 and into the strap channel 404, specifically into the elongate channel portion 406. The portion of the toe strap extending into the elongate channel portion 406 can be referred to as a lower connection portion 410. The lower connection portion 410 can extend coextensive to the elongate channel portion 406 (e.g., a majority of the length 418).

[0055] In these or other examples, the lower connection portion 410 can be positionally fixed in a variety of ways. In some examples, the lower connection portion 410 is coupled to (e.g., adhered to) the mating surface 402 inside the elongate channel portion 406. Additionally or alternatively, the lower connection portion 410 can be coupled to at least one of the end portions 414 — corresponding to a second strap separate from the toe strap — via coupling 416 (e.g., stitching, adhesive, etc.). In particular examples, the lower connection portion 410 is coupled to both end portions 414 via the coupling 416. In such examples, the lower connection portion 410 at least partially overlaps (over the top or underneath) the end portions 414. The lower connection portion 410 can additionally or alternatively be secured in place within the elongate channelportion 406 by being sandwiched against (and / or coupled to) an opposing footwear layer or sole not shown in FIG. 4 — such as the second footwear layer 104, lower sole 206, or outsole 306.

[0056] Additionally shown in FIG. 4, the strap channel 404 can include flank channel portions 408 defined by the mating surface 402. In some examples, the flank channel portions 408 can be positioned at each side of the elongate channel portion 406. For instance, the flank channel portions 408 can offshoot from the elongate channel portion 406 toward respective lateral and medial sides of the sole 400. The medial side is an inner side, closer to a midline of the user’s body and the big toe. The lateral side is the outer side, away from the midline of the user’s body and closer to the little toe. That is, the flank channel portions 408 can extend from an edge region of the mating surface 402 and intersect the elongate channel portion 406. In these or other examples, the flank channel portions 408 can be sized and shaped to receive the end portions 414 of a foot strap (e.g., through a slot or through hole defined adjacent to the side edge of the mating surface 402).

[0057] Similar to the lower connection portion 410, the end portions 414 can be positionally fixed in a variety of ways. In some examples, the end portions 414 can be coupled to the mating surface 402 inside the flank channel portions 408. Additionally or alternatively, the end portions 414 can be coupled together and / or to the lower connection portion 410 via the coupling 416. The end portions 414 can additionally or alternatively be secured in place within the flank channel portions 408 by being sandwiched against (and / or coupled to) an opposing footwear layer or sole not shown in FIG. 4 — such as the second footwear layer 104, lower sole 206, or outsole 306.

[0058] In the embodiment of FIG. 5, a sole 500 can include various features that are the same as or similar to the features just discussed in relation to the sole 400. In addition, however, the sole 500 can include an anchor strip 502. The anchor strip 502 can include a reinforcement membere.g., a support structure, brace, stay, buttress, strengthening material, stiffener, directional strengthener, isotropy enhancer, binder, connector, fastener, securement, etc ). In particular examples, the reinforcement member 502 can include a webbing strip or segment of material added to the lower connection portion 410. In these or other examples, the reinforcement member 502 can be coupled to the lower connection portion 410 at a coupling 504. Additionally or alternatively, the reinforcement member 502 can be coupled (e.g., adhered to or otherwise secured) to at least one of the mating surface 402 or an opposing mating surface of another footwear layer not shown — thus, a concealed bottom surface and / or a concealed top surface of a footwear layer. In certain implementations (as shown), the coupling 504 is positioned adjacent to the toe post hole 412. Additionally or alternatively, the coupling 504 can be positioned elsewhere (e.g., midfoot).

[0059] The anchor strip 502 can anchor the toe strap in one or more different ways and / or in one or more different locations along the mating surface 402. In some examples, the reinforcement member 502 can positionally anchor or fix the lower connection portion 410 by increasing a surface area coverage across the mating surface 402 that is adhered in place and / or adhered to an opposing footwear layer not shown. In particular examples, the reinforcement member 502 can extend in a desired direction that enhances directional stability of the toe strap. For instance, the reinforcement member 502 can extend longitudinally in the toeward direction opposite the heelward direction (e.g., from the about the toe post hole 412 and / or from the coupling 504). In this example, the elongate channel portion 406 can also extend in the toeward direction from the toe post hole 412 to provide a receptacle or guide track for receiving the reinforcement member 502. Additionally or alternatively (albeit not shown), the reinforcement member 502 can branch out laterally (and / or medially) from the elongate channel portion 406, similar to the flank channel portions 408 and / or corresponding end portions 414. In these or other examples, the extension ofthe reinforcement member 502 in the toeward direction (and / or oblique toeward directions) can directionally strengthen the foot strap by extending in a different direction than the lower connection portion 410. For instance, the reinforcement member 502 can increase an amount of resistance to the toe strap pulling out of the toe post hole 412 in response to certain actions that can place relatively high strains on the toe strap (e.g., catching a toe edge of the footwear such as when tripping over an object or stubbing your toe; raising the footwear out of sand, mud, snow, or water; etc.).

[0060] In the embodiment of FIG. 6, a sole 600 can include various features that are the same as or similar to the features just discussed in relation to the soles 400, 500. As shown, however, for the sole 600, the elongate channel portion 406 does not overlap with or intersect the flank channel portions 408. Instead, the elongate channel portion 406 extends from the toe post hole 412 in the heelward direction, but the elongate channel portion 406 stops short of intersecting the flank channel portions 408. In this example, the lower connection portion 410 can be secured to the mating surface 402 inside the elongate channel portion 406 and still provide the desired strength without coupling to the end portions 414. In addition, the end portions 414 can be secured to the mating surface 402 inside the flank channel portions 408. In some examples, the end portions 414 can be additionally or alternatively secured to each other via the coupling 416.

[0061] In these or other examples, maintaining the lower connection portion 410 separate from the end portions 414 can be advantageous. For example, the coupling 416 can be simplified or reduced due to less material being coupled together. As another example, a depth of the strap channel 404 can be reduced where the flank channel portions 408 overlap or connect rather than a corresponding channel depth at this location being locally increased to accommodate the additionof the lower connection portion 410 overlapping the end portions 414. In one or more examples, the embodiment of FIG. 6 may be implemented in certain lower profile footwear, footwear including thinner footwear layers, footwear with certain material densities or tactile properties, and / or footwear with certain adhesive / bond strength ratings.

[0062] In the embodiment of FIG. 7, a sole 700 can include various features that are the same as or similar to the features just discussed in relation to the soles 400, 500, and 600. As shown, however, for the sole 700, none of the lower connection portion 410 or the end portions 414 are coupled together. In such examples, the elongate channel portion 406 and the flank channel portions 408 can each be separate and unconnected from each other. Thus, the lower connection portion 410 and the end portions 414 can be coupled to the mating surface 402 on an individual basis, each respectively within the elongate channel portion 406 and left-right channel portions of the flank channel portions 408. In these or other examples, the lower connection portion 410 and the end portions 414 can be elongated, shaped, and / or routed along the mating surface 402 (without overlapping each other) to still provide a desired strength and durability. In one or more examples, the embodiment of FIG. 7 may be implemented in certain lower profile footwear, footwear including thinner footwear layers, footwear with certain material densities or tactile properties, and / or footwear with certain adhesive / bond strength ratings.

[0063] Any of the features, components, and / or parts, including the arrangements and configurations thereof shown in FIGS. 4-7 can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and / or parts, including the arrangements and configurations thereof shown and described with reference to the other FIGS.can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 4-7.

[0064] FIGS. 8-12 illustrate a midsole 800 in accordance with one or more examples of the present disclosure. As show in FIGS. 8-9 specifically, the midsole 800 can include a top surface 802 that is recessed to receive an insole (not shown). The top surface 802 (and / or surrounding perimeter portion) can define slots 804 and the toe post hole 412 discussed above. The slots 804 can be sized and shaped to receive foot straps (e.g, foot straps 218), and the toe post hole 412 can be sized and shaped to receive a toe strap (e.g, the toe strap 212).

[0065] In FIGS. 10-12, the midsole 800 can include a mating surface 1002 defining various features discussed herein. The mating surface 1002 can be coupled to a corresponding mating surface of an outsole (e.g., mating surface 1302 of outsole 1300 shown in FIG. 13). The mating surface 1002 can define a strap channel 1004 that includes an elongate channel portion 1006 and flank channel portions 1008 — similar to the embodiment of FIG. 4. Additionally shown, however, the strap channel 1004 can include liner channel portions 1010. The liner channel portions 1010 can extend at least partially between the slots 804 and the elongate channel portion 1006. In these or other examples, end portions of a liner (e.g., liner 112, not shown in FIGS. 10-12) can extend through the slots 804 along with the end portions of the foot strap (e.g., end portions 414). The end portions of the liner can be coupled to the mating surface 1002 and thus neatly concealed from external view while being positionally fixed in place. In certain examples, coupling the end portions of the liner within the liner channel portions 1010 can help prevent movement of the liner relative to the foot strap.

[0066] In some examples, the liner channel portions 1010 includes a larger depth and / or perimeter than the flank channel portions 1008. The larger dimensions (depth and / or perimeter) of the liner channel portions 1010 relative to the flank channel portions 1008 can allow the liner to be at least partially (if not entirely) retained within the liner channel portions 1010 to reduce or prevent tactile feel of the liner when the footwear is donned and / or to help prevent visual bulging of the top surface 802 or an adjacent insole. That is, a depth 1012 of the strap channel 1004, and in some cases along an entirety of the strap channel 1004, can be greater than or equal to a thickness of a retained strap positioned within the strap channel 1004. In particular examples, the depth 1012 can vary along the strap channel 1004. For instance, the depth 1012 can be greater where the elongate channel portion 1006 intersects the flank channel portions 1008 (e.g., to accommodate the stacking or overlap of foot straps) in comparison to the depth 1012 at other locations along the strap channel 1004.

[0067] Additionally or alternatively, the depth 1012 of the strap channel 1004 can be dimensioned to account for compression loading of the midsole 800. For instance, in response to a compression load (e.g., an applied downward force from a user’s weight), at least the midsole 800 can be compressible (e.g., squished, compacted, elastically deformed, pliantly altered, etc.). When the midsole 800 is compressed, one or more segments of the retained foot straps and toe straps — despite being retained within the strap channel 1004 — can be compressed (e.g., sandwiched or pushed) against one or both of the midsole 800 or another footwear layer (e.g., the outsole 1300). In some cases, loading the retained strap portions under compression can enhance a durability, increase a strap load rating, and / or induce higher friction forces for retaining the strap portions in place within the strap channel 1004. Additionally or alternatively, the depth 1012 can be sufficiently dimensioned such that, even under compression loads from a user’s weight, thedepth 1012 is still deep enough to be greater than or equal to the thickness of a retained strap portion. In such a case, the depth 1012 can prevent any loading on a retained strap portion.

[0068] Any of the features, components, and / or parts, including the arrangements and configurations thereof shown in FIGS. 8-12 can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and / or parts, including the arrangements and configurations thereof shown and described with reference to the other FIGS, can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 8-12.

[0069] FIGS. 13-14 respectively illustrate a top and bottom perspective views of an outsole 1300 in accordance with one or more examples of the present disclosure. The outsole 1300 can include one or more materials discussed above for footwear layers. As shown, the outsole 1300 can include a mating surface 1302 sized and shaped to mate with an insole or a midsole (e.g., the mating surface 1002 of midsole 800, the mating surface 402, the concealed bottom surface 204 of the upper sole 202, etc.). In these or other examples, the mating surface 1302 can be recessed relative to the outer perimeter edge to accommodate one or more adjacent footwear layers above the outsole 1300.

[0070] The outsole 1300 can additionally include a ground contact surface 1400. The ground contact surface 1400 can contact a ground surface (e.g., an indoor ground surface or an outdoor ground surface). The ground surface may be a walking surface, hiking surface, home surface, road surface, trail surface, building surface, etc. In certain examples, the ground surface may be a vehicle floor, boat floor, bicycle pedal, scooter floorboard, etc. Thus, the ground surface caninclude virtually any surface where human feet can rest, travel, move, or be supported. In some examples, the ground contact surface 1400 is adapted for foot travel over dirt, mud, gravel, concrete, pavement, carpet, wood, snow, etc. In these or other examples, the ground contact surface 1400 can include various aesthetic features and / or ground contact aids (traction aids, treading, spikes, etc.).

[0071] Any of the features, components, and / or parts, including the arrangements and configurations thereof shown in FIGS. 13-14 can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and / or parts, including the arrangements and configurations thereof shown and described with reference to the other FIGS, can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 13-14.

[0072] FIGS. 15A-15C respectively illustrate exploded, assembled, and cross-sectional views of a footwear article 1500 in accordance with one or more examples of the present disclosure. The footwear article 1500 can include a combination of footwear articles and / or layers thereof discussed above. For instance, the footwear article 1500 can include the midsole 800, the outsole 1300, and an insole 302. The footwear article 1500 can also include foot engagement members, including the foot strap 218 above the insole 302 and the toe strap extending internally between footwear layers (e.g., the lower connection portion 410) to internally connect to the end portions 414 of the foot strap 218.

[0073] Any of the features, components, and / or parts, including the arrangements and configurations thereof shown in FIGS. 15A-15C can be included, either alone or in anycombination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and / or parts, including the arrangements and configurations thereof shown and described with reference to the other FIGS, can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 15A-15C.

[0074] FIGS. 1-15C, the corresponding text, and the associated examples thereof provide several different systems, manufacturing methods, techniques, components, and / or articles of footwear in accordance with one or more embodiments. In addition to the above description, one or more embodiments can also be described in terms of flowcharts including acts for accomplishing a particular result or performing a certain function. For example, FIG. 16 illustrates a flowchart of a series of acts 1600 for manufacturing a footwear article in accordance with one or more embodiments. While FIG. 16 illustrates acts according to one embodiment, alternative embodiments may omit, add to, reorder, and / or modify any of the acts shown in FIG. 16. The acts of FIG. 16 can be performed as part of a method. Alternatively, a non-transitory computer-readable medium can comprise instructions that, when executed by one or more processors, cause a computing device (or a computer component, such as a processor, implemented in a manufacturing system, robotic apparatus, or at least semi-autonomous industrial machine) to perform the acts of FIG. 16. In some embodiments, a system can perform the acts of FIG. 16.

[0075] As shown, the series of acts 1600 can include an act 1602 of providing a first footwear layer including a first mating surface and a second footwear layer including a second mating surface.

[0076] An act 1604 can include forming a strap channel in at least one of the first mating surface or the second mating surface. In some examples, forming the strap channel comprises forming an elongate channel portion in a longitudinal direction for the first strap and forming at least one flank channel portion to each side of the elongate channel portion for the second strap. In at least one example, forming the strap channel comprises forming the strap channel with a variable depth, a greatest depth being positioned where the elongate channel portion intersects the flank channel portions.

[0077] An act 1606 can include positioning a first strap and a second strap inside the strap channel. In some examples, the first strap and the second strap are coupled together. In one example, an end portion of the first strap is coupled to each end portion of the second strap. In particular examples, the first strap extends through a toe post hole defined in the first footwear layer, and from the toe post hole the first strap extends longitudinally within the strap channel in a heelward direction.

[0078] An act 1608 can include coupling the first mating surface and the second mating surface together, thereby affixing the first strap and the second strap relative to the first mating surface and the second mating surface.

[0079] Additional or alternative acts can be performed as part of the series of acts 1600. For instance, one example act can include coupling an anchor strip to the first strap, the anchor strip extending longitudinally from the toe post hole in a toeward direction opposite the heelward direction. In another example, the series of acts 1600 can include lining the second strap with a liner, end portions of the liner extending into the strap channel and secured in place between the first mating surface and the second mating surface.

[0080] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described examples. However, it will be apparent to one skilled in the art — having the benefit of this disclosure — that the specific details are not required in order to practice the described examples. Thus, the foregoing descriptions of the specific examples described herein are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the examples to the precise forms disclosed.

[0081] It will be apparent to one of ordinary skill in the art, having the benefit of this disclosure, that many modifications and variations are possible in view of the above teachings. Indeed, various inventions have been described herein with reference to certain specific aspects and examples. However, many variations are possible without departing from the scope and spirit of the inventions disclosed herein. Specifically, those inventions set forth in the claims below are intended to cover all variations and modifications of the inventions disclosed without departing from the spirit of the inventions. The terms “including” or “includes” as used in the specification shall have the same meaning as the term “comprising.” Additionally, the terms “about,” “approximately,” and “substantially” should be interpreted as + / - 10 percent of a stated value.

Claims

CLAIMSWhat is claimed is:

1. A footwear article, comprising: an upper sole including a bottom surface; a lower sole including a top surface coupled to the bottom surface, at least one of the bottom surface or the top surface defining a strap channel; a toe strap comprising an upper connection portion positioned above the upper sole and a lower connection portion fixedly positioned in the strap channel and between the upper sole and the lower sole; and a foot strap comprising opposing end portions fixedly positioned in the strap channel between the upper sole and the lower sole.

2. The footwear article of claim 1, wherein the upper sole is a midsole and the lower sole is an outsole, and the footwear article further comprises an insole positioned above midsole.

3. The footwear article of claim 1, wherein the opposing end portions of the foot strap are coupled to the lower connection portion of the toe strap.

4. The footwear article of claim 1, wherein the opposing end portions of the foot strap are coupled to each other.

5. The footwear article of claim 1, wherein the foot strap comprises a mid-portion between the opposing end portions, the mid-portion being coupled to the upper connection portion of the toe strap above the upper sole.

6. The footwear article of claim 1, wherein the lower connection portion of the toe strap extends a majority of a length of the footwear article.

7. The footwear article of claim 1, wherein the lower connection portion of the toe strap is coupled to a reinforcement member, the reinforcement member secured to at least one of the bottom surface or the top surface.

8. A footwear article, comprising: a first footwear layer and a second footwear layer defining an interface; an internal track defined by at least one of the first footwear layer or the second footwear layer, the internal track being concealed from an exterior view and positioned along the interface; and a plurality of foot engagement members comprising retained portions statically retained in place inside the internal track.

9. The footwear article of claim 8, wherein the retained portions are tactilely imperceivable when the footwear article is donned.

10. The footwear article of claim 8, wherein in response to a compression load from a user’ s weight, at least the first footwear layer is compressible such that one or more segments of the retained portions are compressed against one or both of the first and second footwear layers.

11. The footwear article of claim 8, wherein a depth of an entirety of the internal track is greater than or equal to a thickness of the retained portions.

12. The footwear article of claim 8, wherein the first footwear layer comprises a foam material and the second footwear layer comprises a rubber material.

13. A method of manufacturing a footwear article, the method comprising: providing a first footwear layer including a first mating surface and a second footwear layer including a second mating surface; forming a strap channel in at least one of the first mating surface or the second mating surface; positioning a first strap and a second strap inside the strap channel; and coupling the first mating surface and the second mating surface together, thereby affixing the first strap and the second strap relative to the first mating surface and the second mating surface.

14. The method of claim 13, wherein the first strap and the second strap are coupled together.

15. The method of claim 13, wherein an end portion of the first strap is coupled to each end portion of the second strap.

16. The method of claim 13, wherein the first strap extends through a toe post hole defined in the first footwear layer, and from the toe post hole the first strap extends longitudinally within the strap channel in a heelward direction.

17. The method of claim 16, further comprising coupling an anchor strip to the first strap, the anchor strip extending longitudinally from the toe post hole in a toeward direction opposite the heelward direction.

18. The method of claim 13, wherein forming the strap channel comprises forming an elongate channel portion in a longitudinal direction for the first strap and forming at least one flank channel portion to each side of the elongate channel portion for the second strap.

19. The method of claim 18, wherein forming the strap channel comprises forming the strap channel with a variable depth, a greatest depth being positioned where the elongate channel portion intersects the flank channel portions.

20. The method of claim 13, further comprising lining the second strap with a liner, end portions of the liner extending into the strap channel and secured in place between the first mating surface and the second mating surface.

Images