Footwear sole

Abstract

A footwear sole comprising a first layer (1101), a second layer (1102), and a third layer (1103). The second layer is contactable with a sole of a user's foot, and the second layer is flexible. The third layer is disposed between the first layer and the second layer, and comprises a flowable material which is configured, in use, to deform under the second layer in response to forces exerted upon the second layer by the user's foot. The second layer is in direct contact with the flowable material of the third layer.

Description

[0001] FOOTWEAR SOLE

[0002] Field of invention

[0003] The present invention relates to a footwear sole. More particularly, but not exclusively, the invention relates to a footwear sole with different layers that may assist with the treatment and prevention of plantar fasciitis and other chronic foot pain conditions.

[0004] Background

[0005] Plantar Fasciitis (underfoot heel pain) is one the most common foot conditions in the world, affecting between 8-10% of the population in countries such as South Korea, the UK, and the USA. The condition can be caused by a number of factors, including the type of footwear worn, foot structure, overuse of certain muscles, and types of walking surfaces. Examples of people who may be particularly susceptible to Plantar Fasciitis are the elderly, people who are obese, people who stand for a long time at work, people who experience foot fatigue from playing sports and people who often wear high heels.

[0006] Plantar Fasciitis pain can be temporary and gradually subside within 3-4 weeks. In other cases, it can escalate to a chronic illness which impacts patients’ standard of living. Therefore, it is crucial to treat the condition at an early stage. The most common form of treatment for early Plantar Fasciitis is muscle stretching foot exercises. These are often prescribed by a doctor for the patient to perform at home. However, these stretching exercises may be performed infrequently or incorrectly by the patient, increasing the risk of the condition becoming a chronic illness.

[0007] There is growing demand in the footwear industry to provide shoes which are more comfortable to wear for longer periods of time and which can help to reduce the likelihood of painful conditions, such as the one described above.

[0008] The present invention is devised with the foregoing in mind.

[0009] Summary of invention According to a first aspect of the invention, there is provided a footwear sole.

[0010] The sole may be an insole. The sole may be an insole which is insertable and removable from existing footwear. The sole may be integrally formed as part of an item of footwear.

[0011] The sole may comprise: a first layer; a second layer contactable with a sole of a user’s foot; and a third layer disposed between the first layer and the second layer, wherein the third layer comprises a flowable material which is configured, in use, to deform under the second layer in response to forces exerted upon the second layer by the user’s foot.

[0012] The flowable material may distributed substantially across the entire first layer.

[0013] The first layer may be flexible. The second layer may be flexible.

[0014] Having a sole wherein the third layer deforms underneath the second layer, and wherein the second layer contacts the user’s foot, enables the third layer to adjust and deforms in response to the user’s foot. This may provide the benefits of improving the user’s comfort. The user’s foot can freely stretch by deforming the third layer so as to prevent muscle aches and muscle damage.

[0015] The sole of the present invention may facilitate stretching exercises within a shoe itself. It may enable individuals suffering from foot pain and uncomfortableness, such as plantar fasciitis, to perform therapeutic stretching movements while walking, thereby eliminating the need for dedicated exercise time. The sole may adapt to wearer in their every step which does not only produce a gentle massaging sensation — comparable to walking on sand — but also continuously engage and stretch the underfoot, providing both treatment and comfort.

[0016] In addition, the sole may replicate the biomechanical properties of walking on sand, thereby stimulating and strengthening the muscles of the foot and lower body parts. This strengthening effect functions as an active exercise, which in turn enhances muscular support and reduces the likelihood of recurring foot condition such as foot fatigue and plantar fasciitis. By combining stretching, strengthening, and comfort into a single integrated system, the invention delivers both immediate relief and long-term preventative benefits.

[0017] The first layer may be a base of the shoe. The first layer may be a layer disposed between the base of the shoe and the third layer. The first layer may prevent the flowable material of the third layer from contacting the base of the shoe.

[0018] The second layer may be in direct contact with the flowable material of the third layer. Substantially an entire surface of second layer may be in direct contact with the third layer. The flowable material of the third layer may be the only material / item / component disposed between the first and second layers. Having direct contact (i.e., there are no intermediate layers therebetween) between the third layer and the second layer may enable the user to experience a feeling similar to walking directly on the flowable material.

[0019] The first, second, and third layers may have substantially the same surface area. The first, second, and third layers may have substantially the same surface area perpendicular to a walking surface when in use. The first, second, and third layers may have substantially the same surface area of the sole a user’s foot. The first, second, and third layers may have substantially the same surface area of a base of a shoe.

[0020] The first and second layers may be formed of, or comprise, different materials. The second layer may be more flexible than the first layer. The second layer may be more elastic than the first layer. Having a second layer which is more flexible and / or more elastic may ensure that the user’s foot deforms the third layer by sinking into the third layer.

[0021] The density of the flowable material of the third layer may be between 750 kg m-3- 2000 kg m-3. The density of the flowable material of the third layer may be between 1000 kg m"3- 1500 kg m"3. The density of the flowable material of the third layer may be between 1100 kg m-3- 1400 kg m-3. Having a flowable material with a density in this range may ensure the sole remains lightweight. The thickness of the third layer may be between 5 -30mm. The thickness of the third layer may be between 10-20mm. The thickness of the third layer may refer to the average thickness of the third layer. Having a thickness withing these ranges may ensure the user’s foot is able to sufficiently sink down into the third layer without reaching the first layer.

[0022] The flowable material may be, or comprise, a plurality of particles. The average diameter of the particles may be substantially between 400pm-1200pm. The average diameter of the particles may be substantially between 600pm-1000pm. The average diameter of the particles may be substantially 900pm.

[0023] Each of the plurality of particles may be formed of, or comprise, cellulose. Cellulose may be suitable for providing a plurality of particles with a consistent spherical shape. The use of cellulose particles may provide a soft and a bouncy feeling for a user whilst walking. The use of cellulose particles may reduce the sound generated by the sole whilst walking.

[0024] Each of the plurality of particles may be formed of, or comprise, glass.

[0025] Using a plurality of particles to form the third layer may ensure that the user experiences a feeling similar to walking on sand when using the sole. Using particles, rather than a liquid or gel, may reduce the risk of the flowable material from leaking from between the first and second layers. Using particles, rather than a liquid or gel, may ensure the user’s foot does not sink too deep into the third layer.

[0026] The second layer may have a thickness equal to, or less than, substantially 1mm. The second layer may have a thickness equal to, or less than, substantially 0.5mm. The second layer may have a thickness of between 0.2mm-lmm. The second layer may have a thickness of between 0.4mm-0.5mm. Having a second layer with a thickness within these ranges may maximise the feeling of walking on sand whilst ensuring the second layer is sufficiently strong to avoid tears or rips which would enable the flowable material of the third layer to leak from between the first and second layers.

[0027] The second layer may be formed of, or comprises, an elastic material. The second layer may be formed of, or comprise, polyester polyurethane. The second layer may comprise an elastane content between 5-30%. The second layer may comprise an elastane content between 10-25%. The second layer may comprise an elastane content of substantially 20%. Having an elastic material for the second layer may enable the second layer, and the user’s foot, to press / sink into the third layer.

[0028] Having a second layer which is both sufficiently thin and elastic may maximise the effect of allowing the user to experience the feeling of walking on sand, or any other flowable material.

[0029] The second layer may be configured, in use, to elastically deform by up to at least 5mm into the third layer.

[0030] The thickness of the first layer may be between 0.5 -2mm. The thickness of the first layer may be substantially 1mm. Having a thickness withing this range may maximise user comfort whilst providing sufficient strength to avoid tears or rips to the first layer.

[0031] The footwear sole may comprise a base contactable with a walking surface. The first layer is disposed between the third layer and the base. The first layer may be connected to the base. The first layer may be connected to the base using an adhesive. The first layer may prevent the flowable material from wearing against and damaging the base. The base may prevent the walking surface from damaging the first layer, thereby helping to ensure the flowable material remains sealing between the first and second layers.

[0032] The footwear sole may comprise a fourth layer disposed between the base and the first layer. The fourth layer may be configured, in use, to deform under the first layer. The fourth layer may be or comprise, a gel. Having a fourth layer configured to deform under the first layer may help to shock absorb to improve user comfort when walking.

[0033] The fourth layer may have a thickness between 4-10mm. The fourth layer may have a thickness of substantially 5mm. Having a a fourth layer with these thicknesses may ensure the fourth layer is able to absorb shock forces whilst minimising the weight of the sole. The first, second, third, and fourth layer may have substantially the same surface area. The first, second, third, and fourth layer may have substantially the same surface area perpendicular to walking surface, when in use.

[0034] According to another aspect of the invention, therein is provided an item of footwear. The item of footwear may comprise the footwear sole of the first aspect of the invention. The item of footwear may comprise an upper section connected to the footwear sole.

[0035] According to a third aspect of the invention, there is provide a method of manufacturing a footwear sole. The method may be used to manufacture the sole of the first aspect.

[0036] The method may comprise: partially joining a first layer to a second layer so as to leave a gap between the first and second layers; inserting a flowable material between the partially joined first and second layers so as to form a third layer; and closing the gap to retain the flowable material between the first and second layers.

[0037] Partially joining the first and second layers may comprise joining the first and second layers at, or near to, their peripheral edges. Closing the gap to completely join the first and second layers may comprise joining the first and second layers at, or near to, the remaining portions of their peripheral edges.

[0038] Joining the first and second layers may comprise stitching. Joining the first and second layers may comprise stapling. Joining the first and second layers may comprise application of an adhesive.

[0039] According to a fourth aspect of the invention, there is provided a method of manufacturing an item of footwear. The method of the fourth aspect may be used to manufacture the item of footwear of the second aspect.

[0040] The method may comprise manufacturing a sole. The sole may be manufactures using the method of the third aspect. The method may comprise connecting the sole to an upper section. The method may comprise connecting the combined sole and upper section to a footwear base.

[0041] Optional features of any of the above aspects may be combined with the features of any other aspect, in any combination. Features which are described in the context or separate aspects and embodiments of the invention may be used together and / or be interchangeable wherever possible. Similarly, where features are, for brevity, described in the context of a single embodiment, those features may also be provided separately or in any suitable sub-combination.

[0042] Brief description of the drawings

[0043] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0044] Figure la shows a perspective view of a footwear sole according to an embodiment;

[0045] Figure lb shows top and bottom views of the footwear sole of Figure la;

[0046] Figure 2 shows a lateral cross-sectional view of footwear comprising a sole according to an embodiment;

[0047] Figure 3 shows a transverse cross-sectional view of the footwear of Figure 2;

[0048] Figure 4 shows a lateral cross-sectional view of footwear comprising a sole according to an embodiment together with a cushioning member;

[0049] Figure 5 shows a transverse cross-sectional view of the footwear of Figure 4;

[0050] Figure 6 shows a perspective view of footwear comprising a sole according to an embodiment with an upper portion of the footwear removed to expose the sole;

[0051] Figure 7 shows a flowchart representing a method for forming a sole according to an embodiment; Figures 8a-c show examples of the steps of the method of Figure 7 for forming a sole according to an embodiment;

[0052] Figure 9 shows a flowchart representing a method for forming an item of footwear according to an embodiment;

[0053] Figures lOa-c show examples of the steps of the method of Figure 9 for forming an item of footwear according to an embodiment;

[0054] Detailed description

[0055] Figure la shows a perspective view of a sole 100. Figure lb shows plan views of the sole 100 from above and below to show the top and bottom layers 101, 102 respectively.

[0056] The sole 100 comprises a first layer 101 and a second layer 102. The first layer 101 is configured, in use, to contact the base of a shoe. The second layer 102 is configured in use, to contact the user’s foot.

[0057] The sole 100 comprises a third layer (not shown in Figure 1) disposed between the first 101 and second 102 layers. The third layer comprises a flowable material which is configured, in use, to deform under the second layer 102.

[0058] The sole 100 can be an insole, which is configured to be inserted into an existing item of footwear to improve comfort for the user. Alternatively, the sole 100 can be part of an item of footwear and permanently attached to said item of footwear.

[0059] Figure 2 shows a cross-sectional view of a shoe 1000, taken transversely across a length of the shoe 1000. Figure 3 shows a cross-sectional view of the shoe 1000, taken transversely across a width of the shoe 1000.

[0060] Although a shoe is shown in the Figures, it is to be appreciated that the invention may be used with, or in, any type of footwear, and references to “shoe” throughout apply equally to other types of footwear e.g., a boot, a sandal, etc. The shoe 1000 comprises a sole 1100. The sole 1100 is substantially identical to the sole 100 of Figures la and lb. The sole 1100 comprises a first layer 1101 and a second layer 1102. A third layer 1103 is disposed between the first 1101 and second 1102 layers.

[0061] The shoe 1000 comprises an upper section 1006 and a base 1005. The upper section 1006 is connected to the base 1005. In some examples, the upper section 1006 is connected to the base 1005 via stitching. In other examples, the upper section 1006 is connected to the base 1005 using an adhesive or using any other suitable means.

[0062] The upper section 1006 can be formed of, or comprise, a natural material, such as leather or cotton canvas. The upper section 1006 can be formed of, or comprise, a synthetic material, such as polyester or nylon, and may comprise a mesh woven from one or more synthetic materials.

[0063] The upper section 1006 can be configured to substantially cover a foot of a user, leaving an opening for a user to insert, or remove, their foot from the shoe 1000. Alternatively, the shoe 1000 may be an open shoe, wherein the upper section 1006 comprises one or more of straps arranged to secure the base 1005 and sole 1100 to the user’s foot without covering the user’s entire foot.

[0064] The base 1005 is configured, in use, to contact a walking surface 1008.

[0065] The base 1005 can be formed of, or comprise, one or more of: leather, rubber, foam, Ethylene Vinyl Acetate (EVA), Polyurethane (PU), or any other suitable material. The base 1005 can comprise a plurality of graduations, or a tread arranged to contact the walking surface 1008. The graduations or tread may be adapted to the intended use of the shoe 1000 (for example hiking, walking on concrete or asphalt, etc), to improve grip and stability of the shoe 1000.

[0066] In some examples, the thickness of the base 1005 is between 4mm and 15mm. In some examples, the thickness of the base 1005 is between 5mm and 10mm. In some examples, the thickness of the base 1005 is between 7mm and 8mm. In other examples, the base 1005 can have any other thickness. The base 1005 comprises a rim 1005a. The rim 1005a surrounds a peripheral edge of the base 1005. The rim 1005a is transverse to the rest of the base 1005 (i.e., the rim 1005a is upstanding) such that the base 1005 defines a recess.

[0067] In alternative examples, the base 1005 does not comprise a rim. For example, the base 1005 can be substantially flat.

[0068] The shoe sole 1100 is disposed on the base 1005. The shoe sole 1100 is disposed within the recess defined by the rim 1005a of the base 1005.

[0069] The first layer 1101 of the sole 1100 can be formed of, or comprise, a natural material, such as leather or cotton canvas. Alternatively, the first layer 1101 can be formed of, or comprise, a synthetic material, such as polyester or nylon. The first layer 1101 can be formed of, or comprise, a mesh woven from one or more synthetic materials.

[0070] In some examples, the thickness of the first layer 1101 is between 0.5 mm and 2mm. In some examples, the preferred thickness of the first layer 1101 is substantially 1 mm.

[0071] A peripheral edge of the first layer 1101 is connected to a peripheral edge of the second layer 1102 to define a sealed pocket therebetween. The third layer 1103 is disposed substantially within the pocket defined by the first layer 1101 and second layer 1102 and is retained within the pocket by the connection between the first 1101 and second 1102 layers.

[0072] In some examples, the first layer 1101 has a greater surface area than the second layer 1102. When the peripheral edge of the first layer 1101 is joined to the peripheral edge of the second layer 1102, the first layer 1101 can remain slack whilst the second layer 1102 is taught. As a result of the difference in surface area between the first 1101 and 1102 second layers, the second layer 1102 can remain substantially flat while the first layer 1101 curves to accommodate the third layer 1103, as shown in Figure 3.

[0073] In other examples, the first layer 1101 and the second layer 1102 have substantially equal surface areas. In some examples, the first layer 1101 is connected to the base 1005. For example, an adhesive can be used to connect the first layer 1101 to the base 1005. The connection of the first layer 1101 to the base 1005 can ensure that the first layer 1005 conforms to the shape of the base 1005.

[0074] In some examples, the first 1101 and second 1102 layers are connected via stitching. In other examples, any suitable alternative means can be used to connect the first 1101 and second 1102 layers together to form the pocket, such as an adhesive or staples.

[0075] The second layer 1102 of the sole 1000 is configured, in use, to contact the user’s foot. The second layer 1102 directly contacts the flowable material of the third layer 1103. The sole 1000 is configured such that, in use, only the second layer 1102 separates the user’s foot from the third layer 1103.

[0076] The second layer 1102 is elastic, such that it reversibly deforms in response to forces exerted upon it by the user’s foot.

[0077] The second layer 1102 can be formed of, or comprise, an elastic material. For example, the second layer 1102 can be formed of, or comprise, an elastomeric polymer or copolymer. The second layer 1102 can be formed of, or comprise, polyester, polyurethane (e.g., elastane / LYCRA®), urethane, rubber, synthetic rubber, or any other elastic material.

[0078] In some examples, the material of the second layer 1102 comprises an elastane content of between 5% and 30%. In some examples, the material of the second layer 1102 comprises an elastane content of between 10% and 25%. In other examples, the elastane content of the material of the second layer 1102 is substantially 20%.

[0079] In some examples, the second layer 1102 is formed of a material blend comprising an elastance content between 5% and 30%, with substantially the rest of the material being cotton. In some examples, the second layer 1102 is formed a material blend comprising an elastance content of substantially 20% and a cotton content of substantially 80%. In other examples, cotton can be replaced with, or supplemented by, other materials, such as linen, or polyester. In some embodiments, the thickness of the second layer 1102 is less than, or equal to, substantially 1mm. In some embodiments, the thickness of the second layer 1102 is less than, or equal to, substantially 0.5mm. In some examples, the thickness of the second layer 1102 is between 0.2mm and 1mm. In some examples, the thickness of the second layer 1102 is between 0.4mm and 0.5mm. In other examples, the second layer 1102 can have any other thickness.

[0080] As described in relation to the sole 100 of Figure 1, the third layer 1103 comprises a flowable material. The flowable material is distributed substantially across the entire first layer 1101.

[0081] The flowable material of the third layer 1103 comprises a plurality of solid particles. The flowable material is water insoluble. The flowable material can be a granular material, such as sand.

[0082] Alternatively, in other examples, the flowable material of the third layer 1103 can comprise a liquid, gel, or other flowable material. In such examples, the flowable material can be, or comprise, one or more of polyurethane, silicone, and thermoplastic rubber.

[0083] The particles of the third layer 1103 are substantially spherical. In other examples, the particles can be substantially ovoid shaped, or they can be irregularly shaped. The particles of the third layer 1103 can also comprise a mixture of shapes.

[0084] In some examples, the plurality of particles of the third layer 1103 can have an average diameter between 400pm and 1200pm. In some examples, the plurality of particles of the third layer 1103 can have an average diameter between 600pm and 1000pm. In some examples, the plurality of particles of the third layer 1103 can have an average diameter of 900pm. For non-spherical particles, the diameter may refer to the largest length of the particle.

[0085] The plurality of particles of the third layer 1103 can be formed of, or comprise, cellulose. Alternatively, or additionally, the plurality of particles of the third layer 1103 can be formed of, or comprise, materials such as glass, ceramic, carbon, silica, polymers, seeds, wax, or resins. Alternatively, any other suitable materials can be used. The plurality of particles of the third layer 1103 may be formed of, or comprise, a mixture of different particle materials.

[0086] In some examples, the volume of the third layer 1103 is substantially between 1 / 4 and 3 / 8 of a metric cup (between substantially 60 cm3and 90 cm3). In some examples the mass of the third layer 1103 is substantially between 70 g and 120 g.

[0087] In some examples, the density of the third layer is between 750 kg m-3- 2000 kg m-3. In some examples, the density of the third layer is between 1000 kg m-3- 1500 kg m-3. In some examples, the density of the third layer is between 1100 kg m-3- 1400 kg m-3.

[0088] In some examples, the thickness of the third layer 1103 is between 5mm and 30mm. In some examples, the thickness of the third layer 1103 is between 10mm and 20mm. In other examples, the third layer 1103 can have different thicknesses. The “thickness” of the third layer 1103 may refer to the average thickness of the third layer across the entire area of the third layer 1103.

[0089] In some examples, the third layer 1103 may be configured to, in use, deform under the second layer 1102 by substantially 5mm to 10 mm. In some examples, the third layer 1103 may deform non-uniformly in response to forces exerted upon it by the user’s foot. For example, areas of the third layer 1103 situated under a user’s heel may deform to a greater extent than areas of the third layer 1103 situated under a user’s toes.

[0090] In the example of Figures 2 and 3, the first, second, and third layers 1101, 1102, 1103 of the sole 1100 each have substantially the same cross-sectional area perpendicular to an axis 1007, which is perpendicular to the walking surface 1008 when the shoe 1000 rests on the ground.

[0091] Figure 4 shows a cross-sectional view of a shoe 2000, taken transversely across a length of the shoe 2000. Figure 5 shows a cross-sectional view of the shoe 2000, taken transversely across a width of the shoe 2000.

[0092] The shoe 2000 is substantially similar to the shoe 1000 of Figures 2 and 3, with like reference numerals referring to like features. However, shoe 2000 comprises a fourth layer 2004 disposed between the first layer 2101 and the base 2005. The fourth layer 2004 can comprise a gel material. Alternatively, the fourth layer 2004 can comprise a foam. The fourth layer 2004 can be formed of, or comprise, polyurethane, silicone, thermoplastics, neoprene, ethylene vinyl acetate (EVA), rubber, or any combination thereof. In other examples, any other suitable shock absorbing material may be used.

[0093] The fourth layer 2004 extends substantially across the entire base 2005 of the shoe 2000. However, in other examples, the fourth layer 2004 may only extend across a portion of the base 2005. For example, the fourth layer 2004 may extend across a rear portion of the base 2005, to provide additional heel support to a foot of a user.

[0094] In some embodiments, the thickness of the fourth layer 1004 is between 4mm and 10 mm. In some examples, the thickness of the fourth layer 1004 is substantially 5 mm. In other examples, the second layer 1102 can have any other thickness.

[0095] In the shoe 2000 of Figures 4 and 5, the first 2101, second 2102, and third 2103 layers of the sole 2100, and the fourth layer 2004 of the shoe 2000, each have substantially the same cross-sectional area perpendicular to an axis 2007, which is perpendicular to the walking surface 2008 when the shoe 2000 rests on the ground.

[0096] Figure 6 shows a perspective view of a shoe 3000. The upper portion of the shoe 3000 is not attached to provide a clear view of the inside of the shoe 3000. The shoe 3000 is substantially similar to the shoes 1000, 2000 of Figures 2-5, with like reference numbers used to refer to like features.

[0097] A layer of fabric 3011 is shown to demonstrate how the base 3005 of the shoe 3000 can be connected to an upper section in some examples. An upper section can be connected to the shoe 3000 in the same manner as the layer of fabric 3011 is attached to the base 3005.

[0098] The layer of fabric 3011 is connected to the base 3005 via stitching. The connection 3010 between the layer of fabric 3011 and the shoe sole 306 is visible on an outer surface of the base 3005 of the shoe. In other examples, the layer of fabric 3011 can be connected to the base 3005 using an adhesive. The connection can be positioned between sole 1100 and the base 1005 of the shoe, or in any other suitable position.

[0099] Figure 7 shows a flowchart representing a method 10 of forming a sole. The method can be used to form any of the soles described herein. In other examples, alternative methods can be used.

[0100] The method comprises step 12 of partially joining a first layer and a second layer.

[0101] The first and second layers are partially joined at, or near to, their peripheral edges. For example, the first and second layers can be aligned and then stitched together. In other examples, the first and second layers can be joined using an adhesive, staples, or other suitable means.

[0102] The first and second layers are partially joined so as to leave a gap between the layers at a portion of the peripheral edge of the layers. The gap ensures that a pocket defined between the first and second layers is an open pocket.

[0103] The method then comprises step 14 of inserting the flowable material into the open pocket via the gap so as to form a third layer. In some examples, the flowable material can be poured into the open pocket via the gap.

[0104] The method finally comprises step 16 of closing the gap to seal the open pocket and retain the flowable material of the third layer between the first and second layers.

[0105] Closing the gap can comprise joining the remaining non-joined peripheral edges of the first and second layers. The gap can be closed via stitching, using an adhesive, or via any other suitable means.

[0106] The first, second, and third layers described with reference to the method 10 of Figure 7 can respectively comprise any features of the first, second, and third layers described throughout this description. Figures 8a-c show examples representing each stage of the method 10 according to an example using stitching.

[0107] In Figure 8a, the first and second layers 101, 102 are stitched together around their peripheral edge. The front portions of the peripheral edges of the first and second layers 101, 102 (i.e., the edges proximate the user’s toes, when in use) are not stitched together, thereby forming a gap 110. This is an example of step 12 of method 10.

[0108] In Figure 8b, a flowable material is conveyed into the open pocket defined between the first 101 and second 102 layers. The flowable material is conveyed through the gap 110. This is an example of step 14 of method 10.

[0109] In Figure 8c, the front portions of the peripheral edges of the first and second layers 101, 102 (i.e., the edges proximate the toes) are stitched together to close the gap. Closing the gap ensures that the first 101 and second 102 layers define a closed pocket which retains the flowable material therein. This is an example of step 16 of method 10.

[0110] Figure 9 shows a flowchart representing a method 20 of forming an item of footwear. In other examples, alternative methods can be used.

[0111] The method 20 comprises the step 22 of forming a sole. Step 22 can comprise the method 10 of Figure 7.

[0112] The method 20 comprises the step 24 of connecting the sole to a footwear upper section. In some examples, connecting the sole to the footwear upper section comprises stitching the sole to the upper section. In some examples, the peripheral edge of the sole is stitched to the peripheral edge of the upper section of the footwear.

[0113] The method 20 comprises step 26 of removing excess material from the combined sole and upper section. For example, removing excess material can comprise trimming material from around the edge of the stitches connecting the sole to the upper section. In other examples, this step can be omitted entirely. The method 20 comprises step 28 of connecting the sole and upper section to a footwear base. In some examples, an adhesive is used to form a connection between a first layer of the sole and the base. In other examples, alternative means for connecting the sole and upper section to the base can be used, such as stitches. In other examples, the connection between the base and the sole and upper section can be via a different part of the sole, or via the upper section.

[0114] Figures lOa-c show schematics representing steps 24, 26, and 28 of the method 20 according to an example using stitching.

[0115] In Figure 10a, the sole 100 and the upper section 106 are stitched together around their peripheral edges. This is an example of step 24 of method 20.

[0116] In Figure 10b, excess material is removed from the peripheral edges of the sole 100 and upper section by trimming around the edge of the stitches. This is an example of step 26 of method 20.

[0117] In Figure 10c, the sole 100 and upper section are connected to the footwear base 105. The sole 100 is connected to the base 105 using an adhesive, and the upper section is connected via its connection to the sole 100.

[0118] From reading the present disclosure, other variations and modifications will be apparent to the skilled person. Such variations and modifications may involve equivalent and other features which are already known in the art of footwear and plantar fasciitis relief and which may be used instead of, or in addition to, features already described herein.

[0119] Although the appended claims are directed to particular combinations of features, it should be understood that the scope of the disclosure of the present invention also includes any novel feature or any novel combination of features disclosed herein either explicitly or implicitly or any generalisation thereof, whether or not it relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as does the present invention. Features which are described in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. The applicant hereby gives notice that new claims may be formulated to such features and / or combinations of such features during the prosecution of the present application or of any further application derived therefrom.

Claims

CLAIMS1. A footwear sole comprising: a first layer; a second layer contactable with a sole of a user’s foot, wherein the second layer is flexible; and a third layer disposed between the first layer and the second layer, wherein the third layer comprises a flowable material which is configured, in use, to deform under the second layer in response to forces exerted upon the second layer by the user’s foot; wherein the second layer is in direct contact with the flowable material of the third layer.

2. The footwear sole of claim 1, wherein the first and second layers are formed of, or comprise, different materials.

3. The footwear sole of claim 1 or claim 2, wherein the flowable material is, or comprises, a plurality of particles.

4. The footwear sole of claim 3, wherein the average diameter of the particles is substantially between 400pm-1200pm.

5. The footwear sole of claim 3 or claim 4, wherein each of the plurality of particles are formed of, or comprise, cellulose.

6. The footwear sole of any preceding claim, wherein the density of the flowable material of the third layer is between 750 kg m"3- 2000 kg m"3.

7. The footwear sole of any preceding claim, wherein the thickness of the third layer is between 5-30mm.

8. The footwear sole of any preceding claim, wherein the second layer has a thickness equal to, or less than, substantially 1mm.

9. The footwear sole of claim 8, wherein the second layer has a thickness equal to, or less than, substantially 0.5mm.

10. The footwear sole of any preceding claim, wherein the second layer is formed of, or comprises, an elastic material.

11. The footwear sole of claim 10, wherein the second layer is formed of, or comprises, polyester polyurethane.

12. The footwear sole of claim 10, wherein the second layer comprises an elastane content between 5-30%.

13. The footwear sole of claim 12, wherein the second layer comprises an elastane content of substantially 20%.

14. The footwear sole of any of claims 10-13, wherein the second layer is configured, in use, to elastically deform by up to at least 5mm into the third layer.

15. The footwear sole of any preceding claim, wherein the thickness of the first layer is between 0.5-2mm.

16. The footwear sole of any preceding claim, further comprising a base contactable with a walking surface, wherein the first layer is disposed between the third layer and the base.

17. The footwear sole of any preceding claim, further comprising a fourth layer disposed between the base and the first layer, wherein the fourth layer is configured, in use, to deform under the first layer, and wherein the fourth layer, is or comprises, a gel.

18. The footwear sole of any preceding claim, wherein the thickness of the fourth layer is between 4-10mm.

19. The footwear sole of any preceding claim, wherein the first, second, and third layers and, when dependent on claims 17 or 18, the fourth layer, have substantially the same surface area.

20. The footwear sole of any preceding claim, wherein the flowable material is distributed substantially across the entire first layer.

21. An item of footwear, comprising: the footwear sole of any preceding claim; and an upper section connected to the footwear sole.

22. A method of manufacturing a footwear sole, the method comprising: partially joining a first layer to a second layer so as to leave a gap between the first and second layers; inserting a flowable material between the partially joined first and second layers so as to form a third layer; closing the gap to retain the flowable material between the first and second layers.

23. The method of claim 22, wherein partially joining the first and second layers, and closing the gap, comprising joining the first and second layers at, or near to, their peripheral edges.

24. The method of claim 22 or claim 23, wherein partially joining the first and second layers, and closing the gap, comprising stitching.

25. A method of manufacturing an item of footwear, comprising: manufacturing a sole; connecting the sole to an upper section; and connecting the combined sole and upper section to a footwear base.

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