Secure footwear having open heel and toe-post

Abstract

A footwear piece having an open heel and toe-post is described. The footwear piece, which may generally be in the form of, e.g., a clog, includes a sole portion and an upper portion extending over the front portion of the sole portion to form and define a toe box region. A toe-post extends through the toe box region from the sole portion to the upper portion. When in use, the toe-post may reside between the grand toe and index toe of a user. The footwear piece is free of any type of heel restraint mechanism, include a heel restraint mechanism that is moveable, pivotable, or removable. The footwear piece may be made from lightweight foam material.

Description

SECURE FOOTWEAR HAVING OPEN HEEL AND TOE-POSTCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 717,755, entitled “SECURE FOOTWEAR HAVING OPEN HEEL AND TOE-POST”, filed November 7, 2024, and U.S. Provisional Patent Application No. 63 / 879,176, entitled “SECURE FOOTWEAR HAVING OPEN HEEL AND TOE-POST”, filed September 10, 2025, both of which are incorporated herein by reference in their entirety.BACKGROUND

[0002] Current trends are toward wearing comfortable footwear in the work environment. Of particular note, clog-type shoes made from lightweight, water-proof foam material have gained popularity in jobs that require frequent standing and walking, such as jobs in restaurants and hospitals. A typical version of these clog-type shoes includes an upper defining a toe box for receiving the front portion of the user’s foot and a pivoting heel strap that can be placed behind the user’s heel. The pivoting heel strap is the predominant feature for keeping the shoe secured on the user’s foot. When the pivoting heel strap is pivoted forward to reside on top of the user’s foot instead of behind his or her heel, the shoe effectively becomes a slip on-type shoe without any significant means for keeping the shoe positioned on the user’s foot. When running or even walking quickly without the heel strap positioned behind the user’s heel, the clog-type shoe can easily slip off the user’s foot. While many users prefer to not use the heel strap, such as for comfort and / or style reasons, not positioning the heel strap behind the heel can cause a user to trip, slip, or fall due to the shoe not being securely positioned on the user’s foot. The user may also experience foot pain when not using the heel strap behind the heel, as the user may consciously or unconsciously begin to flex the front of their foot in unnatural ways in order to try and keep the shoe positioned on their foot. For example, a user may begin to flex their toes in an downward position while wearing the shoe to help keep their foot in the toe box, which can lead to pain and cramping in the arch of the foot.

[0003] Accordingly, a need exists for an improved clog-like shoe that addresses some or all of these problems.SUMMARY

[0004] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary, and the foregoing Background, is not intended to identify key aspects or essential aspects of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter.

[0005] In one embodiment described herein, an open-heel footwear piece generally comprises: a sole portion comprising a heel region and a front region opposite the heel region; an upper portion extending over the front region to thereby form and define a toe box region between the upper portion and the front region of the sole portion; and a toe-post extending between the sole portion and the upper portion in the toe box region; wherein the open-heel footwear piece is free of any moveable, removable, or stationary heel restraint mechanism.

[0006] In another embodiment described herein, the open-heel footwear piece comprises the open-heel footwear piece as described in the previous embodiment, wherein the sole portion and upper portion are formed as a unitary structure, and the toe-post is a separate component from the unitary structure.

[0007] In another embodiment described herein, an open-heel footwear piece comprises an open-heel footwear pieces as described in any of the preceding embodiments, wherein the sole portion and the upper portion are made from a moldable foam material.

[0008] In another embodiment described herein, an open-heel footwear piece comprises an open-heel footwear pieces as described in any of the preceding embodiments, wherein at least a portion of the toe-post has an hourglass shape that is narrowest at a middle section of the toe-post.

[0009] In another embodiment described herein, an open-heel footwear piece comprises an open-heel footwear pieces as described in any of the preceding embodiments,wherein the portion of the toe-post having an hourglass shape extends from an upper surface of the sole portion to a lower surface of the upper portion.

[0010] In another embodiment described herein, an open-heel footwear piece comprises an open-heel footwear pieces as described in any of the preceding embodiments, wherein toe-post has an oval, foil, or teardrop cross-sectional shape taken across its vertical axis.

[0011] In another embodiment described herein, an open-heel footwear piece comprises an open-heel footwear pieces as described in any of the preceding embodiments, wherein the upper portion includes an upper portion aperture extending through the thickness of the upper portion, the sole portion includes a sole portion aperture extending through the thickness of the sole portion, and the toe-post extends through both the upper portion aperture and the sole portion aperture.

[0012] In another embodiment described herein, an open-heel footwear piece comprises an open-heel footwear pieces as described in any of the preceding embodiments, wherein the sole portion aperture includes a wide portion at an end of the sole portion aperture proximate a bottom side of the sole portion and a narrow portion extending from the wide portion to a top side of the sole portion, the sole portion narrow portion being narrower than the sole portion wide portion; the toe-post includes a wide portion at a bottom end of the toe-post and a narrow portion extending up from the wide portion, the toe-post narrow portion being narrower than the toe-post wide portion; and the shape and dimensions of the toe-post wide portion are identical to the shape and dimensions of the sole portion aperture wide portion, and the shape and dimensions of the toe-post narrow portion are identical to the shape and dimensions of the sole portion aperture narrow portion, such that when the toe-post wide portion and the toe-post narrow portion are disposed in the sole portion aperture, the toe-post wide portion and the toe-post narrow portion occupy substantially all of the sole portion aperture.

[0013] In another embodiment described herein, an open-heel footwear piece comprises an open-heel footwear pieces as described in any of the preceding embodiments, wherein the open-heel footwear piece further comprises a toe-post cap configured such thata portion of the toe-post cap extends down through the upper portion aperture and engages with a top portion of the toe-post.

[0014] In another embodiment described herein, an open-heel footwear piece comprises an open-heel footwear pieces as described in any of the preceding embodiments, wherein the toe-post cap comprises a wide portion that resides on top of an upper surface of the upper portion when the toe-post cap is engaged with the top portion of the toe-post, the toe-post cap wide portion being wider than the opening of the upper portion aperture.

[0015] In another embodiment described herein, an open-heel footwear piece comprises an open-heel footwear pieces as described in any of the preceding embodiments, wherein: the top portion of the toe-post includes a protruding portion protruding from the top of the portion of the toe-post having an hourglass shape; the toe-post cap includes a recess adapted for receiving the protruding portion of the toe-post; and the toe-post cap recess and the protruding portion are each sized and dimensioned such that when the protruding portion is received in the toe-post cap recess, the protruding portion occupies substantially all of the toe-post cap recess.

[0016] In another embodiment described herein, an open-heel footwear piece comprises an open-heel footwear pieces as described in any of the preceding embodiments, wherein at least a portion of the toe-post cap is adhered to the upper portion and at least a portion of the toe-post is adhered to the toe-post cap.

[0017] In another embodiment described herein, an open-heel footwear piece comprises an open-heel footwear pieces as described in any of the preceding embodiments, wherein at least a portion of the toe-post is adhered to the sole portion aperture.

[0018] In another embodiment described herein, an open-heel footwear piece comprises an open-heel footwear pieces as described in any of the preceding embodiments, wherein the footwear piece is a clog.

[0019] This summary provides only a general outline of some embodiments according to the present invention. Many other objects, features, advantages and other embodiments of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings.

[0020] Additional objects, advantages and novel features of the technology will be set forth in part in the description which follows, and in part will become more apparent to those skilled in the art upon examination of the following, or may be learned from practice of the technology.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Non-limiting and non-exhaustive embodiments of the disclosed technology, including the preferred embodiment, are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.

[0022] FIG. 1 is a perspective view of a footwear piece configured in accordance with various embodiments described herein.

[0023] FIG. 2 is a top view of a footwear piece configured in accordance with various embodiments described herein.

[0024] FIG. 3 is a side view of a footwear piece configured in accordance with various embodiments described herein.

[0025] FIG. 4 is a front view of a footwear piece configured in accordance with various embodiments described herein.

[0026] FIG. 5 is side cross-section view of a footwear piece configured in accordance with various embodiments described herein.

[0027] FIGS. 6A-6D are various views of a toe-post of a footwear piece configured in accordance with various embodiments described herein.

[0028] FIGS. 7A-7E are various views of a cap of a footwear piece configured in accordance with various embodiments described herein.

[0029] FIG. 8 is a side cross-section view of a footwear piece configured in accordance with various embodiments described herein.

[0030] FIGS. 9A-9D are various views of a toe-post of a footwear piece configured in accordance with various embodiments described herein.

[0031] FIGS. 10A-10D are various views of a cap of a footwear piece configured in accordance with various embodiments described herein.

[0032] FIG. 11 is a side cross-section view of a footwear piece configured in accordance with various embodiments described herein.

[0033] FIGS. 12A-12C are various views of a toe-post of a footwear piece configured in accordance with various embodiments described herein.

[0034] FIG. 13 is bottom view of a footwear piece configured in accordance with various embodiments described herein.

[0035] FIG. 14 is a back perspective view of a footwear piece configured in accordance with various embodiments described herein.DETAILED DESCRIPTION

[0036] Embodiments are described more fully below with reference to the accompanying Figures, which form a part hereof and show, by way of illustration, specific exemplary embodiments. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the invention. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense.

[0037] Among other things, the technology described herein provides various footwear pieces, and methods for manufacturing such pieces, having an open heel and a toe-post disposed within a toe box of the footwear piece, the toe-post extending from a sole portion of the footwear piece to an upper portion of the footwear piece. The presence of the toepost in the toe box helps to secure the footwear piece on the user’s foot without need for, e.g., a heel strap. The presence of the toe-post in the toe box also allows the footwear piece to be secured to the user’s foot without requiring the user to flex their foot and / or toes in unnatural positions in order to keep the footwear piece secured to the user’s foot. In some embodiments, the toe-post is shaped and positioned in the toe box such that when the user wears the footwear piece, the user’s toes do not contact or only superficially contact the toe-post. Despite the user’s toes having a lack of contact or only superficial contact with the toe-post, the footwear piece remains securely in place on the user’s foot.

[0038] With reference to FIGS. 1 -5, a footwear piece 100 in accordance with some embodiments of the technology described herein is illustrated. Footwear piece 100 generally includes a sole portion 162 and an upper portion 150. The sole portion 162 has a predominantly horizontal orientation and is shaped and sized to provide a foot bed for the bottom of a user’s foot. The sole portion generally includes a back half that may be considered a heel portion for supporting a user’s heel, and a front half that may be considered a toe portion for supporting the user’s toes as well as the ball of the foot. The upper portion 150 is located at approximately the front half of the sole portion 162 and is shaped and sized to define a toe box region 180 under the upper portion 150 and above the front half of the sole portion 162. The shape and size of the toe box region 180 as defined by the shape and size of the upper portion 150 is adapted to receive therein the front half of a user’s foot when the user is wearing the footwear piece 100. In the embodiments shown in FIGS. 1 -5, the upper portion 150 contacts the sole portion 162 around the entire periphery of the front half of the sole portion 162 to thereby create a toe box region 180 that is closed at the front of the footwear piece 100. However, it should be appreciated that, in other embodiments, the upper portion 150 may contact the sole portion 162 only at the sides of the front half of the sole portion 162 to thereby create a toe box region 180 that is at the front of the footwear piece 100.

[0039] In some embodiments, upper portion 150 and sole portion 162 are formed (e.g., molded) as a single piece of material to provide a unitary construction for the footwear piece 100. In other embodiments, sole portion 162 is formed (e.g., molded) from a first piece of material and upper portion 150 is formed (e.g., molded) from a second piece of material, and the upper portion 150 and the sole portion 162 are then secured together (e.g., using an adhesive) to form the footwear piece 100. When the sole portion 162 and the upper portion 150 are separate pieces, each piece may be made from the same material, or a different material may be used for each piece.

[0040] As described previously, upper portion 150 is shaped and sized to form the toe box region 180 of the footwear piece 100, wherein the front portion of the user’s foot isreceived in the toe box region 180. In some embodiments, upper portion 150 is comprised of a substantially horizontal portion 152 and a substantially vertical region 151 . Substantially horizontal portion 152 predominantly covers the top of the user’s foot when the footwear piece 100 is worn by a user. Substantially horizontal portion 152 can include one or more ventilators 182 formed therein. Ventilators 182 can be, but are not limited to, openings that extend through the thickness of substantially horizontal portion 152. Ventilators 182 can be formed in substantially horizontal portion 152 when upper portion 150 is being formed (e.g., during the molding process), or can be formed in substantially horizontal portion 152 after formation and / or assembly of upper portion 150.

[0041] Substantially vertical portion 151 generally includes the portion of upper portion 150 that extends up from the peripheral edges of the sole portion 162 and provides a transition from the sole portion 162 to the substantially horizontal portion 152. In embodiments where the toe box region 180 has a closed front portion, the substantially vertical portion 151 may extend from one side of the user’s foot (e.g., insole), around the front of the user’s foot (i.e. , in front of the user’s toes), and to the opposite side of the user’s foot (e.g., outsole). In embodiments where the toe box region 180 has an open front portion, the substantially vertical portion 151 will be located only at the sides of the user’s foot. The substantially vertical portion 151 can include one or more ventilators 181. Ventilators 181 can be, but are not limited to, openings that extend through the thickness of substantially vertical portion 151 . Ventilators 181 can be formed in substantially vertical portion 151 when upper portion 150 is being formed, or can be formed in substantially vertical portion 151 after formation and / or assembly of upper portion 150. FIGS. 1 -5 illustrate an embodiment wherein each of the ventilators 181 extend up a majority of the height of substantially vertical region 151 , though other size and shaped ventilators 181 can be used. It should also be appreciated that the footwear piece 100 may include only ventilators 181 with no ventilators 182, only ventilators 182 with no ventilators 181 , both ventilators 181 and ventilators 182, or neither ventilators 181 or ventilators 182. The specific number, shape, and location of ventilators 181 and / or ventilators 182 is generally not limited.

[0042] As noted previously, upper portion 150 is shaped to define a toe box region 180 that surrounds and covers at least the toes of a human foot inserted into footwear piece 100.The front of toe box region 180 may taper from the inner side (i.e. , insole side) of footwear piece 100 to the outer side of footwear piece 100 such that it generally follows the contour of a human foot where larger toes exist at the inside of the foot, and the foot tapers to smaller toes on the outside of the foot. This can be functionally advantageous as the footwear piece 100 conforms to the shape of the human foot. In other embodiments, the front of toe box region 180 may have a square cross section that does not exhibit tapering, while yet other embodiments provide a toe box 180 with a rounded square shape where the toe section has its greatest extension near a central point of the front of footwear piece 100, and tapers in both directions towards the inner side and the outer side from the central point. Based on the disclosure provided herein, one of ordinary skill in the art will appreciate a number of shapes are possible for the front of toe box region 180.

[0043] Upper portion 150 includes a substantially horizontal region 152 that rises toward an upper opening perimeter 170. When worn, the upper opening perimeter 170 can contact an area of the human foot in front of, and below the ankle. Upper portion 150 can be designed such that upper opening perimeter 170 is disposed only a short distance from the front of footwear piece 100, in which case it will be formed in substantially horizontal region 152. Alternatively, upper portion 150 can be designed to extend farther up the foot toward the ankle, in which cases the upper opening perimeter 170 will be in an angled portion of upper portion 150 that extends from the substantially horizontal portion 152 of upper portion 150.

[0044] Sole portion 162 includes a rear sole perimeter 160 that defines the rear portion of sole portion 162. In some cases, this rear sole perimeter 160 is raised above a support base 165 of sole portion 162 that is the area that is in contact with the bottom of the human foot during use. In other embodiments, rear sole perimeter 160 is not raised. Support base 165 may include a raised pattern throughout the surface where the foot contacts support base 165. The bottom surface of sole portion 162 may include a front region 163 that is raised slightly from the generally flat plane of the remainder of sole 162.

[0045] With continued reference to FIGS. 1 -5, footwear piece 100 may be provided having an open heel. That is to say, no heel strap or similar means for retaining the heel in the footwear piece 100 is provided, and instead, the heel area of the footwear piece 100 isopen to the surrounding environment. As used herein, the term “open heel” includes the absence of any heel retaining mechanism, including any heel retaining mechanism that is pivotable, moveable, or removeable such that the heel retaining mechanism may be removed, pivoted, moved or removed out of the heel area if the user so chooses when wearing the footwear piece 100. The open-heel feature also excludes any stationary or fixed heel retaining mechanism. The open heel feature of the footwear piece 100 may also include the lack of any structure or wall extending substantially upwardly from the sole portion 162 in the area of the sole perimeter 160 and that would substantially contact the heel and / or Achilles tendon of a user to assist in maintaining the footwear piece 100 on the user’s foot. The raised portion of the rear sole perimeter 160 described previously is not considered as extending substantially upwardly from the sole 162 since the contemplated height of this raised portion is de minimus and would not substantially function to retain a user’s heel in the footwear piece 100. The open heel feature of the footwear piece 100 may also exclude any strap, band, or other heel retaining mechanism that extends from or is anchored to the upper portion 150 and / or the sole portion 162.

[0046] With reference to FIGS. 6A-6D, 7A-7E and 8, the open heel feature of footwear piece 100 described herein does not negatively impact the ability of the footwear piece 100 to remain on the user’s foot during use due at least to the combined effect of a toe-post 120 disposed within the toe box region 180 and the lateral sides of the upper portion 150 forming and defining the toe box region 180. The shape and size of the toe box region 180 are selected so that the lateral sides of upper potion 150 (which may include substantially vertical region 151 ) generally allow the user’s foot to be maintained in a natural or neutral position when inserted into the toe box region 180. That is to say, the user does not need to flex their foot and / or toes either inwardly or outwardly to accommodate the space (or lack of space) provided within the toe box region 180. Instead, the toe box region 180 has a size and shape approximately equal to the size and shape of front portion of the user’s foot so that the foot can be maintained in a natural or neutral position when disposed therein. In this natural or neutral position, the user’s toes are generally not flexed and muscles in and around the user’s toes are generally not engaged. Furthermore, and with specific respect to a user’s great toe and index toe, the great toe and index toe gently contact each other towards the middle and / or ends of the toes when in a natural or neutral position, whichcreates a small, closed gap between the great toe and index toe closer to the toes’ junction with the foot. As described in greater detail below, the toe-post 120 is positioned within the toe box region 180 such that the toe-post 120 resides within this relatively small, closed gap provided between the user’s great toe and index toe when the foot is in a natural or neutral position within the toe box region 180. The toe-post 120 has a generally slim profile to occupy the small, closed gap without forcing the toes apart. As such, the toe-post 120 is “captured” between the great toe and index toe, but without need for the user to flex their foot and / or toes to keep the toe-post 120 “captured” in the small, closed gap. Instead, the upper portion 150 maintains the foot in its natural or neutral position, which naturally provides the closed gap between the great toe and index toe for the toe-post to be “captured” in. This configuration of toe-post 120 and upper portion 150 thereby generates contact and friction between the user’s toes and the toe-post 120 sufficient to maintain the footwear on the foot without need for a heel strap of the like and without need for the user to engage foot and / or toe muscles to keep the toe-post 120 retained between the great toe and index toe. In this manner, the footwear configured with an open heel, which is devoid of a strap or other closure disposed at the heel portion of the footwear, stays securely on the user’s foot and provides the benefit of an open heel (which does not require bending down to secure the footwear to the foot, eliminates heel chaffing, avoids an undesirable aesthetic, etc.). As compared to, e.g., a traditional flip flop, where lateral support to the foot is not provided and thereby may require the user to engage muscles in the foot and / or toes to maintain the toepost between the great toe and index toe (and thus keep the flip flop secured on the user’s foot), the footwear piece 100 described herein provides the user with a more comfortable and secure experience.

[0047] As shown in, for example, FIG. 8, toe-post 120 is provided within the toe box region 180 and extends substantially vertically from the sole portion 162 to the upper portion 150. The toe-post 120 is generally positioned within the toe box region 180 at a location such that when a user’s foot is disposed within the toe box region 180, the toe-post 120 resides in a gap between the user’s grand toe and index toe, generally close to the junction of the toes with the main portion of the foot. As such, the toe-post 120 will generally be located closer to the inner side of the footwear piece 100 and closer to, though slightly set back from, the front edge of the footwear piece 100. This is illustrated in, e.g., FIG. 2, whichshows that the toe-post 120 will be located closer to the inner side of the footwear 100 piece and set slightly back from the front edge of the footwear piece 100 when installed in the footwear piece 100.

[0048] In some embodiments, the shape and dimensions of the toe-post 120 are selected to be similar to (though in some embodiments, smaller than) the shape of the gap between the grand toe and the index toe from the location closest to where the toes meet the main portion of the foot to the location where the grand toe and index toe contact each other. In some embodiments, the toe-post 120 has a generally hourglass-like shape, wherein the width of the toe-post 120 is largest at the top and bottom ends of the toe-post 120 and then tapers from both ends to a smallest width located at approximately a middle section of the toe-post 120. The cross-sectional shape of the toe-post 120 (taken perpendicular to the vertical axis of the toe-post 120) may have an oval shape, a teardrop shape, or a foil-type shape, wherein the longer axis of the oval, teardrop or foil-like cross- sectional shape is oriented generally parallel to the long axis of the footwear piece 100. This hourglass-like shape with an oval-, teardrop-, or foil-shaped cross-section allows the toepost 120 to be received within the gap between a user’s toes while having minimal contact with the user’s toe (or at least contact that does not force the toes apart from each other. In such a configuration, the toe-post 120 is minimally obtrusive to the user, but still functions to keep the footwear piece 100 secured to the user’s foot.

[0049] The manner of affixing the toe-post 120 to the footwear piece 100 generally includes a top portion of the toe-post 120 extending through the thickness of the upper portion 150, and a bottom portion of the toe-post 120 extending through the thickness of the sole portion 162. In such configurations, the top of the toe-post 120 may be visible when viewing the top of the footwear piece 100 and the bottom of the toe-post 120 may be visible when viewing the bottom of the footwear piece 100.

[0050] In some embodiments, a bottom section 121 (e.g., bottom third) of the toe-post120 has a constant width and cross-sectional shape without tapering. This bottom section121 of the toe-post 120 is adapted to be received in an aperture 163 formed in the sole portion 162 of the footwear piece. As such, the height of the bottom portion 121 of the toepost 120 is approximately equal to the thickness of the sole portion 162 where the aperture163 is formed. A bottom cap 122 having a width / diameter larger than the width / diameter of the bottom section 121 of the toe-post 120 may be provided at the bottom end of the bottom section 121 . For example, the bottom cap 122 may have a circular shape with a diameter that is larger than any cross-sectional dimension of the bottom section 121 of the toe-post 120. The height of the bottom cap 122 is generally substantially smaller than the height of the bottom portion 121 of the toe-post 120.

[0051] Aperture 163 formed in sole 162 generally has a shape adapted to mirror the shape and size of bottom section 121 and bottom cap 122 of toe-post 120 such that when the toe-post 120 is inserted up through the aperture 163 during installation of the toe-post 120 on footwear piece 100, substantially all of the aperture 163 is occupied by the bottom section 121 and bottom cap 122 of toe-post 120. Accordingly, in order to snuggly accommodate both the bottom section 121 and the bottom cap 122 of the toe-post 120, the aperture 163 generally includes a wide mouth portion 163a sized and shaped for receiving the bottom cap 122 and a narrower main portion 163b sized and shaped for receiving the bottom section 121. The shape and dimensions of the wide mouth portion 163a are substantially identical to the shape and dimensions of the bottom cap 122, while the shape and dimensions of the narrower main portion 163b are substantially identical to the shape and dimensions of the bottom section 121. Where the aperture 163 transitions from the wide mouth portion 163a to the narrower main portion 163b, a ledge 163c is formed.

[0052] The wider bottom cap 122 of toe-post 120 ensures that the toe-post 120 cannot be pushed upwardly all the way through the aperture 163. Instead, the axially upper surface of the bottom cap 122 will contact the ledge 163c, which stops further movement of the toepost 120 up through the aperture 163. In some embodiments, an adhesive may be used between the ledge 163c and the axially upper surface of the bottom cap 122 to secure the toe-post 120 to the sole portion 162.

[0053] As mentioned previously, installation of the toe-post 120 in the footwear piece 100 generally begins with the top end of the toe-post 120 being inserted into the aperture 163 from the bottom of sole portion 162 and pushing the toe-post 120 up through the aperture 163 until the upper axial surface of the bottom cap 122 contacts the ledge 163c of aperture 163. The shape and dimensions of the middle and upper portions of the toe-post120 are selected to ensure that the middle and upper portions of the toe-post 120 can pass through the wide mouth portion 163a and narrower main portion 163b of aperture 163. The overall height of the toe-post 120 is selected so that when the upper axial surface of the bottom cap 122 contacts the ledge 163c, the top end of the toe-post 120 contacts or even partially extends into the upper portion 150. In some embodiments, the portion of the toepost having an hourglass-like shape as previously described extends from the top of sole 162 to the underside of upper portion 150.

[0054] In some embodiments, the top portion of toe-post 120 is secured to the upper portion 150 of footwear piece 100 through use of an upper cap 125 that is a separate component from the toe-post 120 but which may be secured to the top end of the toe-post and / or the upper portion 150 in order to secure the top end of the toe-post 120 to the upper portion 150. In some embodiments, upper cap 125 includes a wide portion 125a and a narrow portion 125b, the narrower portion 125b extending downwardly from the underside of the wide portion 125a. The narrow portion 125b is shaped and sized to fit snuggly in a aperture 151 formed through upper portion 150. Aperture 151 is formed at a location in upper portion 150 that is approximately directly over and vertically aligned with aperture 163 so that when installed, toe-post 120 extends substantially vertically through the toe box region 180. The dimensions and cross-sectional shape of aperture 151 are selected to be approximately the same as the dimensions and cross-sectional shape of the narrow portion 125b. For example, as shown in FIG. 7B, the outer perimeter of narrow portion 125b has a foil-like cross-sectional shape, and as shown in FIG. 2, the cross-sectional shape of the aperture 151 has the same foil-like shape with approximately the same dimensions as the outer perimeter of the narrow portion 125b. In some embodiments, the height of narrow section 125b is selected to be approximately equal to the height of the aperture 151.

[0055] Narrow portion 125b further includes a recess 125c formed therein, with the mouth of the recess 125c being located at the bottom end of the narrow portion 125b such that the recess 125c extends upwardly towards the wide portion 125a of upper cap 125. The recess 125c is sized and shaped to be approximately the same size and shape of a top protrusion 127 extending from the top end of toe-post 120. In other words, the recess 125c is shaped and dimensioned to match the shape and dimensions of top protrusion 127 suchthat when top protrusion 127 is received in recess 125c, the top protrusion 127 substantially occupies all of recess 125c. In some embodiments, the height of top protrusion 127 is approximately equal to the thickness of upper portion 150 where aperture 151 is formed. In some embodiments, an adhesive can be used between some or all of the top protrusion 127 and the recess 125c to help secure the upper cap 125 to the toe-post 120.

[0056] As mentioned previously, wide portion 125a is wider than any cross-sectional dimension of narrow portion 125b. As such, the transition from the wide portion 125a to the narrow portion 125b creates a ledge 125d. Wide portion 125a is also wider than any cross- sectional dimension of aperture 151 , which means that when inserted downwardly into aperture 151 to mate with the top of toe-post 120 and thereby secure the toe-post 120 to upper portion 150, the upper cap 125 cannot pass all the way through the aperture 151 in upper portion 150. Instead, the ledge 125d of upper cap 125 will contact the upper side of upper portion 150 and prevent further downward movement of the upper cap 125 through the aperture 151 . In some embodiments, and adhesive can be used between some or all of ledge 125d and upper portion 150 to help secure the toe-post 120 to the upper portion 150.

[0057] Based on the above-described configuration, wide portion 125a effectively sits on top of the upper side of upper portion 150. In other words, the top axial surface of wide portion 125a is not coplanar with the upper side of upper portion 150, but instead sits higher than the upper side of upper portion 150. In some embodiments, the upper side of upper portion 150 includes a boundary protrusion 153 surrounding the aperture 151. Boundary protrusion 153 may have a height approximately equal to the height of wide portion 125a and may bound an area having a shape and dimensions approximately equal to the shape and dimensions of the wide portion 125a. As such, when the upper cap 125 is moved downwardly into the aperture 151 and engages with the top portion of the toe-post 120, the wide portion 125a occupies substantially all of the area bounded by boundary protrusion 152.

[0058] In embodiments where upper 150 has a gently sloping portion and aperture 151 is formed in this gently sloping portion, the top of toe-post 120 may have a corresponding sloping top surface. In this manner, when the toe-post 120 is installed in the footwear piece, the top of toe-post 120 is flush with the underside of upper portion 150. The top surface oftoe-post 120 that may include this slope is generally the surface from which the order to accommodate the top protrusion 127 protrudes.

[0059] While the above-described embodiments detail aspects where adhesive is used to secure the toe-post 120 to the sole portion 162, the toe-post 120 to the upper cap 125, and / or the upper cap 125 to the upper portion 150, it should be appreciated that other securing mechanisms may be used in any or all of these locations.

[0060] In some embodiments, toe-post 120 is not designed or intended to prevent or inhibit lateral and / or forward movement of the user’s foot within the footwear piece 100. For example, the toe post 120 is not constructed with an inflexible or stiff material that will not give laterally or front to back when forces are applied by the foot in those directions. Instead, the footwear piece 100 relies primarily on the upper portion 150 defining the toe box region 180 to prevent lateral and forward movement of the foot within the footwear piece 100. This allows the toe post 120 to be a flexible structure with some amount of give, and which serves primarily to help keep the footwear piece 100 secured to the foot by way of allowing the toe post 120 to be “captured” within the closed gap formed between the user’s great toe and index toe when the foot is in a natural or neutral position.

[0061] FIGS. 9A-9D, 10A-10D, and 11 illustrate an embodiment similar to the embodiment shown in FIGS. 6A-6D, 7A-7E and 8, but wherein the top of toe-post 120 includes a recess 129 for receiving the entirety of narrow portion 125b in order to engage the upper cap 125 with toe-post 120. This configuration otherwise operates in a nearly identical fashion to the configuration previous described.

[0062] FIGS. 12A-12C, 13, illustrate an alternative embodiment for a toe-post 120. In such alternative embodiments, toe-post 120 may be constructed from a central post element 126 having a jacket 128 disposed over the central post element 126. For example, the toepost 120 may include a bottom cap 124a, a central post element 126, a jacket 128, and a top cap 124b. The central post element 126 may be a flexible element, such as a bendable wire or breakable polymer. In the case where the central post element 126 is made from a breakable polymer, the polymer may be selected a polymer that will not break under normal forces exerted by a user during use, but will break at high forces, such as those that may beapplied in the event that the shoe gets caught in, e.g., an escalator. This breakable polymer thereby provides safety measures to the footwear piece 100.

[0063] The bottom end of the central post element 126 may be received in a portion of the bottom cap 124a adapted for receiving and securing the bottom end of the central post element 126. Alternatively, the bottom end of the central post element 126 may be secured to bottom cap 124a using any suitable securing means, or the bottom cap 124a and central post element 126 may be part of a unitary construction. The top end of the central post element 126 may include means for securing the top end of the central post element 126 to the top cap 124b. Any suitable means for securing the central post element 126 at either end with the caps 124a, 124b may be used. In the example shown in FIGS. 12A-12C, the bottom cap 124a includes a narrow protruding portion having a recess formed therein that receives and secures the bottom end of the central post element 126 therein, while the top cap 124b includes a recess for receiving the top end of the centra post element 126. The top end of the central post element 126 may include an additional element that is adapted to be received by the top cap 124b and aid in securing together the top end of the central post element 126 and the top cap 124b. The top end of central post element 126 and / or the recess in top cap 124b may include features that provide for a snap fit, friction fit, or the like, in order to securely retain the top end of the central post element 126 in the top cap 124b after they have been engaged. The bottom end of central post element 126 and / or the recess in bottom cap 124a may include features that provide for a snap fit, friction fit, or the like, in order to securely retain the bottom end of the central post element 126 in the bottom cap 124a after they have been engaged.

[0064] In one non-limiting example, prior to engaging the top end of the central post element 126 with the top cap 124b, the jacket 128 can be placed over the central post element 126, such as by inserting the top end of the central post element 126 through an opening running through and extending the length of the jacket 128. When the central post element 126 is fully inserted through the jacket 128, the top end of the central post element 126 may fully or partially extend out of the top end of the jacket 128 so that it can still engage with the top cap 124b. The reverse operation is also possible, wherein prior to engaging the bottom end of the central post element 126 and the bottom cap 124a, the jacket is passedover the central post element 126 from the bottom end of the central post element 126. In some embodiments, the jacket 128 has the foil shaped cross-section previously described, though it should be appreciated that the jacket 128 may have other shapes and sizes.

[0065] As in previously described embodiments, the sole portion 162 and upper portion 150 may include apertures 163, 151 , respectively, formed therethrough that are specifically sized and shaped to receive the caps 124a and 124b, central post element 126, and jacket 128 and thereby assist with securing the toe-post 120 within the toe box 180 of the footwear piece 100. FIG. 13 shows an aperture 163 formed in the sole portion 162 and which extends all the way through the thickness of the sole portion 162, i.e. , from the bottom side of sole portion 162 that contacts the ground when in use to the top side of sole portion 162 which the foot contacts when in use. The aperture 163 is specifically shaped at a first end (i.e., bottom side of the sole portion 162) to receive some or all of the thickness of the cap 124a, and then narrows to accommodate only the central post structure 126 and jacket 128. This narrower portion of the aperture 163 extends all the way to the opposite side of the sole portion 162 (i.e. , the top side of the sole portion 162). This narrower portion of aperture 163 may have a cross-sectional shape that is approximately equal in size and shape to the cross- sectional shape of the jacket 128. In one manner of installing the toe-post 120 in the footwear piece 100, the top end of the central post element 126 having the jacket 128 placed thereon on is inserted into the aperture 163 from the bottom side of the sole portion 162 and pushed up through the aperture 163 until the bottom cap 124a is at least partially disposed in the wider portion of aperture 163, which prevents the toe-post 120 from moving further upward into the toe box region 180. A completed version of this first step in an embodiment of toe-post installation is shown in FIG. 14 (though without jacket 128 disposed on central post element 126).

[0066] As shown in FIG. 14, the top portion of central post element 126 at least partially extends through aperture 151 formed in upper portion 150. Aperture 151 extends through the entire thickness of upper portion 150 and is formed at a location in upper portion 150 that is approximately directly over and vertically aligned with aperture 163. To complete installation of toe-post 120 in footwear piece 100, the top cap 124b may be engaged with the end of the central post element 126 and jacket 128 that are protruding through aperture151. Referring back to FIG. 12A, it can be seen that top cap 124b may have a wider diameter top portion that then narrows to a smaller diameter portion. The smaller diameter portion may include the recess in which the top end of the central post element 126 and jacket 128 are received to secure the top cap 124b to the central post element 126 / jacket 128. The size and shape of aperture 151 may be approximately identical to the smaller diameter portion of the top cap 124b so that the smaller diameter portion of the top cap 124b may be inserted into the aperture 151. However, the wider diameter portion of the top cap 124b prevents the top cap 124b from passing all the way through the aperture 151 , and in this way, secures the toe-post 120 to the footwear piece 100 once the top portion of the central post element 126 and jacket 128 are engaged with the recess in the smaller diameter portion of the top cap 124b.

[0067] In a variation of the previously described embodiment, the toe-post 120 does not include central support element 126, and instead the jacket 128 is secured at its top and bottom ends to the bottom cap 124a and top cap 124b, respectively, without any central post element inserted into and running through the length of the jacket 128. In such embodiments, both apertures 163 and 151 may be configured in a similar manner as shown in FIG. 13, wherein each aperture includes a wider recess portion sized and shaped to receive the caps before narrowing to a narrower portion that extends the rest of the way through the sole portion 162 and upper portion 150. The cross-sectional shape of the narrower portions of the apertures 163, 151 may be the same as the cross-sectional shape of the jacket 128 so that the jacket occupies substantially all of the narrower portions of the apertures 163, 151 when extending therethrough.

[0068] In the case of the aperture 151 formed in upper portion 150, the wider portion of the aperture for receiving the top cap 124b is formed in the upper surface (i.e., outer surface) of the upper portion 150, and then the aperture narrows and extends the rest of the way down through the upper portion 150 to the underside of the upper portion 150.

[0069] In some embodiments, the caps 124a and 124b can each be configured in a similar fashion as cap 124b shown in FIG. 12A. More specifically, each cap 124a, 124b includes a wider diameter portion and a smaller diameter portion, with the smaller diameter portion including a recess for receiving the top or bottom end of the jacket 128. In someembodiments, the shape and size of the recess in each cap 124a, 124b is the same as the cross-sectional shape of the jacket 128 at its ends, so that the ends of the jacket 128 fit snuggly and securely within the recesses. In an alternate embodiment, the smaller diameter portions of the caps 124a, 124b do not have a recess formed therein, but are instead sized and shaped to be received within a hollow passage that extends through the middle of the jacket 128. The cross-sectional shape of these smaller diameter portions of the caps 124a, 124b may be the same as the cross-sectional shape of the hollow passage extending through the length of the jacket 128. As best seen in FIG. 12C, one embodiment of this passage through the length of the jacket 128 may have a relatively thin and elongated foilshaped cross-section, and thus the smaller diameter portions of the caps 124a, 124b may have a similar cross-sectional shape and size so that the smaller diameter protrusions can be received snuggly within the hollow passage extending through the length of the jacket 128.

[0070] Adhesive may be used to further secure either end of the jacket 128 with the smaller diameter portion of each cap 124a, 124b. Adhesive may also be used on the underside of the wider diameter portion of each cap 124a, 124b such that when the underside of each cap 124a, 124b contacts the wider portion of the recess 190, 191 , the caps 124a, 124b become secured to the sole portion 162 and upper portion 150, respectively.

[0071] As previously described, the footwear pieces disclosed herein can be made of lightweight material, such as a lofted foam material. Manufacturing footwear pieces using such a lofted foam material can include providing a resin that includes a pre-m ixture of resin, pigment, and a growth additive. The resin, originally in pellet form, is heated to a liquid state. This liquid resin is screwed into a mold that has been heated prior to receiving the resin. The volume of resin injected into the mold is controlled by the pitch of the screw that drives the liquid resin into the mold. The liquid resin is allowed to set, at which time the mold is opened and the formed footwear piece is removed from the mold. The formed footwear piece is then placed on a cooling last, where it is allowed to air cool.

[0072] During this process, a relatively small footwear piece conforming to the size of the mold is created, but when the mold opens, the footwear piece springs out as it expandsin size. Then, as the footwear piece is air cooled, it contracts to a final size. Thus, the process involves both an expansion characteristic and a contraction characteristic. Multiplying the size of the shoe in the mold by the expansion characteristic yields the size of the footwear piece after the mold is opened. Multiplying the expansion characteristic by the contraction characteristic provides a final growth value representative of the final size of the shoe relative to the mold.

[0073] In some embodiments, the resin used in the manufacturing process is an ethylene vinyl acetate (EVA) copolymer-based material. Additives may be included with the EVA base to create an expansible and cross-linking material. More particularly, an expanding powder may be added which decomposes at a specific temperature to produce gases which cause the material to rise as it sets within a mold. Accordingly, when the mold is opened, an instantaneous expansion of the molded part results. During this expansion, the dimensions of the part increase rapidly, while the proportions and shape remain reasonably constant providing a consistent shape of the end part relative to the original mold.

[0074] The resin mixture may further include a pigment. In some embodiments, the resin mixture is modified depending upon the desired color of the footwear piece. This is at least in part due to the density of the pigment associated with certain colors. Were the resin mixture not adjusted based on the pigment used, a green shoe would be produced appreciably smaller than a khaki shoe where all other factors remain constant.

[0075] While footwear pieces can be molded as previously described, based on the disclosure provided herein, one of ordinary skill in the art will appreciate that various embodiments of the present invention can be utilized in relation to other molding processes, and or assembly methods. For example, a hard plastic footwear piece could be injection molded using techniques known in the art, or a footwear piece could be at least partially made of leather or other natural materials. As another example, the footwear piece could be Freon cooled, rather than air cooled. This could be used to speed the manufacturing process.

[0076] In one or more embodiments, frictional forces developed by a configuration of the toe-post and the toe box region in contact with toes may be sufficient to maintain the footwear piece in place on a foot. In this manner, the footwear piece may provide an openheel region. This open heel region may be devoid of a strap. The open heel region may be devoid of any closed portion behind the toe region.

[0077] Although the above embodiments have been described in language that is specific to certain structures, elements, compositions, and methodological steps, it is to be understood that the technology defined in the appended claims is not necessarily limited to the specific structures, elements, compositions and / or steps described. Rather, the specific aspects and steps are described as forms of implementing the claimed technology. Since many embodiments of the technology can be practiced without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.

[0078] From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the scope of the invention. Accordingly, the invention is not limited except as by the appended claims.

[0079] Although the technology has been described in language that is specific to certain structures and materials, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific structures and materials described. Rather, the specific aspects are described as forms of implementing the claimed invention. Because many embodiments of the invention can be practiced without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.

[0080] Unless otherwise indicated, all number or expressions, such as those expressing dimensions, physical characteristics, etc., used in the specification (other than the claims) are understood as modified in all instances by the term "approximately". At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter recited in the specification or claims which is modified by the term "approximately" should at least be construed in light of the number of recited significant digits and by applying rounding techniques. Moreover, all ranges disclosed herein are to be understood to encompass and provide support for claims that recite any and all sub-ranges or any and all individual values subsumed therein. For example, a stated range of 1 to 10 should be considered to include and provide support for claims that recite any and all sub-ranges or individual values that are between and / or inclusive of the minimumvalue of 1 and the maximum value of 10; that is, all sub-ranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values from 1 to 10 (e.g., 3, 5.8, 9.9994, and so forth).

Claims

CLAIMSWhat is claimed is:1 . An open-heel footwear piece, comprising: a sole portion comprising a heel region and a front region opposite the heel region; an upper portion extending over the front region to thereby form and define a toe box region between the upper portion and the front region of the sole portion; and a toe-post extending between the sole portion and the upper portion in the toe box region; wherein the open-heel footwear piece is free of any moveable, removable, or stationary heel restraint mechanism.

2. The open-heel footwear piece of claim 1 , wherein the sole portion and upper portion are formed as a unitary structure, and the toe-post is a separate component from the unitary structure.

3. The open-heel footwear piece of claim 1 , wherein the sole portion and the upper portion are made from a moldable foam material.

4. The open-heel footwear piece of claim 1 , wherein at least a portion of the toe-post has an hourglass shape that is narrowest at a middle section of the toe-post.

5. The open-heel footwear piece of claim 4, wherein the portion of the toe-post having an hourglass shape extends from an upper surface of the sole portion to a lower surface of the upper portion.

6. The open-heel footwear piece of claim 1 , wherein toe-post has an oval, foil, or teardrop cross-sectional shape taken across its vertical axis.

7. The open-heel footwear piece of claim 1 , wherein the upper portion includes an upper portion aperture extending through the thickness of the upper portion, the sole portion includes a sole portion aperture extending through the thickness of the sole portion, and the toe-post extends through both the upper portion aperture and the sole portion aperture.

8. The open-heel footwear piece of claim 7, wherein: the sole portion aperture includes a wide portion at an end of the sole portion aperture proximate a bottom side of the sole portion and a narrow portion extending from the wide portion to a top side of the sole portion, the sole portion narrow portion being narrower than the sole portion wide portion; the toe-post includes a wide portion at a bottom end of the toe-post and a narrow portion extending up from the wide portion, the toe-post narrow portion being narrower than the toe-post wide portion; and the shape and dimensions of the toe-post wide portion are identical to the shape and dimensions of the sole portion aperture wide portion, and the shape and dimensions of the toe-post narrow portion are identical to the shape and dimensions of the sole portionaperture narrow portion, such that when the toe-post wide portion and the toe-post narrow portion are disposed in the sole portion aperture, the toe-post wide portion and the toe-post narrow portion occupy substantially all of the sole portion aperture.

9. The open-heel footwear piece of claim 7, further comprising: a toe-post cap configured such that a portion of the toe-post cap extends down through the upper portion aperture and engages with a top portion of the toe-post.

10. The open-heel footwear piece of claim 9, wherein the toe-post cap comprises a wide portion that resides on top of an upper surface of the upper portion when the toe-post cap is engaged with the top portion of the toe-post, the toe-post cap wide portion being wider than the opening of the upper portion aperture.11 . The open-heel footwear piece of claim 9, wherein: the top portion of the toe-post includes a protruding portion protruding from the top of the portion of the toe-post having an hourglass shape; the toe-post cap includes a recess adapted for receiving the protruding portion of the toe-post; and the toe-post cap recess and the protruding portion are each sized and dimensioned such that when the protruding portion is received in the toe-post cap recess, the protruding portion occupies substantially all of the toe-post cap recess.

12. The open-heel footwear piece of claim 9, wherein at least a portion of the toe-post cap is adhered to the upper portion and at least a portion of the toe-post is adhered to the toe-post cap.

13. The open-heel footwear piece of claim 7, wherein at least a portion of the toe-post is adhered to the sole portion aperture.

14. The open-heel footwear piece of claim 1 , wherein the footwear piece is a clog.

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