US20180343976A1

US20180343976A1 - Integrated shoe support structure combining heel counter and shank

Info

Publication number: US20180343976A1
Application number: US15/997,684
Authority: US
Inventors: Kevin Reid; Braden Parker
Original assignee: Casca Designs Inc
Current assignee: Casca Designs Inc
Priority date: 2017-06-05
Filing date: 2018-06-04
Publication date: 2018-12-06

Abstract

Embodiments are described for a semi-rigid apparatus for use in conjunction with the sole and upper of a shoe or sandal. The apparatus involves a heel stabilizer shank enclosing a portion of the heel, with a shank extension from the medial side, a lightweight support structure running along the bottom of the foot between the outsole and insole stiffening the heel and midfoot. Both elements are made from a single piece of material that can be injection molded, 3D printed, or the like. The purpose of this apparatus is to provide all day comfort, protect the heel from lateral shifting, and stiffen the heel and midfoot for less strain on the foot.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application 62/515,302 entitled “INTEGRATED SHOE SUPPORT STRUCTURE COMBINING HEEL COUNTER AND SHANK” filed Jun. 5, 2017 which is hereby incorporated by reference in its entirety.

FIELD

The present invention relates to the field of footwear, and more specifically to the field of integrated support structures in communication with footwear.

BACKGROUND

This invention relates generally to footwear, and more specifically pertains to shoes and the like that include a combined heel counter and shank.
Numerous styles of footwear, constructed of various components and for achieving multiple purposes, have long existed in the prior art. Most of these types of innovations have been in the area of athletic or outdoor shoes. Various styles or modifications to the shoes, as in their heel counters and support systems, to make them more comfortable, more resilient, add support or suitability to fashion have been considered in the prior art. Shoes as a class often use heel counters, but never been combined as a single part with a shank connecting asymmetrically to the medial side.
Previously, it has been conventional to provide shoes with internal heel counters inside the wall of the shoe upper. In some cases, these have been made of metal or hard plastic strips to provide stiff heel counters, as shown in U.S. Pat. No. 882,109 of Harris. In addition, work boots or shoes have sometimes been provided with external metal plates extending around the exterior surface of the heel for added protection, as shown in U.S. Pat. No. 217,761 of Winn and U.S. Pat. No. 706,551 of Gordon et al. More recently, modifications improving the comfort and construction of this design have been patented for example, BRS Inc., U.S. Pat. No. 4,255,877, created an exposed heel counter that wraps around both sides of the heel and extends to the midfoot on each size. Then, the patent to Puma AG Rudolf Dassler Sport, U.S. Pat. No. 4,821,430 relates to a revised form for the heel counter that allows the improved construction of athletic shoes. However, in these cases, the shoes do not provide mid-foot rigidity through the use of an integrated shank. Alternatively, U.S. Ser. No. 09/746,178 relates to a system which features a heel stabilizer in combination with a platform that spans the entire width and length of the foot bed. Locking the heel into place with a heel counter only solves the issue of lateral stability, but does not stiffen the heel and midfoot, a common practice for work boots and all-day comfort footwear. In addition, U.S. Ser. No. 13/120,499 relates to a multi-part system that fully encloses the underside of the heel, and provides a mid-foot brace that spans the full width of the foot. A heel counter in combination with a panel that spans the entire surface area under the foot bed is overly stiff, rigid and weighty for this application. In order to reduce the total number of components, reduce the weight, increase torsional flexibility and provide a more substantial support throughout the rear and mid of the shoe, the present invention employs an integrated shank made of resilient material which may be a plastic, carbon fiber or other rigid/semi-rigid materials. Previously, carbon, plastic, steel and wood have been commonly used for shanks. However, no one has suggested the use of an external heel counter extending around both sides of the heel in combination with a support shank that runs under the metatarsal bones, along the center of the underfoot as a single unit connecting from the medial side of the heel counter.
The current invention modifies internal support between the sole and upper of footwear or shoes. The modifications add support and a more consistent feel for users, and further enhance the comfort of a foot within the shoe, by providing less strain on the foot and reducing lateral movement in a lightweight solution.

SUMMARY OF THE INVENTION

Embodiments disclosed herein relate to a shoe having an integrated support apparatus to provide long-lasting all day comfort to a wearer. In a preferred embodiment, a shoe is provided having an upper and a sole. The sole has an outsole extending the length of the shoe wherein the sole is attached to the upper. A support apparatus has a heel counter with a shank integrally thereto. A shank extension is integrally molded to the shank such that support apparatus is disposed between the upper and the sole.
One object of the present invention is to provide casual footwear with an external heel counter to provide good heel stability and comfort while preventing blistering.
Another object of the invention is to provide such a casual shoe in which the external heel counter member is made of a resilient material which extends around both sides of the heel portion of the shoe upper and additionally, extends from a connection on the medial side of the heel counter under the foot towards the ball, forming the molded shank.
Another object of the invention is to provide such a casual shoe with said molded shank only connecting from the medial side, an asymmetrical connection which leaves the lateral side of the foot open to torsional movement while forming a narrow and lightweight support structure running down the center of the midfoot towards the ball.
A further object of the invention is to provide such a casual shoe in which the external heel counter member is secured to the sole of such shoe for greater strength and stability.
Another object of the invention is to provide such a casual shoe with superior cushioning and wear characteristics in which the shoe sole includes a midsole/insole layer extending substantially the entire length of the foot and an outer sole layer of harder material than the midsole layer extending beneath the length of such midsole layer.
Still another object of the invention is to provide such a casual shoe in which the shoe upper is made of a synthetic fabrics or natural materials and the heel counter/shank member is bonded to the heel portion and metatarsal section of such shoe upper.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the embodiments, and the attendant advantages and features thereof, will be more readily understood by references to the following detailed description when considered in conjunction with the accompanying drawings wherein:

FIG. 1 illustrates a side elevations view of a shoe with lasted upper made from fabrics or natural materials, semi-rigid heel stabilizer/shank, and cup-sole style rubber outsole;

FIG. 2 illustrates a perspective view of semi-rigid heel stabilizer/shank having a heel counter and shank extension running along the bottom of the foot;

FIG. 3 illustrates a perspective view of cup-sole rubber outsole with accommodation for the semi-rigid heel stabilizer/shank;

FIG. 4 illustrates a side elevation view of a boot with lasted upper made from fabrics or natural materials, semi-rigid heel stabilizer/shank, and wedge style rubber outer sole;

FIG. 5 illustrates a perspective view of semi-rigid heel stabilizer/shank comprising of a heel counter, and a shank extension running along the bottom of the foot;

FIG. 6 illustrates a perspective view of cup-sole rubber outsole with accommodation for the semi-rigid heel stabilizer/shank;

FIG. 7 illustrates a side elevation view of inner workings, including an arch-supporting foam insole sandwiched between the foot and the semi-rigid heel stabilizer/shank;

FIG. 8 illustrates a perspective view of foot and arch-supporting foam insole bending at ball while maintaining rigidity and shape in the back two-thirds the shoe as a result of the semi-rigid heel stabilizer/shank; and

FIG. 9 illustrates a rear perspective view of the semi-rigid heel stabilizer/shank's placement along the metatarsal bones of the foot.

DETAILED DESCRIPTION

The specific details of the single embodiment or variety of embodiments described herein are set forth in this application. Any specific details of the embodiments are used for demonstration purposes only and no unnecessary limitation or inferences are to be understood therefrom.
Any reference to “invention” within this document is a reference to an embodiment of a family of inventions, with no single embodiment including features that are necessarily included in all embodiments, unless otherwise stated. Furthermore, although there may be references to “advantage's” provided by some embodiments, other embodiments may not include those same advantages, or may include different advantages. Any advantages described herein are not to be construed as limiting to any of the claims.
Before describing in detail exemplary embodiments, it is noted that the embodiments reside primarily in combinations of components related to the system. Accordingly, the system components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
As used herein, relational terms, such as “first” and “second” and the like, may be used solely to distinguish one entity or element from another entity or element without necessarily requiring or implying any physical or logical relationship or order between such entities or elements.
Specific quantities, dimensions, spatial characteristics, compositional characteristics and performance characteristics may be used explicitly or implicitly herein, but such specific quantities are presented as examples only and are approximate values unless otherwise indicated. Discussions and depictions pertaining to these, if present, are presented as examples only and do not limit the applicability of other characteristics, unless otherwise indicated.
In general, In specific reference to FIGS. 1-6, the invention is illustrated in a preferred embodiment of the present disclosure. An outsole 12 is adapted to receive an upper component 10 each of which having a substantially similar perimeter to permit a sealing engagement about the perimeter. A complete sealing engagement may not be necessary in the embodiment of a sandal, or other shoe 100 with an open heel or toe design. Reception of the outsole 12 and upper component 10 may be made by integral molding, adhesive, or other means of engagement as known in the art.
FIG. 2 illustrates the support apparatus 1 having a heel stabilizer shank 110 is positioned at the heel portion of the shoe 100. The heel stabilizer shank is defined as a heel counter 130 shaped substantially similar to the natural curvature of the user's heel. A front portion of the heel counter 130 has an opening to permit the ingress of the user's foot 200, such that the user may slide the heel through the front portion until rested firmly upon an inner surface of a back portion of the heel counter 130. The heel counter 130 is further comprised of a mating portion that is substantially perpendicular to the substantially vertical heel counter 130. A shank extension 140 horizontally extends from the mating portion to rd the toes of the user. The shank extension 140 extends to the distal end of the foot 200 of the user but stops at a front end 142 adjacent and below the heads of the metatarsal bones of the foot 200. Both the mating portion, and shank extension 140 are dimensioned to engage with an accommodation for the shank 150 positioned on an upper surface of the outsole 12. The accommodation may be a recessed channel which contacts a bottom surface of the mating portion and shank extension 140 permitting the top surface of the mating portion and shank extension 140 sits flush and level with the top surface of the sole.
In an embodiment, the heel counter 130 is bonded to the outer surface of the heel portion of the upper 10. The mating portion is bonded between the outer sole layer and the upper of the shoe 100 such that the mating portion is retained therein and each component of the heel stabilizer shank 11 is retained in position on the heel of the user during use. The heel counter 130 may taper from a maximum height at the rear end 133 positioned rearmost the posterior of the heel of the user, to a minimum height at the front end 135 of the counter 130. Tapering of the counter 130 allows for adequate mobility of the heel during normal use and movement.
In an embodiment, the shank extension 140 extends from the mating portion at the front of the heel of the user, to the ball of the foot 200 to provide resistance during natural walking movements. The shank extension 140 is positioned on the medial side 192 of the shoe 100 and extends down the center of the midfoot towards the ball of the foot 200. In this manner, the shank extension 140 is asymmetrically connected with the medial side of the counter 130.
Another object of the invention is to provide such a casual shoe 100 with said molded shank 150 only connecting from the medial side, an asymmetrical connection which leaves the lateral side 194 of the foot 200 open to torsional movement while forming a narrow and lightweight support structure running down the center of the midfoot towards the ball.
In an embodiment, a lower portion of the heel counter has a ridged portion 132 extending about the outer surface 134 of the heel portion 131 to engage with a top edge 136 of the sole 12. The ridged portion permits a secure engagement to the sole 12 as well as permits maximum surface area contact between the shank 11 and sole 12 to promote a strong bond between. In one embodiment, the ridge portion tapers from a greater thickness at the ridge 132, to a lesser thickness at the top of the counter 130.
The upper 10 may be manufactured from any material 16 known in the art including but not limited to leathers, polymers, synthetics, natural fibers, rubbers, and metals. It is further intended that the shape spirit and nature of the current invention permits it to be utilized in conjunction with numerous styles of shoe including boots, dress-shoes, casual shoes, sneakers, athletic shoes, slippers, sandals, and others as known in the arts.
The heel stabilizer shank 110 may be comprised of one of a number of materials as known as the art. The material or material blend should be suitably resilient as to lock the heel and arch into the shoe 100, prevent over-pronation, and anchor the foot 200 to the midsole of the shoe 100. Further individual components of the heel stabilizer shank, including the heel counter 130, mating portion, shank extension, and individual outer and inner surfaces may each be comprised of different materials to promote proper resilience, texture, comfort, and other utility during use. Each material may be modified or changed for varying shoe style and integration means.
FIGS. 4-6 illustrates the support structed 1 integrated with a boot. It can be understood by one skilled in the arts that specific contour, shape, and molding of the support structure may be modified to fit a number of common footwear styles, without departing from the spirit of the present invention. A boot 400 is illustrated having a boot heel counter 19, boot shank 17 and boot shank extension 20 are configured in a similar manner as illustrated and described in FIGS. 1-3 incorporated herein.
In specific reference to FIGS. 7-9, the present invention is shown engaged with a user's foot 200 while the engaged shoe is cut away from the illustration to show positioning and functionality. During use, the heel of the user is positioned through the open end of the shank 110 and rests against the inner wall to stabilize the heel during normal gait as well as at rest, whether standing or sitting. The shank extension 140 extends along the lower surface of the insole 220 such that the extension 140 is retained between the insole 220 and upper surface of the outsole 12. The counter 130 has a height to prevent over-supination or over-pronation of the heel.
In an embodiment, the overall length of the shank 14 extends no further than ⅔ the entire length of the shoe 100, such that the shank does not terminate past the ball of the foot 200, with respect to the toes. This leaves the front ⅓ of the length of the shoe 100 without direct contact of the device and permits normal movement of the foot 200 and shoe 100 during use. This length ratio, or one substantially similar results in the greatest comfort and support to the wearer. In an embodiment, the width of the shank 140 should be no more than ⅔ the width of the footbed of the user.
In alternate embodiment, the shank 140 may be ribbed or perforated to modulate rigidity and overall weight. The design of the invention does not require that a single material, or material blend be used, but rather, allows for multiple materials or material blends to be used in individual components. The materials should be semi-rigid in nature to promote support and maintain proper movement of the foot during use.
In an embodiment, the device may be constructed of materials having a SHORE D hardness between 20-95. The thickness of heel counter 130 is approximately 0.66 mm to 2.0 mm, preferably 0, 8 mm. The thickening, in other words the material thickness of heel counter 130 in this area or its thickness is approximately 1.5 mm to 3.5 mm, preferably 2.4 mm.
In specific reference to FIG. 9, the heel is able to engage directly with the insole of the shoe 100 through the use of a heel aperture 230 in the shape of the mating component and shank. This permits maximal shock absorption while maintaining adequate movement in the hindfoot and retaining supportive characteristics.
Many different embodiments have been disclosed herein, in connection with the above description and the drawings. It will be understood that it would be unduly repetitious and obfuscating to literally describe and illustrate every combination and subcombination of these embodiments. Accordingly, all embodiments can be combined in any way and/or combination, and the present specification, including the drawings, shall be construed to constitute a complete written description of all combinations and subcombinations of the embodiments described herein, and of the manner and process of making and using them, and shall support claims to any such combination or subcombination.
It will be appreciated by persons skilled in the art that the present embodiment is not limited to what has been particularly shown and described hereinabove. A variety of modifications and variations are possible in light of the above teachings without departing from the following claims.

Claims

What is claimed is:

1. A shoe having a support apparatus comprising:

a. an upper;

b. a sole having an outsole extending the length of the shoe, the sole attached to the upper;

c. a support apparatus comprising:

i. a heel counter;

ii. a shank integrally molded to the heel counter; and

iii. a shank extension integrally molded to the shank,

wherein the support apparatus is disposed between the upper and the sole,

wherein the support apparatus is configured to provide support to the heel of a user.

2. The apparatus of claim 1, wherein the sole has a recessed portion configured to receive the support apparatus.

3. The apparatus of claim 1, having a ridge portion extending perpendicular from an outer surface of the heel counter, wherein the ridge portion is configured to engage with a top edge of the sole.

4. The apparatus of claim 1, wherein a height of the heel counter tapers from a maximum height at a rear end of the heel counter to a minimum height at a front end of the heel counter.

5. The apparatus of claim 4, wherein the front end is positioned adjacent the heads of the metatarsal bones of the user.

6. The apparatus of claim 1, wherein the shank extension along the bottom of the medial side of the user's foot.

7. The apparatus of claim 1, wherein the shank is a U-Shaped member.

8. The apparatus of claim 1, wherein the shank extension is integrally molded to a mating portion, wherein the mating portion is integrally molded to the shank at the medial side only.

9. A shoe having a support apparatus comprising:

a. an upper;

b. a sole having an insole and an outsole extending the length of the shoe, the sole attached to the upper;

c. a support apparatus comprising:

i. a heel counter extending vertically along the heel of a user;

ii. a shank integrally molded to the heel counter, wherein the shank is substantially perpendicular to the heel counter; and

iii. a shank extension integrally molded via a mating portion to the shank, wherein the shank extension to the distal end of the user's foot,

wherein the support apparatus is disposed between the upper and the sole,

wherein the support apparatus is configured prevent over-supination and over-pronation of the foot.

10. The apparatus of claim 9, wherein the sole has a recessed portion configured to receive the support apparatus.

11. The apparatus of claim 9, having a ridge portion extending perpendicular from an outer surface of the heel counter, wherein the ridge portion is configured to engage with a top edge of the sole.

12. The apparatus of claim 9, wherein a height of the heel counter tapers from a maximum height at a rear end of the heel counter to a minimum height at a front end of the heel counter.

13. The apparatus of claim 12, wherein the front end is positioned adjacent the heads of the metatarsal bones of the user.

14. The apparatus of claim 9, wherein the shank extension along the bottom of the medial side of the user's foot.

15. The apparatus of claim 9, wherein the support apparatus is constructed by injection molding.

16. The apparatus of claim 9, wherein the support apparatus is constructed by 3-Dimensional printing.

17. The apparatus of claim 9, wherein the shank is a U-Shaped member.

18. The apparatus of claim 17, wherein the U-Shaped member permits the heel to contact the insole.

19. The apparatus of claim 9, wherein the support apparatus is constructed having a SHORE D hardness between 20 and 95.

20. The apparatus of claim 9, wherein the shoe is fashioned as an athletic shoe, boot, casual shoe, or sandal.