HK40052897B - Article of footwear with inner and outer midsole layers - Google Patents

Description

Footwear products with inner and outer mid-layers

This application is a divisional application of the application filed on May 5, 2015, with application number 201580028514.0 and invention title "Footwear Article Having Inner and Outer Middle and Lower Layers".

Technical Field

This disclosure relates to a sole assembly for footwear products.

Background Technology

Footwear typically includes a sole configured to sit beneath the wearer's foot to separate the foot from the ground or floor surface. The sole can be designed to provide a desired level of cushioning. In particular, athletic shoes sometimes use polyurethane foam, rubber, or other elastic materials in the sole to provide cushioning.

Summary of the Invention

This application mainly involves, but is not limited to, the following aspects:

1) A footwear product, comprising:

Outsole, the outsole having a heel region, a midfoot region and a forefoot region;

Outer mid-base layer, which is fixed to the outsole and extends only in the heel region and at least some of the midfoot regions;

An inner midsole layer, supported by but not fixed to the outer midsole layer and the outsole; wherein the inner midsole layer extends over the heel region, the midfoot region, and the forefoot region; and

The outer middle layer is configured to surround the periphery of the inner middle layer in the heel region.

2) Footwear products as described in 1) further include:

The upper has a periphery surrounded and secured by the outsole and the outer midsole to define a cavity, the inner midsole being selectively inserted into and removed from the cavity.

3) Footwear articles as described in 1) or 2), wherein the outsole has:

The bottom portion defines a grounding surface;

An inner arcuate portion, the inner arcuate portion extending from the bottom portion on the inner side of the bottom portion; and

An outer arcuate portion extends from the bottom portion on the outside of the bottom portion.

4) Footwear article as described in 3), wherein the outsole has a plurality of spaced protrusions extending outward from the inner arched portion and from the outer arched portion.

5) Footwear as described in 4), wherein the protrusions of the interval extending from the inner arched portion extend further outward than the protrusions of the interval extending from the outer arched portion.

6) Footwear articles as described in 4) or 5), wherein the effective diameter of the spaced protrusions decreases in the direction away from the bottom portion.

7) Footwear articles as described in any one of 3)-6), wherein the inner arched portion and the outer arched portion are generally triangular.

8) Footwear articles as described in any one of 1)-7), wherein the outer insole is harder than the inner insole.

9) Footwear articles as described in any one of 1)-8), wherein the outer insole is at least seven points harder than the inner insole on the Shore A scale.

10) Footwear articles as described in any one of 1)-8), wherein the inner insole has a substantially uniform hardness.

11) A footwear article as described in any one of 1)-10), wherein the inner bottom layer has a groove extending over the forefoot region of the outsole.

12) Footwear as described in 11), wherein at least some of the grooves extend laterally from the inside to the outside of the inner bottom layer.

13) Footwear article as described in 12), wherein one of the grooves extends longitudinally and intersects with at least some of the laterally extending grooves.

14) A footwear article as described in any one of 1)-13), wherein the inner bottom layer has a spaced recess extending over the forefoot region of the outsole.

15) A footwear article as described in any one of 1)-14), wherein the outsole has a first portion and a second portion, the first portion having a first hardness and the second portion having a second hardness greater than the first hardness; and wherein the first portion extends only over some of the forefoot region and the second portion extends around the first portion and over the remainder of the outsole.

16) Footwear article as described in any one of 1)-15), wherein the outsole has:

Inner wall portion;

The outer wall portion; and

A bottom portion having a grounded surface, the bottom portion extending from the inner sidewall portion to the outer sidewall portion and defining one edge through the inner sidewall portion and another edge through the outer sidewall portion.

17) Footwear article as described in any one of 1)-15), wherein the outsole has:

The bottom portion has a grounded surface;

The inner sidewall portion has a first side surface extending substantially perpendicular to the grounding surface; and

The outer wall portion has a second side surface that extends substantially perpendicular to the grounding surface.

18) Footwear articles as described in any one of 1)-17) further include:

A last forming unit is fixed to the outer mid-bottom layer and the outsole, such that the outer mid-bottom layer is located between the last forming unit and the outsole in the heel area, and the last forming unit is directly fixed to the outsole in the forefoot area.

19) A footwear product, comprising:

A one-piece outsole having a bottom portion having a heel area, a midfoot area, and a forefoot area and defining a ground surface; wherein the outsole has an inner arched portion and an outer arched portion extending from the bottom portion;

Outer mid-base layer, which is fixed to the outsole and extends only in the heel region and at least some of the midfoot regions;

A last forming unit is fixed to the outer middle and bottom layers and the outsole, such that the outer middle and bottom layers are located between the last forming unit and the outsole in the heel area, and the last forming unit is directly fixed to the outsole in the forefoot area;

The upper is fixed to the last forming unit to define a cavity and is surrounded by the outsole and the outer midsole along the periphery;

The inner midsole is located in the cavity and supported on the last forming unit, but is not fixed to any one of the last forming unit, the outsole, the outer midsole, and the upper; wherein the inner midsole extends over the heel area, the midfoot area, and the forefoot area.

The outer middle layer is configured to surround the periphery of the inner middle layer in the heel region; and

The inner arched portion extends along the upper on the inner side of the upper, and the outer arched portion extends along the upper on the outer side of the upper.

20) Footwear as described in 19), wherein the outer midsole and the inner midsole are ethylene vinyl acetate foam, and wherein the outer midsole is harder than the inner midsole.

21) Footwear as described in 19) or 20), wherein the outer insole is at least seven points harder than the inner insole on the Shore A scale.

22) Footwear articles as described in any one of 19)-21), wherein the inner insole has a substantially uniform hardness.

23) Footwear article as described in any one of 19)-22), wherein the inner bottom layer has a groove in the surface that contacts the last forming unit in the forefoot region.

24) Footwear as described in 23), wherein at least some of the grooves extend laterally from the inside to the outside of the inner bottom layer.

25) Footwear article as described in 24), wherein one of the grooves extends longitudinally and intersects with at least some of the laterally extending grooves.

26) Footwear article as described in any one of 23)-25), wherein the surface of the inner bottom layer that contacts the last forming unit has spaced recesses extending over the forefoot region of the outsole.

27) A footwear article as described in any one of 19)-26), wherein the outsole has a first portion and a second portion, the first portion having a first hardness and the second portion having a second hardness greater than the first hardness; and wherein the first portion extends only over some of the forefoot region and the second portion extends around the first portion and over the remainder of the outsole.

28) Footwear articles as described in any one of 19)-27), wherein the outsole has:

The inner sidewall portion has a first side surface extending substantially perpendicular to the grounding surface at the front foot region; and

The outer wall portion has a second side surface that extends substantially perpendicular to the grounding surface in the front foot region.

29) Footwear article as described in any one of 19)-27), wherein the outsole has:

Inner wall portion;

The outer wall portion; and

The bottom portion extends from the inner wall portion to the outer wall portion and defines one edge through the inner wall portion and another edge through the outer wall portion.

30) Footwear articles as described in any one of 19)-29), wherein the inner arched portion and the outer arched portion are generally triangular.

31) A footwear article as described in any one of 19)-30), wherein the outsole has a plurality of spaced protrusions extending outward from the inner arched portion and from the outer arched portion.

32) Footwear article as described in 31), wherein the protrusions of the interval extending from the inner arched portion extend further outward than the protrusions of the interval extending from the outer arched portion.

33) Footwear articles as described in 31) or 32), wherein the effective diameter of the spaced protrusions decreases in the direction away from the bottom portion.

Attached Figure Description

Figure 1 is a side view of the inside of a footwear product.

Figure 2 is a side view of the outer side of the footwear product shown in Figure 1.

Figure 3 is a schematic perspective view of the inner bottom layer of the footwear product shown in Figure 1.

Figure 4 is a plan view of the sole assembly of the footwear product shown in Figure 1, where the upper is not shown.

Figure 5 is a schematic cross-sectional view of the sole assembly taken at line 5-5 in Figure 4, and the upper is shown in partial dashed lines.

Figure 6 is a schematic cross-sectional view of the sole assembly taken at line 6-6 in Figure 4, and the upper is shown in partial dashed lines.

Figure 7 is a schematic cross-sectional view of the sole assembly taken at line 7-7 in Figure 4, and the strobel unit and upper are shown in partial dashed lines.

Figure 8 is a schematic cross-sectional view of the sole assembly taken at line 8-8 in Figure 4, and the strobel unit and upper are shown in partial dashed lines.

Figure 9 is a schematic cross-sectional view of the sole assembly taken at line 9-9 in Figure 4, and the strobel unit and upper are shown in partial dashed lines.

Figure 10 is a side view of the outer side of the sole assembly in Figure 4.

Figure 11 is a side view of the inner side of the sole assembly in Figure 4.

Figure 12 is a bottom view of the sole assembly in Figure 4, and shows the dashed lines separating the outsole sections with different hardness.

Figure 13 is a front view of the sole assembly in Figure 4.

Figure 14 is a rear view of the sole assembly shown in Figure 4.

Figure 15 is a bottom view of the inner bottom layer of the sole assembly in Figure 4.

Figure 16 is a side view of the outer side of the inner middle layer of Figure 15.

Figure 17 is a side view of the inner side of the inner bottom layer of Figure 15.

Figure 18 is a front view of the inner bottom layer of Figure 15.

Figure 19 is a rear view of the inner bottom layer of Figure 15.

Figure 20 is a schematic diagram of a partial cross-sectional view of the outer arched portion of the outsole.

Figure 21 is a schematic diagram of a partial cross-sectional view of the inner arched portion of the outsole.

Detailed Implementation

A footwear article is disclosed, comprising various features that make it suitable for various activities, including athletic activities such as, but not limited to, running, rope climbing, and weightlifting. The footwear article includes an outsole having a heel region, a midfoot region, and a forefoot region. An outer midsole is attached to the outsole and extends only in the heel region and at least some of the midfoot region. An inner midsole is supported by the outer midsole and the outsole but not attached to them, and extends in the heel region, midfoot region, and forefoot region. Because the inner midsole is supported by the outer midsole and the outsole and is not adhered to or otherwise attached to any part of the footwear article, the inner midsole provides desired cushioning and conformability without any undesirable rigidity. The outer midsole is configured to surround the periphery of the inner midsole in the heel region, thereby limiting lateral outward deformation of the inner midsole during use.

The strobel unit can be attached to the outsole and midsole, such that the outsole and midsole are located between the strobel unit and the outsole in the heel area, and the strobel unit is directly attached to the outsole in the forefoot area. Footwear articles may include an upper having a periphery surrounded and attached to the outsole and outsole and midsole to define a cavity, wherein the midsole is selectively insertable into and removable from the cavity.

Footwear may also include a bottom portion defining a ground surface, an inner arched portion extending from the bottom portion on the inner side of the bottom portion, and an outer arched portion extending from the bottom portion on the outer side of the bottom portion. The inner and outer arched portions may each typically be triangular, or may be of another shape. The outsole may have a plurality of spaced-apart protrusions extending outward from the inner and outer arched portions. The effective diameter of the spaced-apart protrusions may decrease in the direction away from the bottom. The spaced-apart protrusions may extend further outward from the inner arched portion than from the outer arched portion. When the inner side of the footwear is used for activities such as rope climbing, the longer protrusions on the inner arched portion will provide a higher coefficient of friction, while the shorter protrusions on the outer portion will have a lower coefficient of friction, as may be needed, for example, when using the outer arched portion during downhill driving. Additionally, the spaced-apart protrusions may be configured such that their effective diameter decreases in the direction away from the bottom portion. In other words, the spaced protrusions are longest at the bottom part closest to the outsole, where maximum grip is needed during climbing.

The middle and bottom layers are configured collaboratively to provide the desired performance advantages. For example, the outer middle layer may be harder than the inner middle layer. Both the outer and inner middle layers may be ethylene vinyl acetate foam. In one embodiment, the outer middle layer is at least seven points harder than the inner middle layer on the Shore A scale. The inner middle layer may have a generally uniform hardness. As used herein, a component is considered to have “generally uniform” hardness if the hardness variation throughout the component does not exceed 10%. The firmer outer middle layer surrounding the inner middle layer in the heel area provides stability and support, while the softer inner middle layer provides a cushioned feel.

The inner midsole may have grooves extending into the forefoot region of the outsole. These grooves may be in a surface that contacts the strobel unit in the forefoot region. At least some of the grooves may extend laterally from the inside of the inner midsole to the outside. One of the grooves may extend longitudinally and intersect with at least some of the laterally extending grooves. The grooves may increase compliance and flexibility in the forefoot region. Additionally, the inner midsole may have spaced recesses extending into the forefoot region of the outsole.

The outsole has a bottom portion that forms the ground contact surface. This bottom portion may have a first portion with a first hardness and a second portion with a second hardness greater than the first hardness. The first portion extends only over a portion of the forefoot area, and the second portion surrounds the first portion and extends over the remainder of the outsole. The softer first portion increases traction in the forefoot area.

The outsole may also have an inner sidewall portion and an outer sidewall portion. The bottom portion extends from the inner sidewall portion to the outer sidewall portion, defining one edge through the inner sidewall portion and another edge through the outer sidewall portion. The inner sidewall portion may have a first side surface extending substantially perpendicular to the ground surface of the bottom portion, and the outer sidewall portion may have a second side surface extending substantially perpendicular to the ground surface of the bottom portion. The sidewall portions having first and second side surfaces extending substantially perpendicular to the ground surface add stability to footwear, for example, preventing unwanted lateral movement during activities such as weightlifting.

In one embodiment, the footwear article includes a monolithic outsole having a bottom portion having a heel region, a midfoot region, and a forefoot region and defining a ground surface. The outsole has a medial arched portion and a lateral arched portion extending from the bottom portion. A strobel is fixed to the outsole and extends only in the heel region and at least some of the midfoot regions. A strobel unit is fixed to the strobel and the outsole such that the strobel is located between the strobel and the outsole in the heel region, and the strobel is directly fixed to the outsole in the forefoot region. An upper is fixed to the strobel to define a cavity and is surrounded peripherally by the outsole and the strobel. An insole is located within the cavity and supported on the strobel, but is not fixed to any of the strobel, outsole, strobel, and upper. The inner midsole extends across the heel, midfoot, and forefoot areas. The outer midsole is configured to surround the inner midsole around the heel area. The medial arched portion extends along the inner side of the upper, and the lateral arched portion extends along the outer side of the upper.

The terms “A,” “an,” “the,” “at least one,” and “one or more” are used interchangeably to indicate the presence of at least one of the items; multiple such items may exist unless the context clearly indicates otherwise. Unless explicitly or clearly indicated by the context (including the appended claims), all numerical values of parameters (e.g., quantities or conditions) in this specification shall be understood to be modified in all cases by the term “about,” regardless of whether “about” actually appears before the numerical value. “About” indicates that the numerical value allows for some slight imprecision (numerically close to the exact value; approximately or reasonably close to the value; almost). If the imprecision provided by “about” is not understood in any other conventional sense in the art, then “about” as used herein at least indicates variation that may be caused by conventional methods of measuring and using these parameters. Furthermore, the disclosure of a range is understood to specifically disclose all values within that range and further subdivisions of the range.

The terms “comprising,” “including,” and “having” are inclusive, thus specifying the presence of a particular feature, step, operation, element, or component, but not excluding the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be changed, and additional or alternative steps may be used. As used herein, the term “or” includes any one and all combinations of the associated listed items.

Those skilled in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” “top,” and “bottom” are used descriptively with respect to the accompanying drawings and do not imply any limitation on the scope of the invention as defined by the claims.

The foregoing features and advantages, as well as other features and advantages, of this disclosure will become apparent from the following detailed description of the modes for implementing the concepts of this disclosure, taken in conjunction with the accompanying drawings.

Referring to the accompanying drawings, in which the same reference numerals refer to the same parts in several views, Figure 1 is an inner view of footwear article 10, which includes a sole assembly 12 having an outsole 14, an outer midsole 16, and an inner midsole 18 (as shown in Figure 3). As further disclosed herein, the inner midsole 18 is not adhered to or otherwise secured to any part of the footwear article 10, thereby preventing undesirable rigidity. The inner midsole 18 is less rigid than the outer midsole 16 to enhance cushioning for running or other activities, while the outer midsole 16 and outsole 14 provide stability for activities such as weightlifting. Furthermore, the outsole 14 includes inner and outer arched portions 20, 22 as shown in Figures 1 and 2, which extend upward along the inner side 24 of the upper 26 at a periphery 30 and are secured to the inner side 24 of the upper 26, and extend upward along the outer side 28 of the upper 26 and are secured to the outer side 28 of the upper 26 to provide traction for activities such as rope climbing.

As used herein, the outer side of a component for footwear, such as the outer side 28 of the upper 26, is the side corresponding to the side of the wearer's foot of the footwear 10, and is generally farther from the wearer's other foot (i.e., the side closer to the wearer's fifth toe). The fifth toe is generally referred to as the little toe. The inner side of a component for footwear, such as the inner side 24 of the footwear 10, is the side corresponding to the inner region of the wearer's foot, and is generally closer to the wearer's other foot (i.e., the side closer to the wearer's big toe). The big toe is generally referred to as the big toe. Both the outer side 28 and the inner side 24 extend from the foremost portion 32 of the upper 26 to the rearmost portion 34 of the upper 26.

As best shown in Figures 1, 9, and 12, the outsole 14 has a heel region 36, a midfoot region 38, and a forefoot region 40. The midfoot region 38 lies between the heel region 36 and the forefoot region 40. For the purposes of discussion, the heel region 36, midfoot region 38, and forefoot region 40 are defined as the rearmost third, middle third, and frontmost third of the outsole 14, respectively. Therefore, the forefoot region 40 extends from the frontmost region A of the outsole 14 to a lateral marker B, which separates one-third of the path along the longitudinal axis L from the frontmost region A to the rearmost region D of the outsole 14. The middle region 38 extends from the lateral marker B to the lateral marker C, which separates two-thirds of the path along the longitudinal axis L from the frontmost region A to the rearmost region D. The heel region extends from the lateral marker C to the rearmost region D.

The heel region 36 typically includes a portion of the outsole 14 corresponding to the rear of the human foot, including the calcaneus, with the size of the human foot corresponding to the outsole 14 and the footwear 10. The forefoot region 40 typically includes a portion of the outsole 14 corresponding to the toes and the joints connecting the metatarsals to the phalanges of the foot, with the size of the human foot corresponding to the outsole 14 and the footwear 10. The midfoot region 38 typically includes a portion of the outsole 14 corresponding to the arch region of the human foot, with the size of the human foot corresponding to the outsole 14 and the footwear 10.

Figure 9 shows the outer midsole 16 fixed to the outsole 14 and extending only over the heel region 36 and a portion of the midfoot region 38. The inner midsole 18 is supported by the outer midsole 16 and the outsole 14, but is not fixed thereto. In other words, the inner midsole 18 is not adhered to, sewn, bonded, welded, or otherwise fixed to any other part of the footwear article 10. Instead, the inner midsole 18 is simply placed on the strobel unit 42 within the cavity 41, which is defined and bounded by the upper 26 and the strobel unit 42. The strobel unit 42 is sewn to the upper 26. Alternatively, heat stitching, bonding, or other methods of fixing the footwear upper 26 to the strobel unit 42 may be used. The strobel unit 42 is also directly adhered to or bonded to the upward-facing surface 46 of the outsole 16 in the heel region 36, directly adhered to or bonded to the portion of the midfoot region 38 not covered by the outsole 16, and directly adhered to or bonded to the upward-facing surface 48 of the outsole 14 in the forefoot region 40. The upper 26 can be composed of multiple independent components and materials, such as fabric, textiles, leather, plastic, etc. As shown in Figure 1, in the illustrated embodiment, the upper 26 includes a relatively rigid polymer heel stabilizer 27, a leather portion 29, a fabric mesh portion 31, a polymer toe cap 33, a fabric lining 35, and a nylon zipper strap 37.

As shown in Figures 3 and 9, the inner midsole 18 is a full-length midsole, extending over the heel region 36, midfoot region 38, and forefoot region 40 when placed in the cavity 41. The inner midsole 18 can therefore be selectively inserted into or removed from the cavity 41 and is referred to as an insert midsole. Because the inner midsole 18 is not fixed to any part of the footwear 10, it can exhibit minimal relative movement with respect to the strobel unit 42, the outer midsole 16, and the outsole 14 under certain loads. This reduces rigidity and creates a sense of flexibility during wear. However, the inner midsole 18 is supported by the outer midsole 16 and the outsole 14, and is relatively constrained by the outer midsole 16 and the upper 26. As shown in Figures 4 and 8, the outer midsole 16 is configured to surround the periphery 50 of the inner midsole 18 at the heel region 36.

As discussed further herein, the outer midsole layer 16 is harder than the inner midsole layer 18. For example, in one embodiment, when hardness is measured on the Shore A scale, the outer midsole layer 16 is 7 points harder than the inner midsole layer 18. Both the inner midsole layer 18 and the outer midsole layer 16 can be polymer foams, such as ethylene vinyl acetate (EVA) foam. The inner midsole layer 18 can be a lighter and lower density foam than the outer midsole layer 16. The inner midsole layer 18 is configured to have a generally uniform hardness, providing adequate cushioning and flexibility under the wearer's heel, while the surrounding outer midsole layer 16 is harder to provide lateral support, elasticity, and energy absorption in the heel area 36. As shown in Figure 3, the inner midsole layer 18 has a fabric lining 39 fixed to the foot receiving surface 44 (i.e., the upper surface).

On the other hand, the outsole 14 does not have a uniform hardness. Specifically, Figure 12 shows the boundary H that typically separates the first portion 52 of the outsole from the second portion 54 of the outsole 14. The first portion 52 extends only over some of the forefoot region 40 and generally coincides with the pressure-bearing area under the ball of the wearer's foot. The second portion 54 includes the entire remainder of the outsole 14. The first portion 52 has a first hardness, and the second portion 54 has a second hardness greater than the first hardness. The first portion 52 is softer than the second portion 54 and has a larger coefficient of friction relative to the ground GS compared to the harder rubber of the second portion 54, as shown in Figure 9. Therefore, the first portion 52 is more compliant and provides greater traction relative to the force transmitted from the ball of the wearer's foot through the forefoot region 40, such as during lateral movements and/or climbing. The outsole 14 can be thermoplastic rubber or other durable materials. The materials used for the outsole 14 can be selected to provide a desired combination of durability and flexibility.

As shown in Figures 9-12, the outsole 14 has a bottom portion 60 defining a grounding surface GCS. The grounding surface GCS includes those portions of the bottom portion 60 configured to contact the ground surface GS of Figure 9 when the footwear 10 is worn for most activities in which the wearer is typically upright (e.g., running or weightlifting). As shown in Figures 9 and 12, the bottom portion 60 has a plurality of molded grounding elements 62 of different sizes, most or all of which are hexagonal in shape. Other shapes of grounding elements may be used within the scope of this disclosure. The grounding elements 62 extend outward from the base 64 of the outsole 14. Thus, those grounding elements 62 that contact the ground GS establish the grounding surface GS. As shown in Figures 10, 11, 13, and 14, the ground contact element 62 is configured such that when the footwear 10 is placed upright as shown and not worn, i.e., when the outsole 14 is unloaded, or when the outsole 14 bears the weight of a person wearing the footwear 10 and standing upright, the ground contact surface GCS of the outsole 14 is substantially flat from the inner side 66 to the outer side 68 of the outsole 14. As shown in Figures 9, 13, and 14, not all ground contact elements 62 may immediately contact the ground contact surface GCS, and different portions of the outsole 14 will contact the ground as the wearer's foot moves relative to the ground.

At any given location along the longitudinal axis L of the outsole 14, the large flatness of the grounding surface GCS from the inner side 66 to the outer side 68 contributes to the stability of the footwear article 10. Specifically, the footwear article 10 is relatively difficult to roll laterally due to the large width and flatness of the bottom portion 60. Furthermore, as shown in FIG5, the outsole 14 has an inner sidewall portion 70 having a first side surface 72 extending substantially perpendicular to the bottom grounding surface GCS. The outsole 14 also has an outer sidewall portion 74 having a second side surface 76 extending substantially perpendicular to the bottom contact surface GCS. The inner sidewall portion 70 and the outer sidewall portion 74 are adjacent to the forefoot region 40 of the outsole 14. Edge E1 is defined by the bottom portion 60 and the inner sidewall portion 70 at an angled surface 73 and is located between the bottom portion 60 and the inner sidewall portion 70, similar to a chamfer, and edge E2 is defined by the bottom portion 60 and the outer sidewall portion 74 at an angled surface 77 and is located between them, similar to a chamfer as shown in FIG12. By providing angled surfaces 73, 77 with edges E1, E2, instead of a more rounded transition from the bottom 60 to the sidewall portions 70, 74, the stability and resistance to lateral curling of the outsole 14 are improved.

Figures 1, 2, 6-7, and 10-12 show an inner arched portion 20 extending from the bottom portion 60 on the inner side 24 and an outer arched portion 22 extending from the bottom portion 60 on the outer side 26. The inner arched portion 20 and the outer arched portion 22 are approximately triangular in shape and extend upwards along the side of the upper 26 for approximately half a distance to reach vertices A1 and A2, respectively.

Multiple spaced-apart protrusions 80 extend outward from the base 82 of the outsole 14 at the inner arched portion 20 and the outer arched portion 22, as shown in Figures 1 and 2. Similar to the grounding element 62, the protrusions 80 are hexagonal in shape, but other shapes can also be used. Indeed, for example, when the footwear 10 is used for rope climbing, the protrusions 80 serve as grounding elements for the inner arched portion 20 and the outer arched portion 22. During rope climbing, the inner arched portion 20 typically presses against the rope and provides traction during ascent. During descent, the climber can reposition their foot so that the outer arched portion 22 contacts the rope. Generally, greater traction is required during ascent than during descent. During descent, an experienced climber may prefer contact between the rope and the outer arched portion 22, but may also prefer to use the outer arched portion 22 as a sliding support against the rope to increase descent speed. Therefore, a higher coefficient of friction is required at the inner arched portion 20 than at the outer arched portion 22. To accommodate these needs, the spacer protrusions 80 on the inner arcuate portion 20 extend further outward from the base 82 than the spacer protrusions 80 on the outer arcuate portion 22. Figure 21 shows the outer and inner arcuate portions of Figure 7 in a larger view. Figures 7 and 20 show the longest spacer protrusion 80 on the inner arcuate portion 20 extending a distance D1 from the base 82, while Figure 20 shows the longest spacer protrusion 80 on the outer arcuate portion 22 extending a smaller distance D2 from the base 82. The distances D1 and D2 outward from the base 82 are measured along the corresponding central axes C1 and C2 of the protrusions 80.

As is evident in Figures 1, 2, and 7, the spacer protrusions 80 on either the inner arch 20 or the outer arch 22 extend further outward near the bottom portion 60, and the outward extension decreases further away from the bottom portion 60 (i.e., the protrusions 80 closer to vertices A1 or A2 extend outward less than those closer to the bottom portion 60). In addition to the reduced extension length, the effective diameter of the spacer protrusions 80 also decreases in the direction away from the bottom portion 60. In other words, the effective diameter of the protrusions 80 closer to vertices A1 or A2 is smaller than that of those closer to the bottom portion 60. Figures 1 and 2 show protrusions closer to the bottom portion 60 with an effective diameter 88A, while protrusions closer to vertices A1 or A2 have a smaller effective diameter 88B. As used herein, the effective diameter of a hexagonal protrusion 80 is the diameter of a circular protrusion having an equivalent surface area to the hexagonal face of the protrusion.

As shown in Figure 15, the insole layer 18 has grooves 90, 92 formed in the forefoot portion 93 of the insole layer 18. When the insole layer 18 is placed in the cavity 41 of the footwear article 10, the grooves 90, 92 extend over the forefoot region 40 of the outsole 14. The grooves 90, 92 are in the bottom surface 94 of the insole layer 18, which contacts the strobel unit 42 in the forefoot region 40. The grooves 90 are transverse grooves because they extend laterally from the inner side 95 of the insole layer 18 to the outer side 96 of the insole layer 18. The grooves 92 are longitudinal grooves because they extend longitudinally and intersect with at least some of the transverse grooves 92. The grooves 90, 92 increase the conformability and flexibility of the insole layer 18 in the forefoot region 40.

Figure 15 also shows that the bottom surface 94 of the inner bottom layer 18 has spaced recesses 98, which contact the strobel unit 42. Only some of the recesses 98 are marked with reference numerals. The spaced recesses 98 in the bottom surface 94 of the inner bottom layer 18 contact the strobel unit 42 in the forefoot region 40, and thus extend on the forefoot region 40 of the outsole 14 when the inner bottom layer 18 is placed in the cavity 41. The spaced recesses 98 increase the conformability of the material of the inner bottom layer 18 in the forefoot region 40. Furthermore, the spaced recesses 98 increase the coefficient of friction of the inner bottom layer 18 on the strobel unit 42 relative to the relatively smooth midfoot portion 99 of the inner bottom layer 18. The increased coefficient of friction in the forefoot region 93 helps limit the sliding movement of the inner insole 18 relative to the strobel unit 42. The pattern of the spaced-apart recesses 98 in Figure 15 generally corresponds to the first portion 52 of the outsole 14 (as shown in Figure 12), which has a softer rubber than the second portion 54. Therefore, the grooves 90, 92, the spaced-apart recesses 98, and the first portion 52 are all arranged in the forefoot region 40 to increase the conformability, flexibility, and cushioning of the forefoot region 40 of the footwear 10.

Figure 15 shows that the insole midsole 18 also has a lateral groove 100 in the heel region 102 of the insole midsole 18. The groove 100 is generally shallower than the groove 90. Compared to the relatively smooth midfoot portion 99 of the insole midsole 18, the groove 100 helps to increase the suppleness and coefficient of friction of the insole midsole 18 in the heel region 102. When the insole midsole 18 is placed in the cavity 41, the increased coefficient of friction in the heel region 102 helps to limit the sliding movement of the insole midsole 18 relative to the strobel unit.

Figures 16-19 show the inner mid-base layer 18 having outer and inner sidewall portions 106A, 106B, both having longitudinally extending folds 108 generally in the forefoot portion 93 and partially extending into the midfoot portion 99 as shown in Figure 17. The folds 108 can also be described as alternating ridges and valleys. The folds 108 increase the responsiveness of the forefoot portion 93 of the inner mid-base layer 18. As can be clearly seen in Figures 16 and 17, the striking portion 100 of the heel region 102 extends from the bottom surface 94 of the inner mid-base layer 18 to the sidewall portions 106A, 106B.

Although several models for implementing many aspects of this teaching have been described in detail, those skilled in the art will recognize that various alternative aspects for implementing this teaching are within the scope of the appended claims.

Claims (20)

1. A footwear product, comprising: An integral outsole having a bottom portion, the bottom portion having a heel area, a midfoot area, and a forefoot area; Outer mid-base layer, said outer mid-base layer being fixed to said outsole and extending only in said heel region and at least some of said midfoot regions; and The inner bottom layer is supported by the outer bottom layer and the outer bottom layer, but is not fixed to the outer bottom layer and the outer bottom layer; in: The inner bottom layer has a groove extending on the forefoot region of the outsole; The inner bottom layer has spaced recesses extending over the forefoot region of the outsole; The outsole has a first portion and a second portion; The first portion extends only on some of the forefoot area, and the second portion extends around the first portion and on the remainder of the outsole; The first part has a first hardness and the second part has a second hardness greater than the first hardness; The pattern of the first portion is consistent with that of the recessed portion of the interval; The second part surrounds the first part; The grooves are located in the front foot portion of the inner bottom layer, and at least some of the grooves extend laterally from the inner side of the inner bottom layer to the outer side; and One of the grooves extends longitudinally and intersects with at least some of the grooves that extend laterally. 2. The footwear product according to claim 1, further comprising: A last forming unit is fixed to the outer mid-bottom layer and the outsole, such that the outer mid-bottom layer is located between the last forming unit and the outsole in the heel area, and the last forming unit is directly fixed to the outsole in the forefoot area. 3. The footwear product according to claim 2, further comprising: The upper is fixed to the last forming unit to define a cavity and is surrounded by the outsole and the outer midsole along the periphery; The inner midsole is disposed within the cavity and supported on the last forming unit, but is not fixed to any one of the last forming unit, the outsole, the outer midsole, or the upper. The inner bottom layer extends over the heel region, the midfoot region, and the forefoot region. 4. The footwear article of claim 3, wherein the outer midsole is configured to surround the periphery of the inner midsole in the heel region; and The outer middle layer is harder than the inner middle layer. 5. The footwear product according to claim 1, wherein the inner bottom layer has a substantially uniform hardness. 6. The footwear article according to claim 1, wherein the inner bottom layer has an additional transverse groove in the heel portion of the inner bottom layer. 7. The footwear product according to claim 1, wherein: The inner bottom layer has an outer sidewall portion and an inner sidewall portion; Both the outer and inner wall portions of the inner sublayer have folds that extend longitudinally in the forefoot portion of the inner sublayer and partially extend into the midfoot portion of the inner sublayer. 8. The footwear article according to claim 1, wherein the spaced recesses and the grooves are located in the bottom surface of the inner bottom layer. 9. A footwear product, comprising: vamp; Outsole, the outsole having: Heel area, midfoot area, and forefoot area; The bottom portion defines a grounding surface; An inner arc-shaped portion that extends from the bottom portion on the inner side of the bottom portion; An outer arcuate portion that extends from the bottom portion on the outside of the bottom portion; and in: The outsole has a plurality of spaced protrusions extending outward from the inner and outer arched portions; and The inner and outer arched portions are each generally triangular, extending upwards along the side of the shoe upper for approximately half the distance to reach the apex of the triangle. Outer mid-base layer, the outer mid-base layer being fixed to the outsole and extending only in the heel region and at least some of the midfoot regions; and An inner midsole layer, supported by but not fixed to the outer midsole layer and the outsole; wherein the inner midsole layer extends over the heel region, the midfoot region, and the forefoot region, and wherein the outer midsole layer is configured to surround the periphery of the inner midsole layer in the heel region. The upper has a periphery surrounded and fixed by the outsole and the outer midsole to define a cavity, wherein the inner midsole can be selectively inserted into and removed from the cavity. 10. The footwear article of claim 9, wherein the outsole has a first portion and a second portion, the first portion having a first hardness, the second portion having a second hardness greater than the first hardness; and wherein the first portion extends only over some of the forefoot region, and the second portion extends around the first portion and over the remainder of the outsole. 11. The footwear article according to claim 9, wherein the outsole has: Inner wall portion; The outer wall portion; and The bottom portion extends from the inner wall portion to the outer wall portion and defines one edge through the inner wall portion and another edge through the outer wall portion. 12. The footwear article according to claim 9, wherein the outsole has: The inner sidewall portion has a side surface extending substantially perpendicular to the grounding surface at the front foot region; and The outer wall portion has a side surface that extends substantially perpendicular to the grounding surface in the front foot region. 13. The footwear article according to claim 9, wherein the shape of the spaced protrusions is hexagonal. 14. A footwear product, comprising: The outsole has a heel region, a midfoot region, a forefoot region, a bottom portion defining a ground surface, and an inner arched portion extending upward from the bottom portion on the inner side of the bottom portion; The inner arc-shaped portion is roughly triangular; The inner arched portion of the outsole has a base and a plurality of spaced protrusions extending outward from the base; The outsole further includes an outer arched portion extending upward from the bottom portion, the outer arched portion being generally triangular; The outer arched portion has a base and a plurality of spaced protrusions extending outward from the base; and The plurality of protrusions extending outward from the base of the inner arched portion extend further outward than the plurality of protrusions extending outward from the base of the outer arched portion. Outer mid-base layer, which is fixed to the outsole and extends only in the heel region and at least some of the midfoot regions; An inner midsole, supported by and not fixed to the outer midsole and the outsole; wherein the inner midsole extends over the heel region, the midfoot region, and the forefoot region, and wherein the outer midsole is configured to surround the periphery of the inner midsole in the heel region; and The upper has a periphery surrounded and secured by the outsole and the outer midsole to define a cavity, the inner midsole being selectively inserted into and removed from the cavity. The bottom portion extends from the inner sidewall portion of the outer bottom to the outer sidewall portion of the outer bottom, defining one edge through the inner sidewall portion and another edge through the outer sidewall portion. The inner arched portion extends along the upper on the inner side of the upper, and the outer arched portion extends along the upper on the outer side of the upper. The inner arched portion and the outer arched portion extend upwards along the side of the shoe upper for approximately half the distance of the shoe upper to reach the apex of the triangle. 15. The footwear article of claim 14, wherein each of the plurality of protrusions has a hexagonal shape. 16. The footwear article of claim 14, wherein the footwear article has a forefoot region, a midfoot region and a heel region, and the sole portion has a grounding element in the forefoot region, the midfoot region and the heel region. 17. The footwear article of claim 16, wherein the ground-feeding element and the protrusion have a hexagonal shape. 18. A footwear product, comprising: vamp; The outsole has a bottom portion defining a ground surface, an inner arched portion extending from the bottom portion on the inner side of the bottom portion, an inner sidewall portion, and an outer sidewall portion, wherein the bottom portion extends from the inner sidewall portion to the outer sidewall portion and defines one edge through the inner sidewall portion and another edge through the outer sidewall portion, the inner sidewall portion having a first side surface extending substantially perpendicular to the ground surface in the forefoot region, and the outer sidewall portion having a second side surface extending substantially perpendicular to the ground surface in the forefoot region; The inner arc-shaped portion is roughly triangular; The inner arcuate portion has a base and a plurality of spaced protrusions extending outward from the base; The outsole further includes an outer arcuate portion extending upward from the bottom portion on the outer side of the bottom portion, the outer arcuate portion being generally triangular; The inner arched portion extends along the upper on the inner side of the upper, and the outer arched portion extends along the upper on the outer side of the upper. The bottom portion includes a forefoot region, a midfoot region, and a heel region, and ground-contacting elements are present in the forefoot region, the midfoot region, and the heel region; and Outer mid-base layer, the outer mid-base layer being fixed to the outsole and extending only in the heel region and at least some of the midfoot regions; and An inner midsole layer, supported by but not fixed to the outer midsole layer and the outsole; wherein the inner midsole layer extends over the heel region, the midfoot region, and the forefoot region, and wherein the outer midsole layer is configured to surround the periphery of the inner midsole layer in the heel region. The upper has a periphery surrounded and fixed by the outsole and the outer midsole to define a cavity, wherein the inner midsole is selectively inserted into and removed from the cavity; and The inner arched portion and the outer arched portion extend upwards along the side of the shoe upper for approximately half the distance of the shoe upper to reach the apex of the triangle. 19. The footwear article according to claim 18, wherein each of the plurality of protrusions is hexagonal in shape. 20. The footwear article according to claim 18, wherein the grounding element and the plurality of protrusions are hexagonal in shape.