BACKGROUND OF THE INVENTION

The present invention relates to footwear, and more particularly to a sole assembly for an article of footwear.

Footwear is available in a wide variety of constructions. A typical article of footwear includes a sole joined with an upper. Generally, the sole is configured to form a ground engaging structure that underlies and protects the wearer's foot and the upper is configured to receive and retain the wearer's foot with respect to the sole. The design and configuration of the upper varies with the intended function of the article of footwear.

A wide range of sole constructions are available that provide generally adequate cushioning, support and traction for the foot under a variety of conditions, e.g., walking, running, hiking or standing, or a combination thereof. However, there is an ongoing effort to develop new and improved sole constructions that provide optimal performance across various applications. More specifically, it is common to vary the design and configuration of the sole to match the intended application for the article of footwear. For example, in some applications, the sole is a unitary construction formed from a relatively soft cushioning material. Soles of this construction can provide enhanced cushioning, but typically suffer from premature wear and do not provide adequate support for many applications. As another example, a number of conventional soles are manufactured from an assembly of different materials selected to provide specific functionality. To provide enhanced performance, many soles combine a relatively soft midsole layer that underlies the upper with a relatively hard outsole than extends along the bottom surface of the midsole to provide the ground-engaging structure. The midsole material is typically softer being selected to provide enhanced cushioning, while the outsole material is typically harder being selected to provide enhanced durability and wear resistance. In common applications, the outsole material covers all or substantially all of the ground engaging surface of the sole. While constructions of this type can improve wear resistance and enhance traction, the extensive use of outsole material not only increases weight, but also can negatively affect flexibility. Further, a single external layer of outsole material does little to support the foot—let alone provide varying support characteristics in different regions of the sole assembly.

Despite ongoing efforts, there remains a need for a sole assembly that provides both enhanced comfort and a region-specific support profile, while at the same time remaining relatively light-weight and inexpensive.

SUMMARY OF THE INVENTION

The present invention provides an article of footwear having a sole assembly including a cushioning sole fitted with a support frame. The cushioning sole is manufactured from a relatively soft material that provides enhanced cushioning while the support frame is manufactured from a relatively hard material that selectively supports and reinforces the cushioning sole. The cushioning sole includes a ground-engaging bottom surface and defines a frame recess configured to receive and retain the support frame.

In one embodiment, the support frame include a peripheral member extending around the periphery of the cushioning sole. The peripheral member may be affixed to the sidewall of the cushioning sole near its uppermost extent.

In one embodiment, the cushioning sole includes a peripheral recess. The peripheral recess may be defined in the sidewall and may extend entirely around the periphery of the cushioning sole. The peripheral member of the support frame may be closely fitted into the peripheral recess.

In one embodiment, the support frame includes a longitudinal member extending longitudinally along at least a portion of the length of the sole. The longitudinal member may extend from the peripheral member in the heel of the sole along at least a portion of the ground-engaging surface. In one embodiment, the longitudinal member may extend from the peripheral member in the heel to a location approximate under the ball of the foot.

In one embodiment, the support frame includes at least one lateral member extending laterally across the cushioning sole. The at least one lateral member may bridge the peripheral member. The support frame may include two lateral members—a rear lateral member extending laterally across the cushioning sole in the heel or arch region and a forward lateral member extending laterally across the cushioning sole in the forefoot region. In one embodiment, the rear lateral member and the forward lateral member bridge the peripheral member.

In one embodiment, the frame recess includes a plurality of bottom channels in the face of the ground-engaging surface. The bottom channels may be of sufficient depth to recess the support frame into the bottom surface of the cushioning sole away from the ground-engaging surface. In one embodiment, the bottom channels includes a longitudinal channel receiving the longitudinal member. In one embodiment, the bottom channels include a rear lateral channel receiving the rear lateral member. In one embodiment, the bottom channels include a forward lateral channel receiving the forward lateral member.

In one embodiment, the support frame is secured to the cushioning sole by adhesive. Adhesive may be applied over the entire interface between the support frame and the cushioning sole.

In one embodiment, the peripheral member of the support frame is secured to the cushioning sole by stitching. For example, a line of stitching may be sewn through the peripheral member and the cushioning sole around the perimeter of the sole. The peripheral member may define a stitch groove configured to receive the stitching.

In one embodiment, the support frame includes at least one post extending substantially vertically through a hole defined in the cushioning sole. The post may be secured to the top surface of the cushioning sole to resist separation of the support frame from the cushioning sole. The post may include one or more flaps that are secured to the top surface of the cushioning sole by adhesive. In one embodiment, the support frame includes two posts—a rear post disposed at the intersection of the rear lateral member and the longitudinal member and a forward post disposed at the intersection of the forward lateral member and the longitudinal member.

The present invention provides a sole assembly that combines enhanced overall cushioning with selective support. The support frame includes support members configured to provide region specific support to the cushioning sole without unduly affecting weight or unnecessarily diminishing the cushioning of the cushioning sole. Because the support frame is recessed, the cushioning sole forms the primary ground-engaging surface and is generally free to undergo initial compression without interference from the support frame. As a result, the vertical cushioning properties of the sole assembly are largely dictated by the material properties of the cushioning sole. The support frame provides the sole assembly with support in the lateral and longitudinal directions. For example, the perimeter member of the support frame provides peripheral support for the upper portion of the cushioning sole. The longitudinal support member provides longitudinal support for the cushioning sole. The lateral support members provide lateral support at selected locations. For example, the rear lateral support provides lateral support in the heel region or arch region and the forward lateral support provide lateral support in the forefoot region.

These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. In addition, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.

