Footwear with integrated stitchdown/athletic bottom...

Boots – shoes – and leggings – Sole-attaching means

Reexamination Certificate

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Details

C036S021000, C036S046500, C036S091000, C036S142000

Reexamination Certificate

active

06757990

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to upper/insole assemblies for use in constructing articles of footwear that integrate stitchdown construction methods with athletic bottom components and methods for producing such articles of footwear and upper/insole assemblies.
BACKGROUND OF THE INVENTION
Articles of footwear have been designed and worn by humans since very early in recorded history. Articles of footwear were initially designed to protect the tender bottom portion of the feet of wearers while walking or running over rough surfaces. Although the primary purpose of footwear remains basically unchanged, the various types of activity and surfaces in which humans run, walk, or stand on have led to an ever increasing diversity in the style and construction of footwear. Footwear construction and design have also focused on providing better ankle and arch support while retaining flexibility. Fashion and personal taste have also played significant roles leading to the increase in types of footwear.
Humans engage in a wide variety of physical activities. Some of these activities include walking, running, jogging, sprinting and other track and filed events, backpacking, playing tennis, cross-training, golfing, playing soccer, and scuba diving. Footwear has been specifically designed for use in each of these activities. Methods for constructing footwear have been developed to provide the best characteristics necessary for the particular end use. Thus, methods for constructing boots, athletic shoes, waders, moccasins, slippers, dress shoes, and sandals have all developed.
While many different types of footwear have been designed for specific uses, there is still a need for articles of footwear that will adequately serve the needs of a wearer under varying conditions. For example, many boots are specifically made for activities associated with hiking or backpacking. While such articles of footwear are excellent for this type of activity, an owner of such a boot would probably not want to wear it while playing tennis or engaging in track and field activities due to the weight and decreased flexibility of such an article of footwear. A need still remains for articles of footwear that have improved characteristics which enable them to be better used over a variety of different activities.
One challenge associated with the design of footwear for use in various activities such as in cross-training is providing the necessary arch support while maintaining acceptable weight parameters. Thus, a need remains for an article of footwear for use in cross-training activities that has a reduced weight compared to conventional articles of such footwear yet which also provides adequate arch support. A need for a method for constructing such a reduced weight article of footwear also exists.
SUMMARY OF THE INVENTION
The present invention provides upper/insole assemblies, articles of footwear containing the upper/insole assemblies, and methods for manufacturing the upper/insole assemblies and articles of footwear.
An upper/insole assembly for use in constructing an article of footwear includes an upper and an insole. The upper includes an inner surface; an outer surface; a lateral peripheral flange; and a medial peripheral flange. The insole includes a top surface; a bottom surface; a lateral peripheral edge; a medial peripheral edge; an arch portion; a phalangeal portion; and a heel portion. At least a portion of the lateral and medial peripheral flanges of the upper of the upper/insole assembly are stitched to the insole in the phalangeal and heel portions, but the lateral and medial peripheral flanges are not stitched to the insole through the arch portion. The lateral peripheral flange of the upper is wrapped around the lateral peripheral edge of the insole in the arch portion and the medial peripheral flange of the upper is wrapped around the medial peripheral edge of the insole in the arch portion. Additionally, the lateral and medial peripheral flanges are secured to the bottom surface of the arch portion of the insole.
An article of footwear according to the present invention includes an upper/insole assembly as described in the preceding paragraph and a bottom component that includes an outsole component and a midsole component. At least a portion of the midsole component is fixed to the upper/insole assembly. In more preferred articles of footwear, the bottom component further includes at least one shank that provides support to the arch portion of the upper/insole assembly and article of footwear.
In still other preferred articles of footwear, the bottom component further includes a heel portion and substantially all the heel portion of the bottom component is stitched to the lateral and medial peripheral flanges of the upper through the heel portion of the insole component. In still other preferred articles of footwear, the bottom component also includes a phalangeal portion and substantially all the phalangeal portion of the bottom component is stitched to the lateral and medial peripheral flanges of the upper through the phalangeal portion of the insole component. In still other preferred articles of footwear according to the present invention, the bottom component includes a heel portion and a phalangeal portion and both portions are stitched to the lateral and medial peripheral flanges of the upper through the corresponding heel and phalangeal portions of the insole component.
In some preferred upper/insole assemblies for use in constructing an article of footwear, at least a portion of the lateral and medial peripheral flanges are wrapped around the lateral and medial peripheral edges of the phalangeal portion of the insole and are secured to the bottom surface of the phalangeal portion of the insole. Articles of footwear constructed using such preferred upper/insole assemblies include a bottom component having a midsole component, an outsole component, a heel portion, and a phalangeal portion and substantially all the heel portion of the bottom component is stitched to the lateral and medial peripheral flanges of the upper through the heel portion of the insole component. Additionally, the phalangeal portion of the bottom component is fixed to the phalangeal portion of the insole.
In still other preferred upper/insole assemblies, at least a portion of the lateral and medial peripheral flanges are wrapped around the lateral and medial peripheral edges of the heel portion of the insole and secured to the bottom surface of the heel portion of the insole. Articles of footwear constructed using such an upper/insole assembly include a bottom component having a midsole component, an outsole component, a heel portion and a phalangeal portion. In such articles of footwear, substantially all the phalangeal portion of the bottom component is stitched to the lateral and medial peripheral flanges of the upper through the phalangeal portion of the insole component and the heel portion of the bottom component is fixed to the heel portion of the insole.
In yet other preferred upper/insole assemblies, at least a portion of the lateral and medial peripheral flanges are wrapped around the lateral and medial peripheral edges of the heel and phalangeal portion of the insole and secured to the bottom surface of both the heel and the phalangeal portions of the insole. Articles of footwear constructed from such an upper/insole assembly include a bottom component having a midsole component, an outsole component, a heel portion and a phalangeal portion. In such articles of footwear, the phalangeal portion of the bottom component is fixed to the phalangeal portion of the bottom surface of the insole and the heel portion of the bottom component is fixed to the heel portion of the bottom surface of the insole. Additionally, the outer surface of the lateral and medial peripheral flanges of the upper contacts the top surface of the bottom component.
In yet other preferred upper/insole assemblies, the upper also includes a peripheral toe flange and a peripheral heel flange and the lateral peripheral

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