BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention is directed to form-fitting articles, such as athletic shoes,
and a method for providing customized form-fitted articles.
Background Art
[0002] Individuals are concerned with fit when buying items to be worn, such as articles
of footwear or sportswear. For example, while articles of footwear and sportswear
come in a variety of sizes, it is rare to find an article of footwear or sportswear
that is the perfect fit. Often, in the case of footwear, individuals must buy additional
inserts such as heel grippers to prevent the wearer's foot from rubbing against the
heel of the shoe or arch supports to support the arch and prevent pronation. In some
instances, individuals may have two differently shaped feet so that it is necessary
to buy footwear having a different size and/or width for each foot. However, a vast
majority of individuals ignore the less than perfect fit and in so doing minimize
their comfort, performance, and, sometimes, safety. One potential side effect of not
having a good fit is that it may lead to injury over time. Comfort, performance, and
injury prevention are important to everyone, but are particularly important to athletes.
[0003] In the past, heat moldable materials have been used in some ski boots along with
rigid, inflexible outer shells. The heat moldable material was generally a thick foam
liner or stiffener that could be molded to the contour of a wearer's foot. In general,
such ski boots were designed for stiffness and support and the heat moldable materials
used were generally semi-rigid, foam-based materials that would lose their ability
to reform upon repeated heat molding.
[0004] Also in the past, some heat moldable materials have been used as heel counters and
toe boxes in non-athletic, dress shoes. The heat moldable material used was generally
thick, designed for stiffness, and any purposeful heat molding is thought to have
been limited to that done in the shoe factory.
[0005] Accordingly, a need exists for articles of footwear and sportswear that can be customized
and form-fitted to an individual that include a flexible and reusable heat moldable
material.
[0006] US 2009/0293318 A1 relates to heat moldable sport shoes. An embodiment of a cycling shoe comprises a
sole and an upper portion extending upwardly from the sole. The upper portion comprises
an outer layer, an inner layer opposed to the outer layer and a discontinuous heat
moldable layer extending between the outer and the inner layers. In one embodiment,
in heat moldable layer discontinuity sections, the inner layer can be directly juxtaposed
to the outer layer, i.e. the upper portion is solely heat moldable layer free. The
outer layer is made from leather, synthetic or natural. The heat moldable layer is
made of a thermoformable material.
BRIEF SUMMARY OF THE INVENTION
[0007] The above-mentioned need is fulfilled by the subject matter of the independent claims.
Advantageous embodiments can be found in the dependent claims.
[0008] A customized, form-fitting athletic shoe that results from conforming a heat moldable
material to the contours of the wearer's body provides many advantages for consumers.
For instance, it may facilitate the process of buying shoes, as it may eliminate the
need to by different size and/or width shoes for each foot if an individual has differently
shaped feet. The process of fitting the heat moldable material to each wearer's body
to provide a customized form-fit shoe may be accomplished with identical sized shoes.
Such a customized, form-fitting athletic shoe may also provide increased comfort,
performance, or safety to the wearer. In some embodiments, the heat moldable material
may be sufficiently flexible so as not to impede the necessary movements of a wearer
or the athletic shoe while performing activities, such as running, walking, jumping,
etc. In some embodiments, the heat moldable material may be reusable in that it may
be reheated and remolded multiple times so that the athletic shoe may be re-customized
or re-fitted as needed. Such a shoe can be re-customized or re-fitted to a wearer's
changing footwear requirements or re-customized or re-fitted to a different individual.
[0009] In one embodiment, an athletic shoe may include a sole and an upper connected to
the sole. The upper may have a forefoot region, a heel region, and a midfoot region
between the forefoot region and the heel region. The upper may also have a flexible
outer layer, a lining connected to the flexible outer layer, and a flexible heat moldable
sheet disposed between the outer layer and the lining at least in a portion of the
midfoot region. The flexible heat moldable sheet may be configured to conform to a
wearer's body (
e.g., a portion of a wearer's foot, ankle, lower leg, or combination thereof) when heated
to a predetermined temperature to provide the wearer with a customized fit for the
athletic shoe. In some embodiments, the flexible heat moldable sheet may comprise
a fabric and a thermoplastic resin. In some embodiments, the flexible heat moldable
sheet may comprise a thermoplastic resin and does not comprise a fabric. In some embodiments,
the flexible heat moldable sheet may be formed of a material which allows the sheet
to be reusable so that it may be molded multiple times to conform to the wearer.
[0010] In another embodiment, an upper of an athletic shoe may include a forefoot region,
a heel region, and a midfoot region between the forefoot region and the heel region.
The upper may also have a flexible outer layer, a lining connected to the flexible
outer layer, and a flexible heat moldable sheet substantially contacting the outer
layer and the lining at least in a portion of the midfoot region. The flexible heat
moldable sheet may be configured to conform to a wearer's body (
e.g., a portion of a wearer's foot, ankle, lower leg, or combination thereof) when heated
to a predetermined temperature to provide the wearer with a customized fit for the
upper. In some embodiments, the flexible heat moldable sheet may comprise a fabric
and a thermoplastic resin. In some embodiments, the flexible heat moldable sheet may
comprise a thermoplastic resin and does not comprise a fabric, In some embodiments,
the flexible heat moldable sheet may be formed of a material which allows the sheet
to be reusable so that it may be molded multiple times to conform to the wearer.
[0011] In another embodiment, an athletic shoe may include a sole and an upper connected
to the sole, The upper may have a heat moldable sheet configured to conform to a wearer's
body (
e.g., a portion of a wearer's foot, ankle, lower leg, or combination thereof) when heated
to a predetermined temperature. The athletic shoe may also include a temperature sensitive
indicator configured to undergo a visible change when the predetermined temperature
is reached, such as a change in color.
[0012] In a further embodiment, a method for providing a customized fit of an athletic shoe
for a wearer includes providing an athletic shoe. The athletic shoe may include a
sole and an upper connected to the sole. The upper may have a forefoot region, a heel
region, and a midfoot region between the forefoot region and the heel region, The
upper may also have a flexible outer layer, a lining connected to the flexible outer
layer, and a flexible heat moldable sheet disposed between the outer layer and the
lining at least in a portion of the midfoot region, The flexible heat moldable sheet
may be configured to conform to a wearer's body (
e,g., a portion of a wearer's foot, ankle, lower leg, or combination thereof) when heated
to a predetermined temperature to provide the wearer with a customized fit for the
athletic shoe. In some embodiments, the flexible heat moldable sheet may also comprise
a fabric and a thermoplastic resin, In some embodiments, the flexible heat moldable
sheet may comprise a thermoplastic resin and does not comprise a fabric. The athletic
shoe may be heated at a predetermined temperature for a predetermined amount of time.
Then, a wearer may insert their foot into the athletic shoe to allow the flexible
heat moldable sheet to conform to the wearer.
[0013] In another embodiment, a glove may include a first outer layer and a second outer
layer with a flexible heat moldable layer therebetween, The flexible heat moldable
material may be configured, to conform to a wearer's body (
e.g., a portion of a hand, wrist, arm, or combination thereof) when heated to a predetermined
temperature to provide the wearer with a customized fit for the glove, In some embodiments,
the flexible heat moldable sheet may also comprise a fabric and a thermoplastic resin,
In some embodiments, the flexible heat moldable sheet may comprise a thermoplastic
resin and does not comprise a fabric. In some embodiments, the flexible heat moldable
layer may be formed of a material which allows the layer to be reusable so that it
may be molded multiple times to conform to the wearer,
[0014] In another embodiment, a hat may include a heat moldable layer attached to an interior
of the hat. The heat moldable layer may be configured to conform to a wearer's head
when heated to a predetermined temperature to provide the wearer with a customized
fit for the hat. In some embodiments, the flexible heat moldable sheet may also comprise
a fabric and a thermoplastic resin. In some embodiments, the flexible heat moldable
sheet may comprise a thermoplastic resin and does not comprise a fabric. In some embodiments,
the heat moldable layer may be formed of a material which allows the layer to be reusable
so that it may be molded multiple times to conform to the wearer's head.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, which are incorporated herein and form a part of the specification,
illustrate the present invention and, together with the description, further serve
to explain the principles of the invention and to enable a person skilled in the pertinent
art to make and use the invention.
Fig. 1 is a lateral side view of an exemplary article of footwear according to an
embodiment of the present invention.
Fig. 2 is a medial side view of the exemplary article of footwear of Fig. 1 according
to an embodiment of the present invention.
Fig. 3 is a rear view of the exemplary article of footwear of Fig, 1 according to
an embodiment of the present invention.
Fig. 4 is a rear cross-sectional view of the exemplary article of footwear of Fig.
1 according to an embodiment of the present invention.
Fig. 5 is a plan view of an exemplary heat moldable material according to an embodiment
of the present invention.
Fig. 6 is a side view of an exemplary baseball cleat according to an embodiment of
the present invention.
Fig. 7 is a side view of an exemplary soccer cleat according to an embodiment of the
present invention,
Fig. 8 is a side view of an exemplary football cleat according to an embodiment of
the present invention.
Fig. 9 is a side view of an exemplary basketball shoe according to an embodiment of
the present invention.
Fig. 10 is a flowchart illustrating an exemplary method of providing a customized,
form-fitted article of footwear.
Fig. 11 is an exemplary glove with a partial cut-away view according to an embodiment
of the present invention.
Fig. 12 is an exploded view of the exemplary glove of Fig. 11 according to an embodiment
of the present invention,
Fig. 13 is a bottom perspective view of an exemplary hat according to an embodiment
of the present invention,
Fig. 14 is an exploded view of the exemplary hat of Fig. 13 according to an embodiment
of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention will now be described in detail with reference to embodiments
thereof as illustrated in the accompanying drawings, in which like reference numerals
are used to indicate identical or functionally similar elements. References to "one
embodiment", "an embodiment", "an example embodiment", etc., indicate that the embodiment
described may include a particular feature, structure, or characteristic, but every
embodiment may not necessarily include the particular feature, structure, or characteristic.
Moreover, such phrases are not necessarily referring to the same embodiment. Further,
when a particular feature, structure, or characteristic is described in connection
with an embodiment, it is submitted that it is within the knowledge of one skilled
in the art to effect such feature, structure, or characteristic in connection with
other embodiments whether or not explicitly described.
[0017] The following examples are illustrative, but not limiting, of the present invention.
Other suitable modifications and adaptations of the variety of conditions and parameters
normally encountered in the field, and which would be apparent to those skilled in
the art, are within the spirit and scope of the invention,
[0018] A customized, form-fitting article of footwear, such as an athletic shoe, may include
a heat moldable material that conforms to the wearer's foot, ankle, or leg when heated
to a predetermined temperature to provide a customized, form-fit. The heat moldable
material may be sufficiently flexible for use in athletic shoes so that movement of
the foot or shoe is not hampered by the presence of the heat moldable material. While
the heat moldable material is described as being implemented in an article of footwear,
this is a non-limiting example and the heat moldable material may be included in other
articles to provide a customized, form-fit, such as for example, sporting equipment
(
e.g., helmets, helmet liners, chest protectors, arm protectors, rib pads, shin guards,
spats, baseball gloves, goalie gloves, etc.) or articles of clothing (
e.g., gloves, hats, etc.).
[0019] Referring to the drawings and in particular to Figs, 1-3, an exemplary embodiment
of an article of footwear, in particular an athletic shoe, according to the present
invention generally referred to by reference numeral 10 is shown. Although the article
of footwear 10 may be referred to herein as shoe 10, it is contemplated that it may
comprise any type of footwear in which the customized, form-fitting feature of the
present invention may be desirable, including, but not limited to, athletic shoes
(
e.g., walking shoes, running shoes, basketball shoes, court shoes, tennis shoes, cleated
shoes, and training shoes), skates (
e.g., roller, inline, and ice skates), boots (
e.g., ski boots and snowboarding boots), and sandals. The article of footwear may include
a traditional closure system such as, for example, laces or straps.
[0020] As shown in Figs. 1-3, shoe 10 may have a sole 12 and an upper 14 connected to sole
12. Shoe 10 may have a heel region 16, a forefoot region 18, and a midfoot region
20 located between heel region 16 and forefoot region 18. Sole 12 may include a midsole
22 and an outsole 24, Shoe 10 may include a temperature sensitive indicator 26, which
is discussed in more detail below. As shown in Fig. 4, upper 14 may include an outer
layer 28, an interior lining 30, and a heat moldable material or sheet 32 located
therebetween. Outer layer 28 may be flexible and may be any flexible material typically
utilized for an upper, including, but not limited to, leather, canvas, fabric, polymeric
materials, fluid-fillable bladders, and combinations thereof. Interior lining 30 may
also be any material typically utilized in articles of footwear including, but not
limited to, traditional shoe linings, fluid-tillable bladders, foam layers, and combinations
thereof. Fluid-fillable bladders suitable for use in footwear include, but are not
limited to, bladders like those described in
U.S. Patent Nos. 7,395,617 to Christensen, et al. and
7,340,851 to Litchfield, et al.
[0021] In some embodiments, outer layer 28 or interior lining 30 may be porous or perforated.
In some instances, upper 14 may include outer layer 28 and interior lining 30 and
also heat moldable material or sheet 32 and at least one additional layer of padding
(
e.g., foam or fabric padding) located between the outer layer and interior lining, In
particular embodiments, upper 14 may consist essentially of outer layer 28, interior
lining 30, and heat moldable material or sheet 32, wherein no additional comfort padding
is present. In such instances, the ability of the heat moldable material 32 and interior
lining 30 to closely form to a wearer can alleviate the need for additional comfort
padding,
[0022] In some embodiments as shown in Fig. 4, heat moldable material or sheet 32 may be
located between outer layer 28 and interior lining 30 of upper 14, However, in other
embodiments heat moldable material may be the innermost surface of upper 14 or may
be the outermost surface of upper 14. For example, heat moldable material or sheet
32 may form at least a portion of the innermost surface of upper 14 or may form at
least a portion of the outermost surface of upper 14. In yet other embodiments, no
outer layer 28 or interior lining 30 is present on or over at least a portion of heat
moldable material or sheet 32.
[0023] Heat moldable material 32 may have an outer surface 34 and an inner surface 36. In
some embodiments, outer surface 34 of heat moldable material 32 may be attached to
an inner surface 38 of outer layer 28, for example through bonding under heat and
pressure or through stitching, In other embodiments, inner surface 36 of heat moldable
material 32 may be attached to an outer surface 40 of inner lining 30, for example
through bonding under heat and pressure or through stitching. In either scenario,
after heat moldable material 32 is attached to either outer layer 28 or inner lining
30, outer layer 28 and inner lining 30 may be attached, for example through stitching.
Alternatively, heat moldable material 32 may be attached (
e.g., through bonding under heat and pressure or through stitching) to both outer layer
28 and inner lining 30 at the same time. In some embodiments, heat moldable material
32 substantially contacts outer layer 28 and/or inner lining 30. In some embodiments,
for example, heat moldable material 32 substantially contacts outer layer 28 and/or
inner lining 30 through direct contact of heat moldable material 32 and outer layer
28 and/or inner lining 30. In some embodiments, for example, heat moldable material
32 substantially contacts outer layer 28 and/or inner lining 30 through the use of
an adhesive, or other bonding agent or attachment means,
[0024] In some embodiments, a method for making shoe 10 may comprise the steps of flat pressing
heat moldable material 32 and at least one of outer layer 28 and inner lining 30 under
heat and pressure to form a material package; and shaping the material package into
shoe form (
e.g., using conventional shoe making techniques such as lasting). In other embodiments,
a method for manufacturing shoe 10 may comprise the steps of laying-up heat moldable
material 32 and at least one of outer layer 28 and inner lining 30 to form a material
package; and shaping the material package into shoe form (
e.g., using conventional shoe making techniques such as lasting). In some embodiments,
shaping the material package into shoe form includes shaping the material package
over a heated last, In each of these embodiments, the method for making a shoe can
further comprise the steps of heating the shoe (
e.g., at a predetermined temperature for a predetermined amount of time) and inserting
a wearer's foot into the shoe to allow the heat moldable material to conform to the
wearer's body (
e,g., a portion of a wearer's foot, ankle, lower leg, or combination thereof).
[0025] Heat moldable material or sheet 32 may be prepared for shoe making by conventional
means, including, for example, by cutting from a sheet of heat moldable material.
In some instances, heat moldable material 32 may be prepared by die cutting a sheet
of heat moldable material.
[0026] In some embodiments, heat moldable material or sheet 32 may be located between outer
layer 28 and interior lining 30 of upper 14 and may extend to overlie sole 12 of shoe
10. For example, heat moldable material or sheet 32 may extend from the shoe sides
to form a plantar-surface-facing bottom that overlies sole 12 of shoe 10. In other
embodiments, a strobel board may comprise a heat moldable material or sheet 32. For
example, heat moldable material or sheet 32 may form a strobel board that overlies
sole 12 of shoe 10,
[0027] Fig. 5 shows an exemplary plan view of heat moldable material 32 in the form of a
sheet before insertion in shoe 10. In this embodiment, heat moldable material or sheet
32 may have a lateral side region 42, a heel region 44, and a medial side region 46.
Figs. 1-3 show a dashed line illustrating an exemplary placement of heat moldable
material 32 in an interior of upper 14 of shoe 10. Accordingly, lateral side region
42 of heat moldable material or sheet 32 may be located on a lateral side of shoe
10 and may extend into midfoot region 20. Similarly, medial region 46 of heat moldable
material 32 may be located on a medial side of shoe 10 and may extend into midfoot
region 20, Likewise, heel region 44 of heat moldable material 32 may be located in
heel region 16 of shoe 10. The size and shape of heat moldable material 32 in Fig.
5 is merely exemplary and may be sized and shaped to correspond to an entire size
and shape of upper 14 or to any regions of upper 14 where a customized, form-fit is
desired. In some embodiments, heel region 16 of heat moldable material or sheet 32
may be sized and shaped to be located above a heel counter. In certain embodiments,
the heat moldable material or sheet 32 is more flexible than a traditional heel counter,
For example, the heat moldable material or sheet 32 is more flexible than a separate
heel counter, Alternatively, heat moldable material or sheet 32 may extend down over
the heel to take the place of a heel counter wherein at least a portion of the heat
moldable material or sheet extending over the heel is stiffer, thicker, or has other
different properties than the remainder of the heat moldable material or sheet, In
yet another embodiment, a separate piece of heat moldable material or sheet, with
heel counter properties, forms a heel counter in shoe 10.
[0028] In certain embodiments, heat moldable material or sheet 32 may be sized and shaped
to be below a top of shoe 10. For example, in certain embodiments, heat moldable material
or sheet 32 may be sized and shaped to be about 5 to about 10 mm below a top of shoe
10. In some embodiments, lateral side region 42 and medial side region 46 of heat
moldable material may be sized and shaped to be below eyelets of shoe 10. In other
embodiments, lateral side region 42 and medial side region 46 of heat moldable material
may be sized and shaped to extend around the eyelets. For example, eyelets may be
punched though the heat moldable material. In some embodiments, lateral side region
42 and medial side region 46 of heat moldable material may be shaped so that they
do not extend into a flex area of shoe 10, such as the forefoot region 18.
[0029] In some embodiments, heat moldable material 32 may be sized and shaped according
to the intended use of an athletic shoe. For example, Fig. 6 indicates the size and
shape of heat moldable material 32 by the dashed line for an exemplary baseball cleat
50, Fig. 7 indicates the size and shape of heat moldable material 32 by the dashed
line for an exemplary soccer cleat 52, Fig. 8 indicates the size and shape of heat
moldable material 32 by the dashed line for an exemplary football cleat 54, and Fig.
9 indicates the size and shape of heat moldable material 32 by the dashed line for
an exemplary basketball shoe 56.
[0030] In some embodiments, heat moldable material 32 may be a non-foam material, free of
foam materials. In some embodiments, heat moldable material 32 may be in the form
of a sheet that may include a thermoplastic resin. In some embodiments, the thermoplastic
resin may be an ethylene based resin. In some embodiments, the thermoplastic resin
may be a low-melt adhesive. In some instances, the thermoplastic resin may be a non-foam
material. In some embodiments, the thermoplastic resin may include a layer (
e.g., a top coating) of polymeric material such as, for example, urethane.
[0031] In some embodiments, heat moldable material may be in the form of a sheet that may
include a thermoplastic composite, The thermoplastic composite may include a fiber
component with a thermoplastic resin matrix. In some embodiments, heat moldable material
32 is not a thermoplastic composite and does not include a fiber component,
[0032] In embodiments where heat moldable material 32 is a thermoplastic composite, the
fiber component of the thermoplastic composite can include, for example, continuous
fiber, cut fiber (
e.g., with oriented or random fiber orientation), a textile material such as a fabric
(
e.g., non-woven, woven, knitted, or felted material), and combinations thereof. In one
specific embodiment, the fiber component of the thermoplastic composite includes a
non-woven, needle-punched material. The fiber component of the thermoplastic composite
can include, for example, polyester, nylon, polyamide, glass, Kevlar, or carbon fibers,
and combinations thereof. In embodiments where heat moldable material 32 is a thermoplastic
composite, the thermoplastic resin of the thermoplastic resin matrix may be an ethylene
based resin. In some embodiments, the thermoplastic resin may be a low-melt adhesive,
In some instances, the thermoplastic resin may be a non-foam material. In some embodiments,
the thermoplastic composite may include a layer (
e.g., a top coating) of polymeric material such as, for example, urethane. An exemplary
material for a thermoplastic composite for heat moldable material 32 may be the Vantage
product sold by Stanbee Company of New Jersey. Examples of suitable Vantage materials
include, but are not limited to, Vantage 35 Regular, Vantage 15, Vantage 35C, and
Vantage 35D. In some embodiments, the material for heat moldable material 32 may be
chosen that has sufficient workability, resiliency, and shape retention to provide
a customized, form-fit to a wearer when heated. It may also be desirable for heat
moldable material 32 to be reusable so that it may be reheated and reshaped multiple
times. This can provide the advantage of the ability to reform the heat moldable material
contained in an article, such as footwear, to a different individual. This can also
provide the advantage of the ability to reform the material contained in an article
to a wearer's changing requirements. For example, articles of footwear containing
the heat moldable material may be remolded (
e.g., remolded by the consumer) to fit a growing or injured wearer, Also, articles of
footwear containing the heat moldable material may be molded or remolded (e.g., molded
or remolded by the consumer) to fit a user wearing braces, orthotics, bandages, or
sockwear.
[0033] In some embodiments, the material for heat moldable material 32 is sufficiently flexible
for use in athletic articles of footwear so that movement of the wearer is not substantially
hampered by the presence of the heat moldable material. In some embodiments, heat
moldable material or sheet 32 has a uniform flexibility. However, in other embodiments,
heat moldable material or sheet 32 may include portions with a first flexibility and
at least one portion with a second, different flexibility, In some embodiments, heat
moldable material 32 may have an initial collapsing load of less than about 130 Newtons
(N). For example, heat moldable material 32 can have an initial collapsing load of
less than about 80 N such as about 25 to about 80 N, about 40 N to about 60 N, or
about 50 N to about 60 N. Initial collapsing load can be measured using the SATRA
TM 83 1996 test method. In some embodiments, heat moldable material 32 may have a
resilience of at least about 25%, at least about 30%, at least about 40%, at least
about 50%, at least about 60%, or at least about 70%. Resilience can be measured as
percentage retention of initial collapsing load after a given number of collapses
(
e.g., ten collapses).
[0034] It is also important to consider various properties of heat moldable material 32,
such as the activation temperature, the open time, the stiffness, and the thickness.
The material activation temperature may be the temperature at which heat moldable
material 32 softens so that it may be molded to conform to the contour of a wearer's
anatomy. The material activation temperature of the heat moldable material is important
because it should not be so high that other portions of shoe 10 will be burned or
damaged when heating shoe 10 and heat moldable material 32 to the material activation
temperature. In some embodiments, the material activation temperature of heat moldable
material 32 may be in a range between about 120 and about 220 degrees Fahrenheit (F),
between about 125 and about 200 degrees F, between about 130 and about 175 degrees
F, or between about 130 and about 150 degrees F.
[0035] The ambient air activation temperature may be the temperature of surrounding air
at which heat moldable material 32 softens so that it may be molded to conform to
the contour of a wearer's anatomy. The ambient air activation temperature of the heat
moldable material should not be so high that other portions of shoe 10 will be burned
or damaged when heating shoe 10 and heat moldable material 32. In some embodiments,
the ambient air activation temperature may be in a range between about 120 and 220
degrees F, between about 130 and 210 degrees F, between about 150 and 200 degrees
F, between about 160 and 190 degrees F, or between about 165 and about 180 degrees
F.
[0036] The open time of heat moldable material 32 may be a measurement of how long heat
moldable material 32 is moldable after being removed from a heat source, In other
words, a wearer's foot must be inserted in shoe 10 and conformed around the wearer's
anatomy before the open time of heat moldable material 32 elapses in order to obtain
a customized, form-fit, In some embodiments, the open time may be at least about 30
seconds, at least about 1 minute, at least about 2 minutes, at least about 3 minutes,
or at least about 5 minutes. In other embodiments, the open time may be in a range
between about 1 and about 10 minutes, about 1 and about 5 minutes, or about 2 and
about 3 minutes,
[0037] The thickness of heat moldable material 32 is one factor in the flexibility of the
heat moldable material 32 and whether it is suitable for use in an athletic shoe.
In some embodiments, heat moldable material 32 may be a thin sheet, The thin sheet
may have a uniform thickness or may have a non-uniform thickness. In some embodiments,
the heat moldable material may include areas of greater thickness and areas of lesser
thickness. For example, in some embodiments, a sheet of heat moldable material may
include ridges or ribs of heat moldable material having a greater thickness and areas
of heat moldable material adjacent to such ridges or ribs that have a lesser thickness.
In some embodiments, a sheet of heat moldable material may include ridges or ribs
in areas of the sheet, for example, where increased stiffness is desired. In some
embodiments, since areas of a sheet having different thicknesses may soften at different
rates, a sheet of heat moldable material having varying thickness may be used when
a variation in the moldability of the sheet is desired. One method of making a sheet
of heat moldable material having a variable thickness or an increased thickness can
include the step of joining pieces of heat moldable materials (
e.g., sheets, strips, shapes, or combinations thereof) face-to-face to form the sheet
of heat moldable material. Such a method can also include the step of permanently
or temporarily bonding or stitching the pieces of heat moldable materials together.
[0038] In some embodiments, the maximum thickness of heat moldable material or sheet 32
is less than about 2 mm, less than about 1.5 mm, or less than about 1 mm. In some
embodiments, the maximum thickness of heat moldable material 32 may be in a range
between about 0.35 and 0.95 mm, about 0,40 and 0.90 mm, about 0.45 and 0.85 mm, about
0,50 and 0,80 mm, about 0.55 and 0.75 mm, about 0.60 and 0.70 mm, or about 0.65 mm.
In some embodiments, the average thickness of heat moldable material or sheet 32 is
less than about 2 mm, less than about 1.5 mm, or less than about 1 mm, for example,
between about 0.3 and about 1 mm or between about 0.5 and about 0.75 mm,
[0039] The size and shape of heat moldable material 32 is another factor in the flexibility
of the heat moldable material 32 and whether it is suitable for use in an athletic
shoe. In some instances, heat moldable material 32 is a continuous sheet of heat moldable
material. In other embodiments, heat moldable material 32 can include cut-outs, cut-ins,
perforations, slits, or combinations thereof. For example, heat moldable material
32 can include cut-out or cut-in shapes (
e.g., rectangular, square, triangular, circular, elliptical, or irregular cut-outs or
cut-ins). Such cut-outs, cut-ins, perforations, or slits can permit heat moldable
material 32 to flex more easily. In some embodiments, cut-outs, cut-ins, perforations,
or slits can provide ventilation or liquid wicking through heat moldable material
32.
[0040] Table 1 below shows exemplary samples of Vantage product sold by Stanbee Company
of New Jersey suitable for heat moldable material 32. As can be seen below, Samples
A, C, and D have similar thickness ranges, but varying open times, The amount of thermoplastic
resin varied between the Samples A, C, and D with Sample A having the highest amount
of thermoplastic resin and Sample D having the lowest amount of thermoplastic resin.
Sample A has the highest flexibility and the longest open time and Sample D has the
lowest flexibility and the shortest open time, Sample B is similar to Sample A, except
it has a lesser thickness.
TABLE 1
|
Sample A |
Sample B |
Sample C |
Sample D |
Ambient Air Activation Temperature Range (0F) |
167-176 |
167-176 |
176 |
176-185 |
Open time (seconds) |
210 |
165-180 |
90 |
20 |
Thickness Range (mm) |
0,838 -0.94 |
0.368 - 0.432 |
0.838 - 0.94 |
0,838 -0.94 |
[0041] As noted above, shoe 10 includes a temperature sensitive indicator 26. Temperature
sensitive indicator 26 is used in facilitating a method of customizing and form-fitting
shoe 10 to the foot of a wearer as it has a visible change when a predetermined temperature,
such as the activation temperature of heat moldable material 32, is reached. In some
embodiments, the visible change may be a change in color, Temperature sensitive indicator
26 may include a substrate coated in a temperature sensitive ink that changes color
at different temperatures and enclosed in a transparent dome. Such a temperature sensitive
indicator 26 may be obtained from Rongyuan Company in Fuzhou China. Suitable temperature
sensitive ink may be Heat Discoloration Ink, Part Nos. 6C, 072C, 102C, and/or 1935C
available from Shenzhen JieLi Anti-Counterfeiting Technology Co., Ltd. in China, In
some embodiments, the entire substrate may be coated or the ink may be coated on the
substrate in a pattern, such as in the form of an indicium, logo, letter, or word,
In some embodiments, the temperature sensitive ink may be colorless at room temperature
and may change colors as the temperature rises. In other embodiments, the temperature
sensitive ink may be one color at room temperature and may change colors as the temperature
rises. The temperature sensitive ink may only change colors once, or may change colors
multiple times. For example, temperature sensitive indicator 26 may have a first color
change when an activation temperature of the heat moldable material is reached so
that a wearer knows that shoe 10 is ready for customized fitting. In some embodiments,
temperature sensitive indicator 26 may have additional color changes that may indicate
shoe 10 is too hot to touch or that shoe 10 has sufficiently cooled such that heat
moldable material 32 is not at a temperature that corresponds to a moldable state.
For example, in one embodiment temperature sensitive indicator 26 may be a first color
at room temperature, may be a second color between room temperature and an activation
temperature of heat moldable material 26 and a third color at an activation temperature
of heat moldable material 26. Thus, a wearer may know shoe 10 is ready for customizing
and form-fitting when temperature sensitive indicator 26 is the third color, may know
that the open time for heat moldable material 32 has elapsed when indicator 26 is
the second color, and may know that molding of heat moldable material 32 is complete
when indicator 26 is the first color. In some embodiments, when temperature sensitive
indicator 26 has multiple color changes, each color change may be caused by a different
temperature sensitive ink. In some instances, temperature sensitive indicator 26 may
be sectioned off so that each section has a different temperature sensitive ink.
[0042] In some embodiments, temperature sensitive indicator 26 may be attached to upper
14. For example, temperature sensitive indicator 26 may be attached to an exterior
surface of flexible outer layer 28 of upper 14 or may be located in a cavity of flexible
outer layer 28 and covered with a transparent material, In other embodiments, temperature
sensitive indicator 26 may be attached to sole 12. For example, temperature sensitive
indicator 26 may be attached to an exterior surface of sole 12 or may be located in
a cavity of sole 12. In some embodiments, temperature sensitive indicator 26 is in
direct contact with heat moldable material 32. In other embodiments, temperature sensitive
indicator 26 is not in direct contact with heat moldable material 32. In some embodiments,
temperature sensitive indicator 26 is permanently attached to shoe 10.
[0043] While temperature sensitive indicator 26 is described above as having a visible color
change, temperature sensitive indicator 26 may indicate a change in temperature in
other manners as an alternative to a visible color change or in combination therewith.
For example, temperature sensitive indicator 26 may have a tactile change or an audible
signal in different temperature regimes. In some embodiments, temperature sensitive
indicator 26 can undergo a change in configuration to indicate a change in temperature.
For example, in one embodiment, temperature sensitive indicator 26 includes a liquid
crystal device that can indicate a change in temperature. Such liquid crystal devices
can be obtained, for example, from LCR Hallerest (Glenview, IL).
[0044] An exemplary method for providing a customized form-fit for a shoe for a wearer will
be described in combination with the exemplary flowchart of Fig. 10. The method of
Fig. 10 may include a step 60 of providing a shoe, such as shoe 10 described above,
with reference to Figs, 1-4. The method may also include a step 62 of heating shoe
10 to a predetermined temperature, at a predetermined temperature for a predetermined
amount of time, or at a predetermined temperature, following which heat moldable material
32 is softened to permit molding. Subsequently, the method may also include a step
64 of inserting a wearer's foot in shoe 10 after heating step 62 to provide a customized
form-fit of shoe 10 to the wearer,
[0045] Step 60 of providing a shoe may include providing an athletic shoe, such as shoe
10, described above with reference to Figs 1-4. Shoe 10 may or may not have temperature
sensitive indicator 26.
[0046] Step 62 may include heating shoe 10 at a predetermined temperature for a predetermined
amount of time, heating shoe 10 at a predetermined temperature, or heating shoe 10
to a predetermined temperature. Heating may be accomplished by placing shoe 10 in
a heat source (
e.g., in a convection oven, conventional oven, solar oven, or microwave oven), by placing
shoe 10 near or in the path of a heat source (
e.g., by using a heat gun, a hair dryer, a heat lamp, or sunlight), by incorporating
a heat source within shoe 10 (
e.g., a chemical heat source or an electrical resistance heat source located within the
shoe such as a battery-operated electrical resistance heat source), or by placing
a heat source into shoe 10. In some embodiments, the heat source may be preheated
to the desired temperature prior to placing shoe 10 in or near the heat source. Alternatively,
in other embodiments, shoe 10 may be inside or near the heat source while it is heating,
[0047] The predetermined temperature to which shoe 10 is heated may refer to, for example,
the surface temperature of the shoe, the internal temperature of the shoe, or the
temperature of the heat moldable material. The predetermined temperature at which
shoe 10 is heated may refer to, for example, an oven temperature, an ambient air temperature,
or the temperature of a heat source, In some embodiments, the predetermined temperature
for heating shoe 10 or to which shoe 10 is heated may be in a range between about
120 and about 250 degrees F, between about 130 and about 210 degrees F, between about
150 and about 200 degrees F, between about 160 and about 190 degrees F, or between
about 165 and about 180 degrees F. In some embodiments, shoe 10 may be heated to a
predetermined temperature (
e.g., a shoe surface temperature) in a range between about 120 and about 220 degrees
F such as between about 120 and about 140 degrees F or about 125 and about 130 degrees
F. In some embodiments, the predetermined time duration for which shoe 1.0 is heated
may be between about 1 and about 15 minutes, about 1 and about 5 minutes, about 2
and about 4 minutes, or about 35 minutes. In some embodiments, shoe 10 may be heated
in an about 200 degree F oven for between about 1 and about 15 minutes, about 1 and
about 5, about 2 and about 4 minutes, or about 3.S minutes. In one specific embodiment,
shoe 10 may be heated in an about 200 degree F oven for about 3.5 minutes. These parameters
are merely exemplary and may be modified as needed based, for example, upon the physical
properties of heat moldable material 32, the size and shape of shoe 10, the configuration
of heat moldable material 32 within shoe 10, and the choice of heat source,
[0048] In some embodiments, shoe 10 may have temperature sensitive indicator 26 discussed
above. In place of, or in combination with, heating for a predetermined time or heating
at a predetermined temperature, shoe 10 may be heated until temperature sensitive
indicator 26 has a particular visible change, such as a color change, that indicates
shoe 10 has been sufficiently heated to soften heat moldable material 32 so that it
will conform to the contours of a wearer's foot.
[0049] In step 64, once the shoe 10 has been heated for the predetermined time, to the predetermined
temperature, and/or until temperature sensitive indicator 26, if present, indicates
shoe 10 has reached a desired temperature, shoe 10 may be removed from the heat source.
A wearer may then insert their foot into shoe 10. It is important that wearer insert
their foot into shoe 10 during the open time of the heat moldable material. As discussed
above, the open time may be a measurement of how long heat moldable material 32 is
moldable after being removed from a heat source. Heat moldable material 32 is sufficiently
softened so that it may mold to the contour of the wearer's foot, ankle, or lower
leg to provide a customized form-fit of shoe 10 for the wearer, A wearer's foot may
be kept in shoe 10 for providing the customized form-fit for a sufficient time for
heat moldable material 32 to cool and retain the shape customized to the contour of
the wearer's foot, ankle, or lower leg. In some embodiments, shoe 10 may be fastened,
(
e.g., via laces or straps) once it has been placed on the wearer. In some preferred embodiments,
shoe 10 may be tightly fastened (
e.g., via laces or straps) once it has been placed on the wearer.
[0050] In some embodiments, the wearer's foot may be kept in shoe 10 for at least about
30 seconds, at least about 1 minute, at least about 2 minutes, at least about 3 minutes,
or at least about 5 minutes. In some instances, the wearer's foot may be kept in shoe
10 for a duration in a range between about 1 and about 20 minutes, such as about 1
to about 15 minutes, about 1 to about 10 minutes, or about 5 to about 10 minutes.
In some embodiments, when temperature sensitive indicator 26 is present, temperature
sensitive indicator 26 may indicate when a wearer may remove their foot from shoe
10, such as by a visible change, such as a change in color.
[0051] In some embodiments, as discussed above, heat moldable material 32 may be reusable,
meaning it may be reheated and remolded multiple times, This permits the process of
Fig. 10 to be performed multiple times or as often as necessary.
[0052] The present invention also includes an insole or sockliner comprising a heat moldable
material or sheet. In some embodiments, an insole may include a heat moldable material
or sheet and an overlying sockliner. For example, a sockliner may directly overlie
a heat moldable material or sheet, In other embodiments, a sockliner itself can be
formed of a heat moldable material or sheet. In some instances, the heat moldable
material or sheet can be located only in selected portions of the insole or sockliner.
In other instances, the heat moldable material or sheet can be located across the
entire width and length of the insole or sockliner.
[0053] While many of the embodiments described herein make reference to shoe 10 and fitting
such shoe to a wearer's foot, ankle, or lower leg, in other embodiments sporting equipment
(
e.g., helmets, helmet liners, chest protectors, arm protectors, rib pads, shin guards,
spats, baseball gloves, goalie gloves, etc.) or articles of clothing (
e.g., gloves, hats, etc.) may contain heat moldable material and be fitted to a wearer's
anatomy, For example, in some embodiments, a piece of sporting equipment or an article
of clothing may comprise a heat moldable material. In some embodiments, the piece
of sporting equipment or article of clothing may further include a lining, covering,
padding, or combination thereof underlying or overlying the heat moldable material.
In some embodiments, the piece of sporting equipment or the article of clothing may
include a temperature sensitive indicator,
[0054] In some embodiments, as shown for example in Figs. 11 and 12, the customized form-fitted
article may be a glove 70, for example a baseball or softball glove, or a goalie's
glove for hockey, lacrosse, or field hockey. Glove 70 may have a layered construction
from front to back including a first or front outer layer 72, a filler layer 74, a
heat moldable material layer 76, and a second or back outer layer 78. First and second
outer layers 72 and 78 may be any material typically utilized for gloves, such as
leather or synthetic material. First and second outer layer 72 and 78 may be attached
around their peripheries, with filler layer 74 and heat moldable material layer 76
located therebetween, using conventional means, such as stitching.
[0055] The material for filler layer 74 may have a cushioning effect to minimize the impact
of a ball or puck against glove 70. Filler layer 74 and heat moldable material layer
76 may be adhered, laminated, stitched or otherwise joined together to prevent relative
movement within glove 70. Further, the joined together filler layer 74 and heat moldable
material layer 76 may be adhered, laminated, stitched or otherwise joined to first
outer layer 72 and/or second outer layer 78.
[0056] Heat moldable material layer 76 may be flexible to ensure adequate movement of the
fingers and hand of the wearer. Heat moldable material layer 76 may be similar to
heat moldable material 32 discussed above with reference to shoe 10, and therefore
has not been described again in great detail, Heat moldable material layer 76 may
be shaped to be placed inside the entirety of glove 70. In other embodiments, heat
moldable material layer 76 may be present in only a portion of glove 70, for example
only in the fingers, in a webbed portion between fingers, in the palm area, or in
a combination thereof.
[0057] Glove 70 may have an opening 79 for receiving a wearer's hand. In some embodiments
opening 79 may be positioned such that the wearer's hand is inserted into glove 70
between second outer layer 78 and heat moldable material layer 76. However, in other
embodiments opening 79 may be positioned such that the wearer's hand is inserted into
glove 70 between heat moldable material layer 76 and fill layer 74. In some embodiments
there may be two heat moldable material layers 76 such that opening 79 may be positioned
such that the wearer's hand may be inserted into glove 70 between the two heat moldable
material layers 76. In some embodiments, heat moldable material layers 76 or fill
layer 74 may be covered with a layer of additional, hand-contacting material (
e.g., fabric, foam, leather, etc.). Glove 70 may be heated at a predetermined temperature
for a predetermined time and then the user's hand may be inserted into glove 70 to
provide a customized form fit. In some instances, glove 70 may be heated (
e.g., at a predetermined temperature for a predetermined time) and then an object (
e.g., a puck, ball or fist) may be held with glove 70 to provide a user customized space
for such object. Thus, practice of the present invention can provide a custom catching
pocket for glove 70 whereby a wearer can tailor a catching pocket suited to their
preference or style of play. For example, in a baseball glove with a webbed portion
between the thumb and index finger, heat moldable material can be present in the thumb
area, the index finger area, the webbed area, or a combination thereof and glove 70
may be heated (
e.g., at a predetermined temperature for a predetermined time) and a custom pocket for
a ball formed therein.
[0058] An exemplary method for providing a customized form fit for glove 70 to a wearer's
hand may include providing a glove 70 having a flexible heat moldable material layer
76 configured to conform to a wearer's hand when heated to a predetermined temperature
to provide the wearer with a customized fit for the glove. In some embodiments, flexible
heat moldable layer 76 may include a fabric and a thermoplastic resin. In some embodiments,
flexible heat moldable layer 76 may include a thermoplastic resin and does not include
a fabric. In some embodiments, the method for providing a customized form fit for
glove 70 to a wearer's hand may correspond to the method discussed above with reference
to shoe 10 and Fig. 10, and therefore has not been described in great detail again.
Glove 70 may also have a temperature sensitive indicator (not shown) similar to temperature
sensitive indicator 26 for use in customizing and form-fitting an article as discussed
above with reference to shoe 10, and therefore has not been described again.
[0059] In some embodiments, as shown for example in Figs. 13 and 14, the customized form-fitted
article may be an article of headwear 80 such as a hat, for example a baseball cap.
Although the article of headwear 80 may be referred to herein as hat 80, it is contemplated
that it may comprise any type of headgear in which the customized, form-fitting feature
of the present invention may be desirable, including, but not limited to a baseball
or softball batting helmet, a helmet with a mask, such as for football, hockey, or
lacrosse, or a helmet without a visor such as for bikes or motorcycles.
[0060] Hat 80 may include a heat moldable material 82 attached to an interior of hat 80
to provide a hat that may be customized and form-fitted to the contour of the head
of a wearer, Heat moldable material 82 may be attached to the interior of hat 80 through
conventional means, for example by stitching, adhering or laminating. Heat moldable
material 82 may be similar to heat moldable material 32 discussed above with reference
to shoe 10, and therefore has not been described again in great detail. In some embodiments,
hat 80 may also include an interior lining that overlies heat moldable material 32.
[0061] In some embodiments, as shown for example in Figs. 13 and 14, heat moldable material
82 may be substantially hemispherical in shape and may have a substantially circular
rim 84 with a plurality of strips 86 extending from rim 84 and joining at a topmost
point of the hemisphere, which may correspond to a topmost point 88 of hat 80, In
some embodiments, as shown in Figs. 13 and 14, there may be six strips 86 with gaps
90 that are void of material in between adjacent strips 86. However, the number of
strips may be varied. In some instances, heat moldable material 82 may include rim
84, with no strips 86 present. In other embodiments, heat moldable material 82 may
include strips 86, with no rim 84 present. In other embodiments, heat moldable material
82 may be a hollow hemisphere in shape such that there are no strips 86 and no gaps
90, In some embodiments, heat moldable material 82 may have slits, perforations, cut-ins,
or cut-outs present for breathability or flexibility. In some embodiments, hat 80
may include heat moldable material 82 located within the brim of the hat to permit
customized molding of the brim by the wearer.
[0062] An exemplary method for providing a customized form fit for hat 80 to a wearer's
head may include providing a hat 80 having a heat moldable material 82 configured
to conform to a wearer's head when heated to a predetermined temperature to provide
the wearer with a customized fit for the hat. In some embodiments, heat moldable material
82 may include a fabric and a thermoplastic resin. In some embodiments, heat moldable
material 82 may include a thermoplastic resin and does not include a fabric. In some
embodiments, the method for providing a customized form fit for hat 80 to a wearer's
head may correspond to the method, discussed above with reference to shoe 10 and Fig.
10, and therefore has not been described in great detail again. Hat 80 may also have
a temperature sensitive indicator (not shown) similar to temperature sensitive indicator
26 for use in customizing and form fitting an article as discussed above with reference
to shoe 10, and therefore has not been described again,
[0063] Thus, a customized, form-fitting article, such as an athletic shoe, glove, or hat,
may include a heat moldable material that conforms to the wearer's anatomy when heated
to a predetermined temperature to provide a customized, form-fit is presented. The
heat moldable material may be sufficiently flexible for use in athletic shoes so that
movement of the foot or shoe is not hampered by the presence of the heat moldable
material. The heat moldable material may also be reusable, so that it may be reheated
and remolded multiple times.
[0064] The foregoing description of the specific embodiments will so fully reveal the general
nature of the invention that others can, by applying knowledge within the skill of
the art, readily modify and/or adapt for various applications such specific embodiments,
without undue experimentation, without departing from the scope of the present invention
as defined by the appended claims.