Footbed system with variable sized heel cups

[0002] The present invention relates to shoes, and more particularly, relates to a removable footbed system with variable sized heel cups for use with golf shoes.

[0003] A golfer's performance depends substantially on the ability of the golfer's shoes to provide a solid base of support. To that end, golf shoes generally include a shoe upper joined to an outsole to define a chamber for receiving the golfer's foot. Furthermore, the bottom surface of the outsole includes numerous cleats for providing traction.

[0004] The traction provided by the cleats upon interaction between the outsole and the ground enables the golfer to perform the body movements necessary to culminate in an ideal contact between the club head and the ball (i.e., a golf swing), if the shoes fit properly. If the shoes are too loose in the heel area, a golfer's foot can move relative to the ground which is undesirable. Since the majority of golfers cannot afford custom made shoes, they must wear shoes of a pre-made size that best fit their feet. In order to improve fit, insertable shoe insoles are commonly used. These insoles also provide cushioning and arch support for a user's foot.

[0005] One example of such an insole is disclosed in U.S. Pat. No. 5,068,983 to Marc. The shoe insole in this patent includes a resilient base piece that is disposed primarily at the heel area and has a cupped peripheral wall. A heel piece is disposed within the base piece and provides shock absorption at the heel, A top cushioning layer overlies the base and heel pieces and is affixed to them with an adhesive. The top cushioning layer extends from the heel area forwardly to underlie the ball and toe areas.

[0006] There remains, however, a need in the art for other insoles, which are easy to manufacture and improve the fit of user's feet within their shoes.

[0007] The invention relates to a footbed system at least two heel cups. Each heel cup includes a base and a side wall that extends upwardly from the base. The first heel cup has a first volume of the side wall and the second heel cup has a second volume of the side wall, with the second volume is different from the first volume. One, selected heel cup is used. The narrower the heel width the greater the volume of the side walls of the heel cup are to assure good fit.

[0008] In another embodiment, the footbed system further includes a sole pad detachably connectable to the selected heel cup. In yet another embodiment, the footbed system includes a third heel cup with a third volume of the side wall is different from the first and second volumes.

[0009] Preferably, the first and second volumes are different adjacent a user's heel, and modified by changing the heights and/or thicknesses of the heel cups.

[0010] A cushion may be coupled to the lower surface of the sole pad in a forefoot region, and a viscoelastic damper may be coupled to the lower surface of the sole pad in a heel region. Fasteners may be included for to detachably connect the sole pad to each heel cup. The height of the side walls of the heel cups rearward of a shank area may additionally be varied.

[0011] The present invention further concerns a shoe that includes an upper, a midsole, an outsole, at least one sole pad, and a heel cup selected from at least two heel cups. Each heel cup includes a base and a side wall that extends from the base, with the first heel cup has a first volume of the side wall and the second heel cup has a second volume of the side wall. The second volume is different from the first volume. The selected heel cup is detachably connected to the sole pad to form a footbed system. The upper, midsole, and outsole are joined together to define an opening for receiving the footbed system.

[0012] The present invention is also related to a method of providing variable fit for a pair of shoes, the method including: providing a first sole pad, providing a first set of first heel cups of variable sizes, each first heel cup has side walls of different volumes from one another, selecting the first heel cup that provides preferred fit for a first foot; detachably connecting the first sole pad to the first selected heel cup to form a first footbed system, with the first selected heel cup underlying the first sole pad; and inserting the first footbed system in one shoe. The method may further include: providing a second sole pad; providing a second set of second heel cups of variable sizes, each second heel cup has side walls of different volumes from one another; selecting the second heel cup that provides preferred fit for a second foot; detachably connecting the second sole pad to the second selected heel cup to form a second footbed system, with the second selected heel cup underlying the second sole pad; and inserting the second footbed system in the remaining shoe.

[0013] To facilitate the understanding of the characteristics of the invention, the following drawings have been provided wherein:

[0014] FIG. 1 is an exploded, perspective view of a footbed system of the present invention for placement in a shoe;

[0015] FIG. 2 is a top view of a sole pad of the present invention;

[0016] FIG. 3 is a top view of a heel cup of the present invention;

[0017] FIG. 4 is a front, perspective view of the heel cup of FIG. 3;

[0018] FIG. 5 is a bottom view of the footbed system of the present invention;

[0019] FIG. 6 is a side view of a medial side of the footbed system of FIG. 5;

[0020] FIG. 7 is a side view of a lateral side of the footbed system of FIG. 5;

[0021] FIG. 8 is a side, perspective view of a “low” heel cup for accommodating a wide heel;

[0022] FIG. 9 is a side, perspective view of a “medium” heel cup for accommodating a medium-width heel;

[0023] FIG. 10 is a side, perspective view of a “high” heel cup for accommodating a narrow-width heel;

[0024] FIGS. 11a-care side views of the medial side of the three different heel cups of FIGS. 8-10, respectively;

[0025] FIGS. 12a-care side views of the lateral side of the three different heel cups of FIGS. 8-10, respectively;

[0026] FIG. 13 is a cross-sectional view of the footbed system shown in FIG. 5 along the line 13—13 of FIG. 5 without a cushion;

[0027] FIG. 14 is a cross-sectional view of the footbed system shown in FIG. 5 along the line 14—14 of FIG. 5 without the cushion;

[0028] FIG. 15 is a cross-sectional view of the footbed system shown in FIG. 5 along the line 15—15 of FIG. 5;

[0029] FIG. 16 is a cross-sectional view of the footbed system shown in FIG. 5 along the line 16—16 of FIG. 5.

[0030] Referring to the drawings, wherein like reference numbers are used to designate like parts, and as shown in FIG. 1, there is illustrated an embodiment of a footbed system 10 for placement in a golf shoe 12 according to the present development. Golf shoe 12 includes an upper 14, a midsole 16, and an outsole 18. The upper 14 is conventional and formed from a suitable material, such as leather, a synthetic material or the like. The upper 14 is joined to the midsole 16 using cement or the like and conventional techniques. Once joined thereto the upper 14 defines an opening 20 for receiving the footbed system 10 and a wearer's foot (not shown).

[0031] The midsole 16 provides cushioning to the wearer, and is formed of a material such as ethylene vinyl acetate copolymer (EVA). The midsole 16 is formed on the outsole 18. Once the midsole and outsole are joined, the outsole forms the bottom of shoe 12.

[0032] Referring to FIGS. 1-5, footbed system 10 includes a sole pad 22 and a heel cup 24, both of which are preferably formed of EVA. Perforations (not shown) may be provided through sole pad 22 for enhanced breathability. Sole pad 22 has a fabric-covered top side 25aand a bottom side 25b, and underlies substantially the entire length of the user's foot. The heel cup 24 also has a fabric-covered top side 26aand a bottom side 26b. The EVA is lightweight, and the polymer/fabric composite effectively handles the moisture that develops at the base of the foot. The sole pad and base are formed as separate, single molded pieces with the recesses and other portions as discussed below formed therein during molding. The holes are subsequently die cut.

[0033] The sole pad 22 further includes cushion 27 provided in the forefoot area and a damper 28 in the heel area. Preferably, the cushion 27 fits within a recess 30 (as best seen in FIG. 14) on the bottom side 25bof sole pad 22, and includes a recess peripheral portion 31 that extends to a peripheral edge 31a.

[0034] The cushion 27 may be, for example, a soft polymer pad, an air bladder, or a bladder filled with a cushioning material like a gel or liquid. Most preferably, the cushion is formed by filling a plastic bladder with air and small discrete pieces of cushioning material such as pellets 33. The pellets 33 are formed of thermoplastic rubber (TPR) with a Shore A hardness of between about 5 to about 15, and more preferably about 10. The pellets 33 have a generally cylindrical shape. However, pellets of other shapes can also be used. Such pellets have rubbery properties which permit deformation and thus serve as an effective cushioning material. The bladder is glued, bonded, or otherwise connected to the bottom side of sole pad 22, thereby encasing pellets 33 within recess 30. The contents of the cushion 27, such as pellets, and air. It is recommended that the pellets 33 are at least 4 grams per piece.

[0035] Referring to FIGS. 2 and 3, damper 28 (shown in phantom) preferably has a generally oval shape, and has a protrusion 34 that fits in a locating hole 36 in sole pad 22. The remaining portion of the damper 28, less the protrusion 34, fits in a recess 37 in sole pad 22. The damper is permanently attached to sole pad 22 by adhesive, thermal, or other bonding techniques. Damper 28 is accommodated in a matching hole 38 that extends through heel cup 24. The damper 28 and hole 38 are configured and dimensioned so that damper 28 fits snugly in hole 38 and has about the same thickness as heel cup 24. Alternate shapes may also be used for damper 28, such as a circle or two partially-overlapping ovals. The damper may be formed of materials including viscoelastic materials, such as a polyurethane gel.

[0036] In another embodiment, cushion 27 and damper 28 can be removably attached to sole pad 22. Additionally, damper 28 may instead be accommodated in a matching recess in the top side 26aof heel cup 24 instead of the hole 38 therethrough.

[0037] Referring again to FIGS. 2 and 3, sole pad 22 is detachably connected to heel cup 24, such as by hook and loop fasteners 42. Preferably, separate, matching, circular-shaped fasteners are adhered in recessed areas on both sole pad 22 and heel cup 24, with the fastener hook portion adhered to one and the fastener loop portion adhered to the other. To adequately secure sole pad 22 to heel cup 24, fasteners 42 are located near a front edge 44 and a rear area 46 of heel cup 24, and fasteners are secured at the rear and middle of the sole pad 22. Although hook and loop fasteners have been used to attach a sole pad to a heel cup, the type of fasteners can vary.

[0038] Referring to FIGS. 3 and 4, the heel cup 24 further includes side walls 50aand 50b, and back wall 52, surrounding a raised platform area 54. Side walls 50a,band back wall 52 extend upwardly from platform area 54, which extends above base 56. The medial side wall 50ais configured at arch portion 49 to support the arch area of a user's foot. Notably, the inward slope of the lateral side wall 50bis significantly more steep that the inward slope on the medial side wall 50a(as best seen in FIG. 15). When sole pad 22 is placed on top of heel cup 24 on base 56, top side 25aof sole pad 22 (as shown in FIG. 1) is slightly below the inside edge 57 of raised platform area 54. Criss-crossing indentations 32 (as best seen in FIG. 5) also may be provided along the bottom side of heel cup 24.

[0039] Referring again to FIGS. 2 and 3, different configurations of sole pads 22 and heel cups 24 must be provided for the left foot and the right foot. In particular, because the arch is located on the medial side of the foot, the heel cup arch portion 49 must be provided on the medial side of heel cup 24 In order to facilitate the proper matching of sole pad 22 configured for a left foot and shoe with heel cup 24 configured for a left foot, a notch 58 is provided on the cup 24. Preferably, notch 58 is triangular. A matching triangular tongue 59 is provided on the bottom side 25bof sole pad 22 for interlocking engagement with notch 58. Thus, a user can match sole pad 22 configured and dimensioned for use with a left foot with heel cup 24 that is also configured and dimensioned for use with a left foot. Similarly, sole pad 22 and heel cup 24 may be matched for a right foot and shoe. Additional indicia or side indicators may be provided to assist the user in matching sole pads and heel cups, for example lettering on each sole pad and heel cup designating the components for a left or right foot and shoe can be used.

[0040] As seen in FIGS. 6 and 7, the medial side 50aand the lateral side 50bof heel cup 24 have different contours at the free edge. For example, medial side wall 50aextends to a greater height H_Mthan the height H_Lof lateral side wall 50b.

[0041] Referring to FIGS. 8-10, the present footbed system preferably includes a set of three heel cups 60, 62, 64 having varying sizes for use with one sole pad 22 (as shown in FIG. 1). These heel cups 60, 62, 64 are designated “low”, “medium”, and high”, respectively. Heel cups 60, 62, 64 are sized to accommodate heel widths of wide (low height walls), medium (medium height walls), and narrow (high walls), respectively. The heel cups are optionally color-coded to facilitate use, such as by using fabric coverings of blue, black, and green for heel cups 60, 62, 64. Thus, three different ranges of widths of heel sizes are accommodated with such a footbed system, and as a result, the wearer can customize the footbed by selecting the heel cup that best matches the wearer's heel width.

[0042] As shown in FIGS. 8-12, the dimensions for heel cups 60, 62, 64 are shown. Preferably, the front height of the medial side wall 50aremains constant for the different heel cups 60, 62, 64 or widths, such that H_MW1=H_MM1=H_MN1. The rear height of the medial side wall 50adecreases as heel width increases, with H_MN2greater than H_MM2, and H_MM2greater than H_MW2. Similarly, the front height of the lateral side wall 50bremains constant for the different heel cup sizes, such that H_LW1=H_LM1=H_LN1, while the rear height of the lateral side wall 50bdecreases as heel width increases, with H_LN2greater than H_LM2, and H_LM2greater than H_LW2. As used herein, subscripts when read from left to right refer to the side with M for medial or L for lateral, the heel width accommodated with N for narrow, M for medium, or W for wide, and the location of measurement with 1 for the front location and 2 for the rear location.

[0043] The height of each back wall 52 remains constant for the different heel cup sizes, such that H_BW=H_BM=H_BN, where the subscripts when read from left to right refer to B for back wall, and the heel width accommodated with N for narrow, M for medium, or W for wide. Most preferably, the front and rear heights of the medial and lateral side walls, as well as the height of the back walls, are the values listed in Table I.

[0044] The thickness of the side walls also changes between cups so that the volume of the side walls for the low cup is less than the volume of the side walls for the high cup.

[0045] These and other aspects of the present invention may be more filly understood with reference to the following non-limiting example, which is merely illustrative of one embodiment of the present invention footbed system. Commonly, the dimensions will vary depending on the footbed dimensions built into the last, which is the form around which the shoe is made. Thus, this embodiment is not to be construed as limiting the invention, the scope of which is defined by the appended claims.

[0046] Table I sets forth dimensions for high, medium, and low heel cups of the present invention.

[0047] As seen from the dimensions above, the front heights of the medial and lateral side walls each remains constant for high, medium, and low heel cup sizes. Furthermore, the rear heights of the medial and lateral side walls decrease as heel width increases. The back wall heights remain constant for high, medium, and low heel cup sizes.

[0048] All of the thickness measurements above are taken at the same vertical position on each heel cup side wall. The thickness at the front location is the thickness of both the medial and lateral walls at the position 1 in FIGS. 11a-cand 12a-c. The front location thickness of the high cup 64 for narrow heels is greater than the front thickness of the medium and low cups at the front position. The thickness at the rear position is the thickness of both the medial and lateral walls at the position 2 in FIGS. 11a-cand 12a-c. The thickness of the high cup 64 for narrow heels is greater than the thickness of the medium cup 62 for medium width heels. The thickness of the medium cup 62 is greater than the thickness of the low cup 60 for wide heels. The thickness of the back wall is the thickness of the wall 52 in FIGS. 11a-cand 12a-c. The back wall thickness of the high cup 64 is greater than the back wall thicknesses of the remaining cups.

[0049] As a result of the height and thickness variations of the side walls between cups, the volume of the side walls of the high cup 64 is greater than the same volume of the medium cup 62, and the side wall volume of the medium cup 62 is greater than the side wall volume of the low cup 60. Thus, the high cup for use with narrow heels has a larger side wall volume to fill gaps between the foot and the shoe when compared to the other cups for use with wider heels.

[0050] Referring to FIG. 13, when the sole pad 22 and heel cup 24 are mated, preferably there is a slight taper such that the thickness T_Fof sole pad 22 at front end 66 is less than the combined thickness T_Bof sole pad 22 and heel cup 24 near back end 68. Most preferably, the combined thickness of the sole pad 22 and heel cup 24, T_M, near the front edge 44 of heel cup 24 is equivalent to the combined thickness T_Bnear the rear end 68.

[0051] In a preferred embodiment, sole pad 22 has a thickness T_Fat front end 66 of about 5.0 mm, a thickness T_Mnear the front edge 44 of heel cup 24 of about 6.0 mm, and a thickness T_Bat back end 68 of about 6.0 mm. There is a slight taper from the front end 66 of the sole pad 22 to front edge 44 of heel cup 24, such that the intermediate thickness, T_I, of the sole pad is about 5.5 mm. Preferably, the heel cup 24 has a primary cup thickness, T_C, of about 3.0 mm, and the portion of sole pad 22 overlaying heel cup 24 also has a thickness T_Oof about 3.0 mm. Each indentation 32 on heel cup 24 has a depth of about 1.5 mm, and the portion of sole pad 21 surrounding protrusion 34 in locating hole 36 preferably has a thickness, T_H, of about 1.0 mm. Furthermore, a lower rear edge 70 of heel cup 24 is rounded.

[0052] FIGS. 14-16 show cross-sections of the footbed system 10 (as shown in FIG. 5) at various longitudinal positions. In a preferred embodiment, recess peripheral portion 31 has a depth D₁of 1.5 mm to accommodate the peripheral edge of the cover 27a(as shown in FIG. 1) on cushion 27 that extends to peripheral edge 31a. Preferably, the recess 30 has a total depth D₂of about 3.0 mm, including the depth of recess peripheral portion 31 used for sealing the cover to sole pad 22.

[0053] A kit for custom fitting a user's foot in a shoe can also be provided. For example, a sole pad 22 (as shown in FIG. 1) and a set of three heel cups 60, 62, 64 (as shown in FIGS. 8-10) having varying sizes, as discussed above, can be provided for each shoe, packaged together so that the wearer of the shoe can customize the fit in the heel area of the shoe to improve performance. The heel cups and pad can be provided with shoes at the time of sale, or the footbed system may be offered separately for use with existing shoes. The degree of support for each foot can thus be individually selected, and different sized heel cups can even be chosen for use simultaneously, one in each of the left and right shoes of a user.

[0054] The present invention also involves a method of providing variable fit for a shoe. At least one sole pad is initially provided with a number of heel cups of variable sizes to accommodate different heel widths. The user selects the heel cup that provides a preferred fit for a particular foot based on heel width. The sole pad is detachably connected to the selected heel cup to form a footbed. The sole pad and heel cup are inserted into the shoe. This is repeated for the user's second foot.

[0055] While it is apparent that the invention herein disclosed is well calculated to fulfill the objects above stated, it will be appreciated that modifications and other embodiments may be devised by those skilled in the art. For example, the height of the front side walls of the cups can be varied between cups, as can the height of the back wall. In addition, the sole pad can be provided with side walls adjacent the forefoot of the wearer. Sole pads of different sizes and/or different configurations can be provided with each system. Alternatively, sole pads can be provided in an oversized configuration that can include a trimming grid for selective shaping by the user. Likewise, heel cups can include oversize portions with a trimming grid. Furthermore, sets of two or more heel cups are contemplated for each footbed system. Thus, although the aforementioned footbed system contained three heel cups and one sole pad for each shoe, other systems may include a different number of heel cups and sole pads. The present invention is not limited to the heel cup lengths disclosed above. Alternatively, the heel cups can extend the length of the foot and form part of a set with various volumes of sidewalls in the rearward portion. The embodiments above can be modified so that some features of one embodiment are used with the features of another embodiment. It is intended that the appended claims cover all such modifications and embodiments as fall within the true spirit and scope of the present invention.