Outer sole having resilient mid-sole with floating hinges

Abstract

An outer sole includes an upper sole, a tread layer disposed below the upper sole, and a resilient mid-sol disposed between the upper sole and the tread layer. The mid-sole resists compression under load, and comprises at least one floating hinge extending transversely to the longitudinal axis of the sole. Each floating hinge includes an upper resilient convex leaf spring, a lower resilient convex leaf spring, and a U-spring joining the leaf springs together. Each leaf spring has a root and a head opposite the root. Each U-spring has a pair of integrally-formed legs, each upper leaf spring is integrally formed at the root thereof with the upper sole, and each lower leaf spring is integrally formed at the root thereof with the tread layer. The leaf springs of each floating hinge are integrally joined at their heads to one of the legs of the associated U-spring.

1 . An outer sole comprising:
 an upper sole;   a tread layer disposed below the upper sole; and   a resilient mid-sole disposed between the upper sole and the tread layer and being configured to resist compression under load, the mid-sole comprising at least one floating hinge extending transversely to a longitudinal axis of the sole, each said floating hinge including an upper resilient convex leaf spring, a lower resilient convex leaf spring, and a U-spring joining the leaf springs together, each said leaf spring having a root and a head opposite the root, each said U-spring having a pair of integrally-formed legs, each said upper leaf spring being integrally formed at the root thereof with the upper sole, each said lower leaf spring being integrally formed at the root thereof with the tread layer, the leaf springs of each said floating hinge being integrally joined at their respective heads to a respective one of the legs of the associated U-spring.   
   
   
       2 . The outer sole according to  claim 1 , wherein the leaf springs are configured to resist the compression by progressively straightening under the load. 
   
   
       3 . The outer sole according to  claim 2 , wherein the U-springs are configured to resist the compression by progressively compressing under the load. 
   
   
       4 . The outer sole according to  claim 3 , wherein the U-springs are disposed equidistantly between the upper sole and the tread layer. 
   
   
       5 . The outer sole according to  claim 4 , wherein the upper sole includes a toe region and a heel region, and each said floating hinge has the U-spring oriented towards the toe region. 
   
   
       6 . The outer sole according to  claim 5 , wherein the mid-sole includes an intervening channel disposed between each adjacent pair of the floating hinges, the floating hinges and the intervening channels each extending continuously, without interruption, across a width of the sole. 
   
   
       7 . The outer sole according to  claim 6 , wherein the mid-sole includes a resilient foam disposed within the channels. 
   
   
       8 . The outer sole according to  claim 7 , wherein the leaf springs extend transversely across the entire width of the sole. 
   
   
       9 . The outer sole according to  claim 8 , wherein a thickness of each said leaf spring is substantially constant between the root and the head thereof. 
   
   
       10 . The outer sole according to  claim 8 , wherein a thickness of each said leaf spring varies between the root and the head thereof. 
   
   
       11 . The outer sole according to  claim 9 , wherein the thickness of each said leaf spring is substantially constant across the entire width of the sole. 
   
   
       12 . The outer sole according to  claim 11 , wherein the height of the floating hinges is greater proximate the heel region than the toe region. 
   
   
       13 . The outer sole according to  claim 12 , wherein the mid-sole comprises a resilient rubber material. 
   
   
       14 . A foot covering comprising:
 a shoe upper; and   an outer sole secured to the shoe, upper, the outer sole being configured according to any one of  claims 1  to  13 .   
   
   
       15 . The foot covering according to  claim 14 , wherein the shoe upper and the outer sole together comprise a shoe. 
   
   
       16 . The foot covering according to  claim 15 , wherein the shoe upper and the outer sole together comprise a boot.