Flexible shank for an article of footwear

Abstract

A directionally flexible shank for an article of footwear is disclosed, which provides support to the bottom of a user's foot while providing flexibility for foot movements in one or more particular directions. The directionally flexible shank may also support the arch of the foot. The directionally flexible shank may include a plurality of articulatable segments that can easily rotate with respect to each other in a first direction and thereby permit the directionally flexible shank to flex away from the foot, while limiting articulation in an opposite direction. The articulatable segments are connected to each other via hinge structures, which may include living hinges formed of a thermoplastic material. The hinge structures may also be formed from a flexible sheet attached to a bottom portion of the directionally flexible shank. Methods are also disclosed for manufacturing the directionally flexible shank.

1 . A directionally flexible shank for a sole of an article of footwear, the directionally flexible shank comprising:
 a plurality of segments arranged seriatim along a length of the directionally flexible shank;   a pile fabric attached to the segments at a bottom portion of the directionally flexible shank; and   a plurality of hinge structures, each one of the hinge structures being disposed between adjacent ones of the segments and oriented in a direction transverse to the length of the directionally flexible shank.   
     
     
         2 . The directionally flexible shank recited in claim wherein the pile fabric includes a flexible sheet and fibers extending from the flexible sheet. 
     
     
         3 . The directionally flexible shank recited in  claim 2 , wherein the pile fabric includes a loop side of a hook and loop fastener. 
     
     
         4 . The directionally flexible shank recited in  claim 2 , wherein the plurality of segments are formed from an elastomeric material molded into the fibers. 
     
     
         5 . The directionally flexible shank recited in  claim 2 , wherein e flexible sheet forms the plurality of hinge structures. 
     
     
         6 . The directionally flexible shank recited in  claim 1 , wherein each segment includes a bottom portion and an opposite upper portion, and the hinge structures are disposed on the bottom portion. 
     
     
         7 . The directionally flexible shank recited in  claim 3 , wherein each segment includes a shoulder region at a lateral side disposed proximate one of the hinge structures and opposing a shoulder region for an adjacent segment, opposing ones of the shoulder regions moving apart when the directionally flexible shank flexes in a first direction about the hinge structures and moving together when the directionally flexible shank flexes in an opposite second direction. 
     
     
         8 . The directionally flexible shank recited in  claim 7 , wherein opposing ones of the shoulder regions form stops that interfere with each other when the directionally flexible shank flexes in the second direction to resist bending of the directionally flexible shank in the second direction. 
     
     
         9 . The directionally flexible shank recited in  claim 11 , wherein the hinge structures have a width less than a width of adjacent segments and are disposed in a central, longitudinal portion of the directionally flexible shank to generally form a longitudinal axis of the directionally flexible shank and to permit twisting of the directionally flexible shank about the longitudinal axis. 
     
     
         10 . The directionally flexible shank recited in  claim 1 , further comprising a top surface formed from upper surfaces of the segments, the top surface including contours adapted for engaging a foot. 
     
     
         11 . The directionally flexible shank recited in claim  110 , wherein the contours include a raised portion forming an arch support. 
     
     
         12 . The directionally flexible shank recited in  claim 10 , wherein the contours include a dished portion for receiving a user's heel. 
     
     
         13 . An arch support for an article of footwear, the arch support comprising:
 a plurality of segments arranged seriatim along a length of the arch support and forming a top surface, the top surface having a raised contour forming an arch support fur a foot, the plurality of segments being formed of a thermoplastic material;   a pile fabric attached to the segments at a bottom side of the arch support opposite the top side; and   a plurality of hinge structures, each one of the hinge structures being disposed between adjacent ones of the segments and oriented in a direction transverse to the length of the arch support, the hinge structures permitting the plurality of segments to rotate about respective ones of the hinges in a first direction away from the top surface, while limiting rotation of the plurality of segments in an opposite, second direction,   
     
     
         14 . The arch support recited in  claim 13 , wherein each segment includes a shoulder region at a lateral side disposed proximate one of the hinge structures and opposing a shoulder region for an adjacent segment, opposing ones of the shoulder regions moving apart when the arch support flexes in the first direction about the hinge structures and moving together when the arch support flexes in the opposite second direction. 
     
     
         15 . The arch support recited in  claim 13 , wherein each segment includes a bottom portion and an opposite upper portion, and the hinge structures are disposed on the bottom portion. 
     
     
         16 . The arch support recited in  claim 13 , wherein the pile fabric includes a flexible sheet and fibers extending from the flexible sheet, 
     
     
         17 . The arch support recited in  claim 16 , wherein the plurality of segments are formed from an elastomeric material molded into the fibers. 
     
     
         18 . The arch support recited in  claim 13 , wherein the pile fabric includes a loop side of a hook and loop fastener. 
     
     
         19 . The arch support recited in  claim 13 , wherein the flexible sheet forms the plurality of hinge structures, 
     
     
         20 . The arch support recited in  claim 13 , wherein the hinge structures have a width less than a width of adjacent segments and are disposed in a central, longitudinal portion of the directionally flexible shank to generally form a longitudinal axis of the directionally flexible shank and to permit twisting of the directionally flexible shank about the longitudinal axis.