Sole with integrated mechanical device and method of assembling the same

Abstract

A sole capable of being integrated in a boot or shoe and a method of assembling the same. The sole comprises an outsole, made of at least a first material, which defines an exterior lateral shape and an inner space for receiving a filling material and a housing for receiving a rigid mechanical device having protrusions that extend through corresponding openings of the sole. A wall surrounding the housing, made of the first material, has a minimum thickness of 20 mils. A portion of the wall is shared with a heel-section of the outsole. A seal plate is provided for, at least partly, covering the wall. the seal plate is for preventing the filling material from entering the housing. The filling material, once the sole is assembled, comprises a layer covering the seal plate and the sole conceals the mechanical device except for the protrusions.

What is claimed is: 
     
         1 . A sole capable of being integrated in a boot or shoe, the sole comprising:
 an outsole made of at least a first material, comprising:
 an outer boundary defining an exterior lateral shape of the sole and an inner boundary defining an inner space of the midsole for receiving a filling material; and 
 a housing within the inner space for receiving a rigid mechanical device, the rigid mechanical device having a plurality of protrusions that extend from the midsole through a corresponding plurality of openings of the sole, wherein a wall surrounding the housing, made of the first material, has a thickness of at least 20 mils (0.5 mm) and wherein a portion of the wall is shared with the inner boundary along a heel-section of the midsole; and 
   a midsole comprising a seal plate, covering at least a portion of the wall surrounding the housing of the outsole, for preventing the filling material from entering the housing of the outsole, the filling material, once the sole is assembled, comprising a layer covering the seal plate;   wherein the sole, once assembled, conceals the mechanical device except for the plurality of protrusions.   
     
     
         2 . The sole of  claim 1 , wherein the plurality of openings comprises:
 a plurality of bottom openings from the outsole for allowing therethrough a plurality of retractable spike protrusions of the plurality of protrusions of the mechanical device; and   a lateral heel opening along the heel-section of the outsole for allowing an actuator protrusion of the plurality of protrusions of the mechanical device through the portion of the wall shared with the inner boundary of the outsole.   
     
     
         3 . The sole of  claim 1 , wherein the first material is one of natural rubber, synthetic rubber, polyurethane, thermoplastic or a blend thereof. 
     
     
         4 . The sole of  claim 3 , wherein the outsole is made of at least a second material different from the first material. 
     
     
         5 . The sole of  claim 1 , wherein the filling material is a polymer and the layer has a thickness of at least 20 mils (0.5 mm). 
     
     
         6 . The sole of  claim 6 , wherein the layer provides electric isolation considering the mechanical device. 
     
     
         7 . The sole of  claim 6 , wherein the polymer is a polyurethane. 
     
     
         8 . The sole of  claim 1 , wherein the seal plate is a polymer sheet non-porous to the filling material. 
     
     
         9 . The sole of  claim 1 , wherein the seal plate is an alloy sheet non-porous to the filling material. 
     
     
         10 . The sole of  claim 1 , wherein the seal plate is made of cardboard sheet non-porous to the filling material. 
     
     
         11 . The sole of  claim 10 , wherein the seal plate is made of undulated cardboard sheet non-porous to the filling material. 
     
     
         12 . The sole of  claim 1 , wherein the housing further comprises inner intermediate walls. 
     
     
         13 . A method of assembling a sole with a rigid integrated mechanical device, the sole being capable of being integrated in a boot or shoe, the method comprising:
 providing a sole frame comprising:
 an outsole made of at least a first material, comprising:
 an outer boundary defining an exterior lateral shape of the sole frame and an inner boundary defining an inner space of the outsole for receiving a filling material; and 
 a housing within the inner space for receiving a rigid mechanical device, wherein a wall surrounding the housing, made of the first material, has a thickness of at least 20 mils (0.5 mm) and wherein a portion of the wall is shared with the inner boundary along a heel-section of the outsole; and 
 
   inserting the rigid mechanical device within the housing of the outsole, the rigid mechanical device having a plurality of protrusions that extend from the outsole through a corresponding plurality of openings of the sole frame;   covering at least a portion of the wall surrounding the housing of the outsole with a seal plate; and   filling the outsole with the filling material, wherein the filling material is prevented from entering the housing of the outsole by the seal plate, the filling material comprising a layer covering the seal plate, thereby concealing the mechanical device within the sole except for the plurality of protrusions.   
     
     
         14 . The method of  claim 13 , wherein inserting the rigid mechanical device within the housing of the outsole comprises:
 inserting an actuator protrusion of the plurality of protrusions of the mechanical device through a lateral heel opening along the heel-section of the outsole; and   inserting plurality of retractable spike protrusions of the plurality of protrusions of the mechanical device through a corresponding plurality of bottom openings from the outsole.   
     
     
         15 . The method of  claim 13 , wherein the first material is one of natural rubber, synthetic rubber, polyurethane, thermoplastic or a blend thereof. 
     
     
         16 . The method of  claim 15 , wherein the outsole is made of at least a second material different from the first material. 
     
     
         17 . The method of  claim 13 , wherein the filling material is a polymer and the layer has a thickness of at least 20 mils (0.5 mm). 
     
     
         18 . The method of  claim 13 , wherein the layer provides electric isolation considering the mechanical device. 
     
     
         19 . The method of  claim 13 , wherein the seal plate is a polymer sheet non-porous to the filling material, an alloy sheet non-porous to the filling material, is made of cardboard sheet non-porous to the filling material or is made of undulated cardboard sheet non-porous to the filling material. 
     
     
         20 . The method of  claim 13 , wherein the housing further comprises inner intermediate walls.