EP2840920B1

EP2840920B1 - Sandal with toe separators

Info

Publication number: EP2840920B1
Application number: EP13781454.7A
Authority: EP
Inventors: Stuart Alan Kalinsky; Selim DUSHEY
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-04-27
Filing date: 2013-04-26
Publication date: 2020-12-02
Anticipated expiration: 2033-04-26
Also published as: US20130333243A1; EP2840920A4; US20190116923A1; EP2840920A1; WO2013163501A1

Description

Field of the Invention

This invention relates to sandals with toe separators and particularly to sandals with multiple toe separators.

BACKGROUND OF THE INVENTION

A new category of footwear has been developed, based on the venerable "flip-flop" sandal design. These sandals have additional toe separation elements in addition to the flip-flop strap worn between a big toe and a first adjacent toe. Because of the tendency of adjacent toes to naturally be close to each other, if not if not actually touching, insertion of physical separators therebetween can provide a measure of discomfort not normally associated with "flip-flop" sandals having a single separator between a big toe and an adjacent toe where spacing therebetween is more pronounced and discomfort is minimized. Nevertheless, discomfort is occasioned in any common sandal having a toe separator with the toe separation and slipper wearing holding being effected between a relatively hard rubber or plastic between the toes and bearing against the foot at the base of the toes. The toe separation element in the common flip-flop sandal is unitary with and of a one piece construction of the upper holding strap. The hard nature of the strap for structural holding is thus carried through with the portion thereof, which effects the toe separation and pressing against the foot at the base of the toes with significant discomfort or irritation.
In addition, the area between the toes is subject to retention of moisture and fungus and bacteria build up resulting in conditions such as athlete's foot with the condition with increased irritation being exacerbated as a result of the toe separation of the flip flop type of slippers or sandals.
Issues of comfort and aesthetic design remain to be resolved and improved upon with single toe separated flip-flop sandals and particularly with the use of the multiple toe separator sandals being used for active foot care.
US 2,740,207 discloses a slipper or shoe in which the inner elements which come into contact with the foot are medicated for the treatment of irritations caused by such diseases as athlete's foot, fungus infections and other similar irritations of the skin.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide sandal footwear with one or more toe separators of an aesthetic appearance, which provides an increased level of comfort and which actively provides or promotes foot care.
According to a first aspect of the invention, an article of footwear is recited in Claim 1. Generally the first aspect of the present invention comprises an article of footwear comprising a base sole element and an upper element configured to enclose a human foot therebetween, wherein one to four separate and discrete toe separator elements fully extend between the base sole element and the upper element, wherein each of the one to four toe separator elements is comprised of a material tube having two ends, and wherein the material tube is of a circular, elliptical, or oval cross section, without edges, and wherein a cushioning material comprised of at least one of a foam, memory foam and gel is contained within the respective material tube, with one of the two ends of the material tube being attached to the upper element and another of the two ends being attached to the base sole element, thereby forming a material tube of a circular, elliptical, or oval cross section, without edges, configured to be a toe separator and wherein the cushioning material is fully enclosed and contained within the material tube between the base sole element and the upper element. Each of the separate and discrete one to four toe separator elements is configured and positioned to provide a wedging separation between adjacent toes of the enclosed human foot and configured to provide a cushioning sensation to the adjacent toes in contact therewith.
According to a second aspect of the invention, a method of configuring an article of footwear is recited in Claim 15. The second aspect of the present invention comprises a method of configuring an article of footwear for prevention of microbial, bacterial and fungal growth between toes of a human foot, wherein the article of footwear is an article of footwear according to claim 4, the method comprising the steps of:

a) aligning three adjacent toe separator elements of the article of footwear recited in Claim 4, starting from a small toe of the human foot along a distally extending diagonal line and positioning a fourth toe separator element for placement between a big toe and an adjacent toe, the fourth toe separator element being out of line from the diagonal line and proximally behind an adjacent toe separator
b) element, the toe separator elements being positioned in conformity with the anatomical configuration of the human foot;
c) attaching all toe separator elements to the upper element and the base sole element;
d) providing the tube material of the four toe separator elements as one of an antimicrobial, antibacterial and antifungal fabric; and
e) providing the article of footwear for placement on a human foot such that the toe separator elements provide a wedging separation between adjacent toes of the human foot.

Generally the present invention comprises sandals, defined herein as footwear having at least one toe separator element (preferably one or four toe separators) configured for placement between adjacent foot toes, the at least one toe separator extending between an upper footwear element and a bottom base or sole wherein the toe separator element or elements, particularly between the small toes, are comprised of a material which provides an external soft or cushioned sensation to the toes of a wearer. The soft or cushioned material is configured to provide a compressive reaction or "give" to lateral forces exerted by the adjacent toes and foot at the base of the toes with reduced or minimal pressure or binding such as exerted with hard rubber, hard plastic and even fabrics alone (which would be susceptible to a cutting sensation) or fabrics on a relatively hard support.
Preferably the toe separator elements are elements separate from and of different compositions than the compositions of the uppers (usually straps in sandals) and soles or bases of the sandals, which, for structural integrity in use, are usually made of harder materials. These separator elements are integrated with the uppers and soles such as by being sewn or anchored therewith or by other attachment expedients. It is also highly preferred that the cushioning compositions of the toe separators be able to resist wear and degradation, as a result of cushioning compressions, and that they are wearably reusable, i.e., effectively maintain their structural configuration with continued wearing use. Non-limiting examples of cushioning elements included foam, memory foam, air filled tubes, gels, etc.
A highly preferred material, for use as a cushioned toe separator or separators, is the material commonly known as "memory foam" or gel, which is able to provide cushioning comfort and retains such comfort and aesthetic appearance with a "memory" resilience to substantially an original dimension, even with continued wearing and use. In a preferred embodiment the memory foam or gel is encased in a material tube such as (lycra, jersey,etc) backed with the memory foam material. If desired, central hard cores may be utilized to provide structural integrity for the separators but with the separators being configured to minimize or eliminate any external hard sensations by such hard cores
Memory foam is polyurethane with additional chemicals increasing its viscosity and density. It is often referred to as "visco-elastic" polyurethane foam, or low-resilience polyurethane foam. Higher-density memory foam softens in reaction to body heat, allowing it to mold to a warm body in a few minutes. A lower density memory foam is pressure-sensitive and molds quickly to the shape of a body pressing against it, returning to its original shape once the pressure is removed. The speed with which a foam returns to its original shape, after a weight or pressure is removed, is often part of the marketing message among memory-foam mattress producers, many of whom tout "newer generation" foams with "faster recovery." Memory foam has been used in shoes and footwear but generally only in a pressure-cushioning weight bearing manner, such as in or as an insole.
Other types of memory foam include synthetic memory sponge of man-made cellulose dervid from sodium sulphate as well as a variety of other materials.
Memory foam separators as utilized in the present invention between the toes have been found to provide meaningful separation in a comfortable way to give the benefits of toe separation, such as better circulation in the feet; which often provides added benefits for people with circulation problems, diabetics, etc. Better balance is also provided, by allowing for a broader foundation. In addition, a body is better able to respond to subtle shifts in weight and react appropriately and a better grip can be had while walking. The toe separators can also keep toes separated sufficiently and comfortably for healing after foot surgery, as needed. Additional benefits include helping keep toes flexible, which improves gait especially with toes used to wearing shoes that keep toes stiff which can cause knee problems, tendinitis, and bunion formation. The toe separators also help regain a more natural line in feet and helps redistribute weight to the outside edges of feet, as opposed to middle of feet. This better distribution of weight contributes to healthy alignment.
In preferred embodiments, based on typical toe comfort considerations, the thickness of the memory foam is between 2 and 5mm and is more preferably about 3 or 4mm. The width of the material preferably used in forming the toe tube separator is about 28-35mm (in an initial sheet form) with a preferred average width of about 30mm. For aesthetic considerations and to reduce wear, the memory foam is provided or produced as an integral backing for a decorative fabric material.
A planar element of appropriate size with the fabric and foam backing is folded and stitched to provide the respective toe separator elements. The tube is of circular, elliptical, or oval cross section, without edges, though other cross sectional configurations are possible, with the compression or cushioning minimizing the effect of any edges of the foam material. Preferably, the formed tube is provided with a reinforcement or stiffening material core, such as a thin rubber core rod therewithin of typically about 2mm in width. The stitching is preferably positioned between 2-5mm from the edge in order to minimize toe irritation. This tubing is then used as toe separators for sandals or shoes. The toe separators can also be made from encapsulated gel or silicone or latex. Preferably stitching seams are positioned, with connection to the sandal, away from contact with adjacent toes to minimize irritation and facing toward the foot at the base of the toes, for aesthetic appearance. The memory foam and surface material as well as core reinforcement materials are preferably all slightly stretchable to provide a degree of give for the wearer's toes. Modifications in this regard of degree of stretchability are a function of different styles
During the tubing preparation procedure, seam irritation may be further minimized by skiving or tapering the ends before formation of the tube. Alternatively, the memory foam can be seamlessly extruded with a fully enclosing fabric cover, without a seam.
In addition to memory foam as the base material of the tube or with any other base material, the present invention further comprises the use of an enclosing fabric or any other fabric used in toe separation of anti-fungal and anti-bacterial and therapeutic materials within or on the fabric. This can benefit the between toes areas subject to "athlete's foot" and can serves to prevent deterioration of fabrics used in the toe separator material subject to fungus and bacterial growth in a moist area between the toes. These fabrics are well known and are commonly used in hospital bedding and patient gowns. Examples of sources for the fabrics or antimicrobials for use in fabrics include X-STATIC® fabrics, Silvadur® antimicrobials from the Dow Corporation and antimicrobials for fabrics from Belton Industries.
Antimicrobial textile products increase the comfort and hygiene factor making them more pleasant to wear with odors being neutralized and skin problems, caused by microbial growth reduced. Comfort in sandals as well as overall well being is enhanced by the direct application of antimicrobials in the toe separators to areas subject to fungus and microbial growth.
Microbes fall into three categories; bacteria, fungi and algae, although only the first two are generally applicable to textiles or to skin. Bacteria and fungi can cause deterioration in a range of textiles including sports textiles, leading to loss of performance and aging, as well as unsightly staining, unpleasant odors and potential skin infections caused by fungal growth .The use of antimicrobial finishes and treatments within textiles can help to avoid or control cross infection, and by stopping microbial growth, can extend the lifetime of the sandal and control problems.
Antimicrobial treatments can be added in a number of ways including as a coating to the finished fabric or fiber or by incorporating the antimicrobial agent within the fiber during the spinning process, as in the manufacturing of polyester and nylon.
Antimicrobial agents used to treat textiles fall into two categories, known as "static" and "cidalff and the table below outlines the main differences. Many traditional treatments fall into the "cidal" category and because of their leaching action need to be evaluated for their health and environmental effects. New development tends to favor the "Static" type agents as these are of lower risk.
Antimicrobial fabrics can deter microbial growth in one of two ways. Either "passively", by inhibiting the growth of micro-organisms through inherent surface structure without the use of agents - linen for example displays such characteristics, as well as lambs wool, or "actively", using antimicrobial agents to either kill or inhibit the growth of any microbes present such as in treated cotton/denim fabrics.
Examples of commonly used standard tests for assessing antimicrobial function are given below including that of training shoes.
In a further embodiment of enhancing the comfort level of the sandals of present invention, the fabric surface used in the toe separators may have bumps or other texture irregularities to stimulate blood flow in between the toes and effect a massaging function for additional comfort and foot care. Alternatively, or in addition, the toe separators may include vibrating coils to effect a similar or massaging function
The actual positioning of the toe separation tubular elements may also determine a greater or lesser degree of comfort because of the physiology or anatomical configurationof a typical foot. Thus, many sandals with multiple toe separators have such separators arrange regularly in a straight, albeit angle line. However, for increased comfort the toe separator between the big toe and the first digit is preferably offset from the straight line to either be horizontal (relative to the long axis of the sandal) with respect to the next toe separator or with the latter being slightly forward of the big toe separator.
The above objects features and advantages of the present invention will become more evident from the following drawings in which:

SHORT DESCRIPTION OF THE DRAWINGS

Figure 1 is a bottom view of a typical human left foot;
Figure 2 is a left foot sandal with toe separators of the present invention adapted for use with the foot of Figure 1;
Figure 3 is a corresponding right foot sandal with the first toe separator having been cut to show the cross section of the toe separator;
Figure 4A is a top perspective view of a composite fabric-memory foam from which the toe separators of the sandals of Figures 2-3 are sized and formed, showing the fabric layer;
Figure 4B is a bottom view of the composite fabric-memory foam of Figure 4, showing the memory foam layer;
Figure 5 depicts a manufactured sheet of six sections of the material with memory foam backing, each of which is separated to make the individual toe separators;
Figure 6 depicts a toe separator material prior to rolling formation, together with a centrally placed stiffener element,
Figure 7A and 7B respectively depict a stitched toe separator element rolled into a seamed tube with straight cut ends and the separator material prior to rolling and stitching;
Figures 7C and 7D respectively depict a section of separator material with skived ends and the rolled seamed tube formed therefrom; and
Figures 8A-C depict various textured surfaces for use as the fabric in the toe separators with massaging functions.

DETAILED DESCRIPTION OF THE INVENTION AND DRAWINGS

A typical human foot 10 is shown in Figure 1 with toes 1-5 (big toe to pinky) and the respective spacings 1a-4a therebetween. The sandal 20 in Figure 2 is conformed to be worn by the foot 10 with spacings 21a, 22a and 23a being conformed to contain toes 2-4 respectively and with big toe 1 and pinky 5 being positioned exterior to toe separator elements 21 and 25 respectively. Toe separator elements 21-24 are affixed to upper strap element 26 and sole 25 to hold them together but are not initially integral with elements 25 and 26 and are comprised of different materials. The toe separator elements 21-24 are shown as being stitched to upper strap element 26. The toe separator elements 21-24 are positioned to respectively separate toes 1 and 2, toes 2 and 3, toes 3 and 4, and toes 4 and 5. Relative positioning of the toe separators 22-24 is generally along diagonal line D-D with toe separator 21 being out of line D-D and below toe separator 22, in conformity with the anatomical configuration of the human foot 10 shown in Figure 1 and the between toe spacings thereof.
In Figure 3 a first toe separator 21' is shown as severed from the sole 25' of sandal 20' to show the cross section 30 of the toe separator. The cross sectioned toe separator 21' has a fabric exterior 32 enclosing and covering memory foam 31 with a stitched section 33 facing the inside of the sandal.
Figures 4A and 4B depict both sides of the sheet 15 used to form the toe separators 21-24 with fabric layer 16 configured to face the outside when the sheet is rolled and the toe separator is formed and with the memory foam layer 17 forming the central core element. Figure 5 depicts a manufactured fabric-foam layer sheet 45 preformed with severable elements 45a-f for the cutting to size and rolling of six toe separator elements. Figure 6 depicts the sheet 15 with an optional then rubber, rigidizing central element 50 for rolling in the formation of the separator elements to provide structural rigidity as required.
Figures 7A and 7B depict the sheet 15 rolled into toe separator 100 with seamed fold 101, without the ends 15a and 15b having been skived. Figures 7C and 7D depict the sheet 15 with skived ends 15c and 15d with formation of toe separator 200.. The seamed fold 201 is of lesser volume and area extent as compared to seamed fold 101 and accordingly provides additional comfort enhancement.
Figures 8A, 8B and 8C depict alternative textured surfaces 61, 71 and 81 of outer facing fabric layers 60, 70 and 80 to provide a massaging effect to the toes in contact therewith.
It is understood that the antimicrobials may be added to any or all of the fabric layers or to any fabric or similar outer layers of toe separators in order to enhance comfort and well being of a wear of sandals with toe separation.
It is understood that the above description and drawings are only illustrative of the present invention and that changes in structure, components and compositions may be made without departing from the scope of the present invention as defined in the following claims.

Claims

An article of footwear comprising a base sole element (25) and an upper element (26) configured to enclose a human foot therebetween, wherein one to four separate and discrete toe separator elements (21-24) fully extend between the base sole element (25) and the upper element (26), wherein each of the one to four toe separator elements (21-24) is comprised of a material tube having two ends, and wherein the material tube is of a circular, elliptical, or oval cross section, without edges, and wherein a cushioning material comprised of at least one of a foam, memory foam and gel is contained within the respective material tube, with one of the two ends of the material tube being attached to the upper element (26) and another of the two ends being attached to the base sole element (25), thereby forming a material tube of a circular, elliptical, or oval cross section, without edges, configured to be a toe separator and wherein the cushioning material is fully enclosed and contained within the material tube between the base sole element (25) and the upper element (26), with each of the separate and discrete one to four toe separator elements (21-24) being configured and positioned to provide a wedging separation between adjacent toes (1-5) of the enclosed human foot (10) and wherein each of the one to four toe separator elements (21-24) is configured to provide a cushioning sensation to the adjacent toes (1-5) in contact therewith.
The article of footwear of claim 1, wherein the one of the two ends of the material tube is sewn to the upper element.
The article of footwear of claim 1, wherein the footwear comprises a sandal (20) with one toe separator element (21), configured and positioned for separation of a big toe (1) and adjacent toe (2) of the human foot (10).
The article of footwear of claim 1, wherein the footwear comprises a sandal (20) with four toe separator elements (21-24), respectively configured and positioned for separation between five toes (1-5) of the human foot (10).
The article of footwear of claim 1, wherein the cushioning material is configured to give with lateral pressure applied by the adjacent toes (1-5) to provide the cushioning sensation and wherein the cushioning material substantially recovers to an initial configuration with removal of the toe (1-5) from contact therewith.
The article of footwear of claim 5, wherein the material tube is comprised of a decorative fabric layer (16).
The article of footwear of claim 6, wherein the fabric layer (16) comprises a textured outer surface configured to provide a massaging effect to adjacent toes (1-5) in contact therewith.
The article of footwear of claim 1, wherein the material tube is comprised of at least one of an antimicrobial, an antibacterial and an antifungal fabric configured to provide respective antimicrobial, antibacterial and antifungal activity treatment to an area between the adjacent toes (1-5) with which the toe separator element (21-24) is in contact.
The article of footwear of claim 6, wherein the cushioning material is comprised of memory foam (31) integrally formed with the fabric layer (16) as a bi- layer material (15), wherein the material tube comprises a sized section of the bi-layer material rolled into a tube, with the rolled tube comprising each toe separator element (21-24), with the fabric layer (16) facing outwardly and with lateral ends of the sized section being seamed together to maintain configuration of the tube and wherein the seam (101, 201) of the tube is positioned to face the foot (10) when the footwear is worn.
The article of footwear of claim 9, wherein the seamed ends (15c, 15d) of the sized section are skived prior to the bi-layer material (15) being rolled into the tube.
The article of footwear of claim 6, wherein the fabric layer (16) comprises an un-seamed tubular enclosure for the cushioning material.
The article of footwear of claim 6, wherein the toe separator element (21-24) includes a centrally and longitudinally positioned stiffener element (50) configured to provide structural support for the cushioning material and fabric tubular enclosure.
The article of footwear of claim 1, wherein the footwear comprises four toe separator elements (21-24) with the cushioning material of each of the toe separator elements (21-24) being comprised of memory foam (31) enclosed within a decorative fabric material comprised of at least one of antimicrobial, antibacterial and antifungal fabric and configured to provide respective antimicrobial, antibacterial and antifungal activity treatment to an area between the adjacent toes (1-5) with which the toe separator elements are respectively in contact.
The article of footwear of claim 1, wherein each of the one to four toe separator elements (21-24) is comprised of at least one of an antimicrobial, antibacterial and antifungal material with each of the one to four toe separator elements being configured to provide respective antimicrobial, antibacterial and antifungal activity treatment directly to an area between the adjacent toes (1-5) with which the toe separator element is in contact.
A method of configuring an article of footwear for prevention of microbial, bacterial and fungal growth between toes of a human foot (10), wherein the article of footwear is an article of footwear according to claim 4, the method comprising the steps of:
a) aligning three adjacent toe separator elements (22-24) of the article of footwear of claim 4, starting from a small toe (5) of the human foot (10) along a distally extending diagonal line and positioning a fourth toe separator element (21) for placement between a big toe (1) and an adjacent toe (2), the fourth toe separator element (21) being out of line from the diagonal line and proximally behind an adjacent toe separator element (22), the toe separator elements (21-24) being positioned in conformity with the anatomical configuration of the human foot (10);

b) attaching all toe separator elements (21-24) to the upper element (26) and the base sole element (25);

c) providing the tube material of the four toe separator elements (21-24) as one of an antimicrobial, antibacterial and antifungal fabric; and

d) providing the article of footwear for placement on a human foot (10) such that the toe separator elements (21-24) provide a wedging separation between adjacent toes (1-5) of the human foot (10).