Footwear with a hybrid outsole structure

Abstract

A hybrid outsole construction comprises high-density carbon rubber molded to low-density blown rubber, providing increased flexibility, cushion, and comfort while maintaining durability, traction, and shock absorbency of the footwear. In accordance with another aspect of the present invention, the hybrid outsole construction is stitched to the upper layers of the footwear, for example using a welt.

What is claimed is:  
     
         1 . A shoe including an upper portion and an outsole portion coupled to the upper portion, the outsole portion comprising: 
 an outer sole layer formed from a substantially wear resistant material for traction on a walking surface, wherein the outer sole layer includes a shaped hole defined through the outer sole layer; and    an inner sole layer formed from a substantially resilient cushioning material, wherein the inner sole layer is disposed between the outer sole layer and the upper portion, wherein a portion of the inner sole layer extends through the shaped hole in the outer sole layer.    
     
     
         2 . The shoe of  claim 1 , wherein the outer sole layer includes a plurality of treads, and wherein the portion of the inner sole layer extending through the shaped hole defines a tread.  
     
     
         3 . The shoe of  claim 2 , wherein the inner sole layer comprises a heel section and a toe section, wherein the heel section is substantially thicker than the toe section.  
     
     
         4 . The shoe of  claim 1 , wherein the upper portion and the outsole portion are coupled by stitching a welt to the upper portion and the outsole portion.  
     
     
         5 . The shoe of  claim 3 , wherein the sides of the inner sole layer are exposed, so to allow the inner sole layer to deform out through the sides of the outer sole layer under the weight of a wearer.  
     
     
         6 . The shoe of  claim 5 , further comprising an upper sole layer disposed between the upper portion and the inner sole layer.  
     
     
         7 . The shoe of  claim 6 , wherein the wear resistant material comprises carbon rubber, and the resilient material comprises blown rubber.  
     
     
         8 . A footwear comprising: 
 an upper portion; and    a lower portion coupled to the upper portion, said lower portion having a toe section and a heel section, and comprising an outsole portion having a hybrid structure that includes an outer layer for traction on a walking surface and made of a wear resistant material, and an inner layer for cushioning made of a resilient material softer than the wear resistant material, wherein the outer layer covers entirely the front of the toe section and rear of the heel section of the inner layer, but exposing lateral sides of the inner layer.    
     
     
         9 . The footwear as in  claim 8 , wherein the lower portion defines an arch area, at which the outer layer exposes the inner layer.  
     
     
         10 . The footwear as in  claim 8 , wherein the exposed lateral sides of the inner layer has a convex profile in the absence of the weight of a user, and a concave profile under the weight of the user.  
     
     
         11 . The footwear as in  claim 8 , wherein the upper portion and the lower potion are coupled by stitching.  
     
     
         12 . The footwear as in  claim 11 , wherein the upper portion and the lower portion are coupled by stitching a welt to the upper portion and lower portion.  
     
     
         13 . The footwear as in  claim 8 , wherein the exposed lateral side of the inner layer is recessed from an edge of the outer layer.  
     
     
         14 . The footwear as in  claim 8 , wherein the resilient material comprises blown rubber, and the wear resistant material comprises carbon rubber.  
     
     
         15 . A footwear comprising: 
 an upper portion; and    a lower portion coupled to the upper portion, and comprising an outsole portion having a hybrid structure that includes an outer layer for traction on a walking surface and made of a wear resistant material, and an inner layer for cushioning made of a resilient material softer than the wear resistant material;    wherein the upper portion is coupled to the lower portion by stitching a welt to the upper portion and the lower portion.    
     
     
         16 . The footwear as in  claim 15 , wherein the inner layer includes an exposed lateral side recessed from an edge of the outer layer.  
     
     
         17 . The footwear as in  claim 15 , wherein the exposed lateral side of the inner layer has a convex profile in the absence of the weight of a user, and a concave profile under the weight of the user.  
     
     
         18 . The footwear as in  claim 15 , wherein the resilient material comprises blown rubber, and the wear resistant material comprises carbon rubber.  
     
     
         19 . The footwear as in  claim 15 , wherein the lower portion defines an arch area, at which the outer layer exposes the inner layer.