Shoe Having A Midsole With Heel Support

Abstract

Shoes having midsoles with heel support, specifically designed to facilitate production via efficient shoe manufacturing methods and systems are described. In embodiments, the shoe upper is designed by way of a flat forming process. Additionally, in embodiments upper forms may be coupled with dual hardness midsole structures that provide heel support and eliminate the need for a heel counter in the shoe upper.

1 . A shoe designed to facilitate a system for manufacturing shoes customized to an order placed by a customer, the shoe comprising: an upper, a midsole affixed to the upper, the midsole comprising: a heel region extending around at least a portion of a wearer's heel in an as worn position, the heel region having a first hardness, and a midsole bed region extending substantially under a wearer's foot in an as worn position, the midsole bed region having a second hardness; and an outsole affixed to the midsole opposing the upper. 
     
     
         2 . The shoe of  claim 1 , wherein the upper is manufactured by way of a flat forming process whereby the upper is maintained in a two-dimensional shape during its manufacture. 
     
     
         3 . The shoe of  claim 1 , wherein a hardness of the heel region is greater than the hardness of the midsole bed region. 
     
     
         4 . The shoe of  claim 1 , wherein the upper includes a first heel element and a second heel element that is wrapped around the first heel element and secured into place. 
     
     
         5 . The shoe of  claim 1 , wherein a hardness of the midsole bed region depends on a shoe type. 
     
     
         6 . The shoe of  claim 1 , wherein the midsole bed region is formed by heat treating a plurality of pre-formed phylon biscuits. 
     
     
         7 . The shoe of  claim 1 , wherein the midsole bed region is comprised of an upper midsole portion having a first hardness and a lower midsole portion having a second hardness wherein the upper and lower midsole portions are affixed. 
     
     
         8 . A shoe having a midsole with heel support manufactured according to a method comprising: securing an upper midsole portion having a first hardness to a lower midsole portion having a second hardness; aligning an upper component having a first heel element and a second heel element with a midsole component having the upper midsole portion and the lower midsole portion, wherein the midsole component has a heel region extending around at least a portion of a wearer's heel; affixing the upper component to the midsole component; and securing the first heel element to the second heel element, wherein the first heel element and the second heel element cover at least a portion of the heel region. 
     
     
         9 . The shoe of  claim 8 , wherein the midsole component is affixed to the upper component by way of a flange secured to the midsole component. 
     
     
         10 . The shoe of  claim 9 , wherein the flange extends at least partially around a perimeter of the midsole component. 
     
     
         11 . The shoe of  claim 9 , wherein the flange has a different hardness than other portions of the midsole component. 
     
     
         12 . The shoe of  claim 8 , wherein the heel region has a greater hardness than other portions of the midsole component. 
     
     
         13 . The shoe of  claim 8 , wherein the first heel element overlaps at least a portion of the second heel element. 
     
     
         14 . The shoe of  claim 8 , wherein the first heel element and the second heel element do not overlap such that they are flush and are secured together by way of one or more stitches. 
     
     
         15 . The shoe of  claim 8 , wherein the midsole component is made of a dual hardness phylon. 
     
     
         16 . The shoe of  claim 8 , further comprising securing the midsole component to an outsole component. 
     
     
         17 . A shoe designed to facilitate a system for manufacturing shoes customized to an order placed by a customer, the shoe comprising: a midsole affixed to an upper, the midsole comprising: a first midsole layer that includes a heel region that extends around at least a portion of a wearer's heel in an as worn position; a second midsole layer that is affixed to the first midsole layer and that is underneath the first midsole layer in an as worn position; and an attachment flange that covers at least a portion of a perimeter of the first midsole layer and that is located above the first midsole layer in an as worn position. 
     
     
         18 . The shoe of  claim 17 , wherein the first midsole layer has a first hardness and the second midsole layer has a second hardness. 
     
     
         19 . The shoe of  claim 17 , wherein a hardness of the heel region is greater than the hardness of other regions of the midsole. 
     
     
         20 . The shoe of  claim 17 , wherein the upper is affixed to the attachment flange by way of one or more of gluing, stitching, or welding.