MOLDED FOOTBED WITH INTEGRALLY FORMED MASSAGING DOMES

A footbed according to an embodiment of the present disclosure includes: a top surface; a bottom surface; a plurality of domes formed in the footbed, the plurality of domes protruding at the top surface; each of the plurality of domes having an outer diameter at the top surface and a cavity formed under the dome, the cavity extending to the bottom surface; a first set of the plurality of domes each having a first outer diameter at the top surface; a second set of the plurality of domes each having a second outer diameter at the top surface; wherein the first outer diameter is larger than the second outer diameter, and wherein the footbed is a single piece of injection molded foam material.

TECHNICAL FIELD

Embodiments of the present disclosure relate generally to footwear, and more particularly to a footbed and outsole construction and assembly.

BACKGROUND

Existing massaging footbeds often include stiff protrusions that often sacrifice foot massaging performance for overall comfort. Massaging footbed elements are often solid nubs can cause irritation and discomfort, particularly for users whose feet are not accustomed to such footbeds.

SUMMARY

A footbed according to an embodiment of the present disclosure includes: a top surface; a bottom surface; a plurality of domes formed in the footbed, the plurality of domes protruding at the top surface; each of the plurality of domes having an outer diameter at the top surface and a cavity formed under the dome, the cavity extending to the bottom surface; a first set of the plurality of domes each having a first outer diameter at the top surface; a second set of the plurality of domes each having a second outer diameter at the top surface; wherein the first outer diameter is larger than the second outer diameter, and wherein the footbed is a single piece of injection molded foam material.

The footbed of Example 1, the first set of the plurality of domes each having a first inner diameter at the bottom surface, wherein the first inner diameter is smaller than the first outer diameter.

The footbed of any of Examples 1 to 2, the second set of the plurality of domes each having a second inner diameter at the bottom surface, and wherein the first inner diameter is larger than the second inner diameter.

The footbed of any of Examples 1 to 3, wherein the top surface comprises a heel region, a midfoot region, and a forefoot region, the heel region configured to engage a user's heel and the forefoot region configured to engage a user's forefoot during use of the footbed; wherein the heel region comprises more of the first set of the plurality of domes than the second set of the plurality of domes.

The footbed of any of Examples 1 to 4, wherein the heel region does not include any of the second set of the plurality of domes, and wherein the forefoot region does not include any of the first set of the plurality of domes.

The footbed of any of Examples 1 to 5, further comprising: a third set of the plurality of domes each having a third outer diameter at the top surface, wherein the second outer diameter is larger than the third outer diameter.

The footbed of any of Examples 1 to 6, wherein the top surface comprises a heel region, a midfoot region, and a forefoot region, the heel region configured to engage a user's heel and the forefoot region configured to engage a user's forefoot during use of the footbed, the midfoot region situated between the heel region and the forefoot region; wherein the heel region comprises more of the first set of the plurality of domes than the second and third sets of the plurality of domes; wherein the forefoot region comprises more of the second set of the plurality of domes than the first and third sets of the plurality of domes; and wherein the midfoot region comprises more of the third set of the plurality of domes than the first and second sets of the plurality of domes.

The footbed of any of Examples 1 to 7, wherein, along a length from a heel end toward a toe end of the footbed, the heel region comprises a first third of the length, the midfoot region comprises a second third of the length, and the forefoot region comprises a third third of the length.

The footbed of any of Examples 1 to 8, wherein the first set of the plurality of domes is situated only at the heel region or between the heel region and the midfoot region; wherein the second set of the plurality of domes is situated only at the forefoot region or between the forefoot region and the midfoot region and between the midfoot region and the heel region; and wherein the third set of the plurality of domes is situated only at the midfoot region or between the midfoot region and the heel region or between the midfoot region and the forefoot region.

The footbed of any of Examples 1 to 9, wherein the first outer diameter is at least five millimeters, and wherein the first outer diameter is fifteen to seventy-five percent larger than the second outer diameter.

The footbed of any of Examples 1 to 10, wherein the first inner diameter is at least four millimeters.

The footbed of any of Examples 1 to 11, wherein a thickness of each of the plurality of domes between the top surface and the cavity is between 1 and 2.5 millimeters.

The footbed of any of Examples 1 to 12, wherein a bottom surface of each of the plurality of domes is flush with the top surface.

A footwear system according to an embodiment of the present disclosure comprises a footbed comprising: a footbed top surface; a footbed bottom surface; a plurality of domes formed in the footbed, the plurality of domes protruding at the footbed top surface; each of the plurality of domes having an outer diameter at the top surface and a cavity formed under the dome, the cavity extending to the footbed bottom surface; a first set of the plurality of domes each having a first outer diameter at the footbed top surface; a second set of the plurality of domes each having a second outer diameter at the footbed top surface; wherein the first outer diameter is larger than the second outer diameter, and wherein the footbed is a single piece of injection molded foam material; and an outsole comprising: an outsole top surface; and an outsole bottom surface, wherein the outsole top surface is adhered to the footbed bottom surface such that the cavity of each of the plurality of domes entraps air in the cavity during use.

The footwear system of any of Examples 1 to 14, wherein the cavity of each of the plurality of domes permanently entraps air, such that the entrapped air provides greater resistance to deformation of each of the plurality of domes than each of the plurality of domes would exhibit without such air entrapment.

The footwear system of any of Examples 1 to 15, wherein each cavity of the plurality of domes is not in fluid communication with other cavities of the plurality of domes.

The footwear system of any of Examples 1 to 16, wherein the top surface comprises a heel region, a midfoot region, and a forefoot region, the heel region configured to engage a user's heel and the forefoot region configured to engage a user's forefoot during use of the footbed; wherein the forefoot region does not include any of the first set of the plurality of domes.

The footwear system of any of Examples 1 to 17, further comprising: a third set of the plurality of domes each having a third outer diameter at the top surface, wherein the second outer diameter is larger than the third outer diameter.

The footwear system of any of Examples 1 to 18, wherein the top surface comprises a heel region, a midfoot region, and a forefoot region, the heel region configured to engage a user's heel and the forefoot region configured to engage a user's forefoot during use of the footbed, the midfoot region situated between the heel region and the forefoot region; wherein the heel region comprises more of the first set of the plurality of domes than the second and third sets of the plurality of domes; wherein the forefoot region comprises more of the second set of the plurality of domes than the first and third sets of the plurality of domes; and wherein the midfoot region comprises more of the third set of the plurality of domes than the first and second sets of the plurality of domes.

The footwear system of any of Examples 1 to 19, wherein the first set of the plurality of domes is situated only at the heel region or between the heel region and the midfoot region; wherein the second set of the plurality of domes is situated only at the forefoot region or between the forefoot region and the midfoot region or between the midfoot region and the heel region; and wherein the third set of the plurality of domes is situated only at the midfoot region or between the midfoot region and the heel region or between the midfoot region and the forefoot region.

DETAILED DESCRIPTION

FIGS. 1-7illustrate a footbed10according to an embodiment of the present disclosure. The footbed10may include a top surface50, a bottom surface60, and a plurality of domes20formed in the footbed. The footbed10may further include corresponding cavities70at the bottom surface60under one or more of the domes20. The plurality of domes20protrudes at the top surface50. The domes20may be formed of different sizes; for example, a first dome or set of domes22may have a first outer diameter at the top surface50; a second dome or set of domes24may have a second outer diameter at the top surface50that is smaller than the outer diameter of the domes22; and a third dome or set of domes26may have a third outer diameter at the top surface50that is smaller than the outer diameter of domes24, according to an embodiment of the present disclosure. Footbed10may also include a protruding island32that extends under the base of the toes of the wearer, as well as a hole34configured to receive a toe bar, for example as used with sandal-type footwear. The top surface50may further include a raised bump pattern36. The footbed10may further include a large heel dome40with an optional corresponding cavity42on the bottom surface60, according to an embodiment of the present disclosure.

According to an embodiment of the present disclosure, and as illustrated inFIGS. 8-11, each of the plurality of domes20has an outer diameter at the top surface and a cavity70formed under the dome, the cavity70extending to the bottom surface60. A first set of the plurality of domes22may each have a first outer diameter OD1at the top surface50; a second set of the plurality of domes24may each have a second outer diameter OD2at the top surface50; and the first outer diameter OD1may be larger than the second outer diameter OD2.

As illustrated, the footbed10is a single piece of injection molded foam material; in other words, the footbed10and each of the plurality of domes20and cavities70is formed integrally as a single piece of injection molded foam material. Footbed10may alternatively be described as unitary, monolithic, homogeneous, and/or integral, according to embodiments of the present disclosure. In one embodiment of the present disclosure, all elements shown inFIGS. 1-11are formed integrally as a single piece of injection molded foam material, and, in some embodiments, all elements shown inFIGS. 1-11are unitary, monolithic, homogeneous, and/or integral. In an embodiment of the present disclosure, forming the footbed10as a single piece of molded foam material adds comfort and durability while permitting the integrally formed domes to perform massaging and/or cushioning functions.

FIG. 12illustrates an exemplary pressure profile for a human foot while standing, during the act of walking. When comparing the heel area, the midfoot area, and the forefoot area, the highest pressure concentration is in the heel area, followed by the forefoot area, followed by the midfoot area. Given this typical pressure profile, an embodiment of the footbed10of the present disclosure includes domes having a larger outer diameter at the top surface in the heel area (whereFIG. 12indicates “big bubbles”), includes domes having a smaller outer diameter at the top surface in the forefoot area (whereFIG. 12indicates “medium bubble”), and includes domes having an even smaller outer diameter at the top surface in the midfoot area (whereFIG. 12indicates “small bubbles”). The larger the domes, which may alternatively be referred to as bubbles and/or air pockets and/or gas pockets, the greater the degree of cushioning effect applied to the bottom of the user's foot when the user steps on and/or is using the footbed10. The smaller the domes, the lesser the degree of cushioning effect applied to the bottom of the user's foot when the user steps on and/or is using the footbed10. As such, using large domes at the heel area, medium domes at the forefoot area, and small domes at the midfoot area provides a massaging effect on the bottom of the foot, while simultaneously providing cushioning and relative pressure distribution across the footbed10from heel to midfoot to forefoot, according to an embodiment of the present disclosure.

FIG. 8illustrates examples of outer diameters for various domes. For example, outer diameter OD1of domes22may be 9.98 millimeters (mm), outer diameter OD2of domes24may be 8.46 mm, and outer diameter OD3of domes26may be 5.81 mm. Other dimensions, ranges of dimensions, and/or relative dimensions are both possible and contemplated by the present disclosure. According to an embodiment of the present disclosure, the first set of the plurality of domes22may each have a first inner diameter ID1at the bottom surface60, and the first inner diameter ID1may be smaller than the first outer diameter OD1. For example,FIG. 9shows a first inner diameter ID1as 8.24 mm, although other dimensions, ranges of dimensions, and/or relative dimensions are both possible and contemplated by the present disclosure.

FIG. 9further shows that a height H1of the cavity70formed under dome22may be 16.13 mm, and the thickness T1of dome22may be 1.99 mm, although other dimensions, ranges of dimensions, and/or relative dimensions are both possible and contemplated by the present disclosure.FIG. 10shows that an inner diameter ID2may be 6.62 mm, height H2of the cavity70formed under dome24may be 11.25 mm, and the thickness T2of dome24may be 2.36 mm, although other dimensions, ranges of dimensions, and/or relative dimensions are both possible and contemplated by the present disclosure.FIG. 11shows that an inner diameter ID3may be 4.51 mm, height H3of the cavity70formed under dome26may be 8.53 mm, and the thickness T3of the dome26may be 1.30 mm, although other dimensions, ranges of dimensions, and/or relative dimensions are both possible and contemplated by the present disclosure.

According to an embodiment of the present disclosure, the second set of the plurality of domes24each has a second inner diameter ID2at the bottom surface60, and the first inner diameter ID1is larger than the second inner diameter ID2.

As illustrated by the boundary lines80,82ofFIG. 2, the top surface50of the footbed10may include a heel region90, a midfoot region94, and a forefoot region92. Boundary80illustrates an exemplary boundary between the heel region90(or heel section90or heel portion90) and the midfoot region94(or midfoot section94or midfoot portion94). Boundary82illustrates an exemplary boundary between the midfoot region94and the forefoot region92(or forefoot section92or forefoot portion92), according to an embodiment of the present disclosure. One of ordinary skill in the art, based on the present disclosure, will understand that such imaginary boundaries80,82may be situated in different places depending on the type and size of footbed, while still serving as boundaries between such heel, midfoot, and forefoot areas as understood by one of ordinary skill in the art. As another non-limiting example, along a length from a heel end84toward a toe end86of the footbed, the heel region comprises a first third of the length, the midfoot region comprises a second third of the length, and the forefoot region comprises a third third of the length.

The heel region90is configured to engage a user's heel and the forefoot region92is configured to engage a user's forefoot during use of the footbed10, according to an embodiment of the present disclosure. According to one embodiment, the heel region90includes more of the first set of the plurality of domes22than the second set of the plurality of domes24. According to some embodiments of the present disclosure, the heel region90does not include any of the second set of the plurality of domes24, and the forefoot region92does not include any of the first set of the plurality of domes22. According to some embodiments of the present disclosure, boundaries80and/or82are straight.

According to an embodiment of the present disclosure, the footbed10includes a third set of the plurality of domes26each having a third outer diameter ID3at the top surface50. According to such embodiments, the second outer diameter OD2is larger than the third outer diameter OD3.

As described above, the top surface50, and/or the footbed itself10, comprises a heel region90, a midfoot region94, and a forefoot region92, the heel region90configured to engage a user's heel and the forefoot region92configured to engage a user's forefoot during use of the footbed, the midfoot region94situated between the heel region90and the forefoot region92, according to an embodiment of the present disclosure. The heel region90may include more of the first set of the plurality of domes22than the second24and third sets of the plurality of domes26; and the forefoot region92may include more of the second set of the plurality of domes24than the first22and third sets of the plurality of domes26; and the midfoot region may include more of the third set of the plurality of domes26than the first22and second sets of the plurality of domes24, according to an embodiment of the present disclosure.

According to an embodiment of the present disclosure, the first set of the plurality of domes22is situated only at the heel region90or between the heel region90and the midfoot region94; he second set of the plurality of domes24is situated only at the forefoot region92or between the forefoot region92and the midfoot region94and between the midfoot region94and the heel region90; and the third set of the plurality of domes26is situated only at the midfoot region94or between the midfoot region94and the heel region90or between the midfoot region94and the forefoot region92, for example as shown inFIGS. 1-8.

According to an embodiment of the present disclosure, the first outer diameter OD1is at least five millimeters, and the first outer diameter OD1is fifteen to seventy-five percent larger than the second outer diameter OD2. According to another embodiment of the present disclosure, the first outer diameter OD1is at least four millimeters. According to another embodiment of the present disclosure, the first outer diameter OD1is fifteen to twenty-five percent larger than the second outer diameter OD2. According to another embodiment of the present disclosure, the first outer diameter OD1is ten to thirty percent larger than the second outer diameter OD2. According to an embodiment of the present disclosure, the first inner diameter ID1is at least four millimeters. According to an embodiment of the present disclosure, first outer diameter OD1is sixty-five to eighty percent larger than the third outer diameter OD3. According to an embodiment of the present disclosure, the first outer diameter OD1is sixty to eighty-five percent larger than the third outer diameter OD3.

According to some embodiments of the present disclosure, a thickness of each of the plurality of domes between the top surface and the cavity (for example, T1, T2, and/or T3) is between 1 and 2.5 millimeters. According to some embodiments of the present disclosure, a thickness of each of the plurality of domes between the top surface and the cavity (for example, T1, T2, and/or T3) is between 0.5 and 3.0 millimeters. According to some embodiments of the present disclosure, a bottom surface72of each of the plurality of domes20is flush with the top surface50. According to some embodiments of the present disclosure, a ratio of an overall height (for example, H1, H2, and/or H3) of each cavity70with respect to a thickness (for example, T1, T2, and/or T3) of the dome at the top of each cavity70is between four and eight. According to some embodiments of the present disclosure, a ratio of an overall height (for example, H1, H2, and/or H3) of each cavity70with respect to a thickness (for example, T1, T2, and/or T3) of the dome at the top of each cavity70for the highest instance of each cavity70of the sets22,24,26is between four and eight.

As illustrated byFIGS. 1-11 and 16, a footwear system100according to an embodiment of the present disclosure includes a footbed10including a footbed top surface50, a footbed bottom surface60, a plurality of domes20formed in the footbed10, with the plurality of domes20protruding at the footbed top surface50. The plurality of domes may each include an outer diameter at the top surface50and a cavity70formed under the dome20, the cavity70extending to the footbed bottom surface60. In some embodiments, a first set of the plurality of domes22each has a first outer diameter OD1at the footbed top surface50and a second set of the plurality of domes24each has a second outer diameter OD2at the footbed top surface50. According to such embodiments, the first outer diameter OD1is larger than the second outer diameter OD2, and the footbed10is a single piece of injection molded foam material. A footbed system100according to an embodiment of the present disclosure may further include an outsole101including an outsole top surface102, and an outsole bottom surface104. As illustrated inFIG. 16, the outsole top surface102is adhered to the footbed bottom surface60such that the cavity70of each of the plurality of domes20entraps air in the cavity during use.

According to an embodiment of the present disclosure, the cavity70of each of the plurality of domes20permanently entraps air, such that the entrapped air provides greater resistance to deformation of each of the plurality of domes20than each of the plurality of domes20would exhibit without such air entrapment.FIG. 16illustrates a user's heel UH compressing the plurality of domes20and the footbed10as the user steps on the footbed10while the footbed is adhered to the outsole101. According to one embodiment of the present disclosure,FIG. 16shows the cavities70and the air or gas therein being compressed by the weight of the user as transmitted through the user's heel UH (which may also be referred to as the user's foot). As shown inFIG. 16, a compression force applied to the top of the system100causes the overall height of one or more of the domes20to decrease, and/or causes the dome portion over each cavity70to become compressed and/or deformed such that it becomes flush or closer to flush with a top surface50of the footbed10, according to one embodiment of the present disclosure. According to some embodiments of the present disclosure, the cavities70of entrapped or entrained air or gas exhibit a greater resistance to deformation than the injection molded foam material in the footbed10surrounding such cavities70, thus permitting the domes20and the cavities70over which the domes20extend to exhibit both a cushioning and a massaging quality or performance with respect to the bottom of the user's foot.

According to an embodiment of the present disclosure, each cavity70of the plurality of domes20is not in fluid communication with other cavities70of the plurality of domes20. According to some embodiments of the present disclosure, the top surface50comprises a heel region90, a midfoot region94, and a forefoot region92, the heel region90being configured to engage a user's heel and the forefoot region92being configured to engage a user's forefoot during use of the footwear system100. According to such embodiments, the forefoot region94does not include any of the first set of the plurality of domes22.

FIGS. 13-15illustrate a method of creating footwear system100, according to an embodiment of the present disclosure. After the outsole101and footbed10are molded, for example via an injection (e.g. a single injection) molding process, an adhesive or bonding agent may be applied (e.g. brushed) onto a top surface102of the outsole101, as illustrated inFIG. 13. An adhesive or bonding agent may be applied (e.g. brushed) onto a bottom surface60of footbed10, as illustrated inFIG. 14. The footbed10may be placed onto the outsole101as illustrated inFIG. 15, in which the bottom surface60of footbed10is placed into contact with the top surface102of outsole101. An optional step or steps may include activating the adhesive via light, for example ultraviolet light, and/or via other energy source such as ultrasonic energy or heat, according to an embodiment of the present disclosure. In one embodiment, the adhesive or bonding agent is activated by ambient air and/or by one or more chemicals applied to the bottom surface60and/or top surface102and/or contained within the adhesive or bonding agent. According to embodiments of the present disclosure, other methods may be used to join or couple the bottom surface60of the footbed10with the top surface102of the outsole101. Such joining or coupling creates an air-tight or hermetic seal around the cavity70of one or more, or the entire plurality of, domes20, according to an embodiment of the present disclosure. According to an alternative embodiment of the present disclosure, the seal between the bottom surface60and the top surface102is not hermetic and/or is not sufficient, for any or necessarily all of the cavities70, to prevent passage of gas (e.g. air) into or out of the cavity70upon compression or expansion of (e.g. walking on) the domes20of the footbed10, but which still creates a deformation resistance of the cavity70that is greater than the deformation resistance of the cavity70had the bottom surface60not have been joined to the top surface102.

According to an embodiment of the present disclosure, the footwear system100includes a third set of the plurality of domes26each having a third outer diameter OD3at the top surface50, with the second outer diameter OD2being larger than the third outer diameter OD3. According to some embodiment of the present disclosure, the footwear system100includes a heel region90, a midfoot region94, and a forefoot region92, the heel region90being configured to engage a user's heel and the forefoot region94being configured to engage a user's forefoot during use of the footbed10, the midfoot region92situated between the heel region90and the forefoot region92; wherein the heel region90includes more of the first set of the plurality of domes22than the second24and third26sets of the plurality of domes, wherein the forefoot region92includes more of the second24set of the plurality of domes than the first22and third26sets of the plurality of domes, and wherein the midfoot region94includes more of the third26set of the plurality of domes than the first22and second24sets of the plurality of domes.

According to some embodiments of the present disclosure, the first22set of the plurality of domes is situated only at the heel region90or between the heel region90and the midfoot region94, the second set24of the plurality of domes is situated only at the forefoot region92or between the forefoot region92and the midfoot region94or between the midfoot region94and the heel region90, and the third set26of the plurality of domes is situated only at the midfoot region94or between the midfoot region94and the heel region90or between the midfoot region94and the forefoot region92.

FIGS. 17-20illustrate another embodiment of the present disclosure in which the outer diameter of the domes decreases from the heel end toward the toe end, for example from a “low pressure” (large outer diameter domes) region near the heel region, a “mid pressure” (medium outer diameter domes) region near the midfoot region, and a “high pressure” (smaller diameter domes) region near the forefoot region.FIG. 18illustrates six different outer diameter sized sets of domes (decreasing in outer diameter from the heel end toward the toe end), andFIG. 19illustrates an exemplary cross-sectional view of such footbed.FIG. 20illustrates examples of each of the six different outer diameter sized sets of domes ofFIGS. 17-19, according to an embodiment of the present disclosure.

According to embodiments of the present disclosure, the cavities70and/or the domes20above them, formed in the footbed10, are resilient, such that they resume their original shape after foot pressure is released (e.g. after being compressed). According to some embodiments, they do so even after repeated cycles, for example in a dynamic compression set test of 500,000 cycles of compression. According to another embodiment of the present disclosure, they footbed10does not become delaminated from the outsole101during use, including after repeated cycles, for example after one hundred thousand cycles of flexing of the footbed to an angle of sixty degrees at a temperature of twenty-three degrees Celsius. According to an embodiment of the present disclosure, the inclusion of a plurality of domes20and corresponding cavities70under the domes20results in a footbed10that is at least fifteen percent lighter, in other words weighs at least fifteen percent less, than if the cavities70had been filled in with molded foam material, for example with the same molded foam material out of which the rest of the footbed10has been constructed. The presence of a plurality of domes20further promotes air ventilation below the foot, for example by creating air channels below the foot and above the top surface50, according to an embodiment of the present disclosure. Molding the footbed10as a single piece of molded material, for example a closed-cell foam material, also promotes durability, ease of cleaning and drying, and/or odor resistance.

The footbed10and/or the outsole101may be injection molded, for example each with a two- or three-piece spring loaded injection mold, with resin molded foam, for example with ethylene vinyl acetate (EVA), according to an embodiment of the present disclosure. Such foam molding process may result in the footbed10and/or outsole101expanding immediately following injection, prior to contraction and/or cooling, for example. Footbed10and/or outsole101may alternatively be injection molded, and/or molded, via other molding processes as would be appreciated by one of ordinary skill in the art, based on the present disclosure.