Patent Description:
A sockliner is a piece of a material, usually thin, within a shoe or other article of footwear that contacts at least the bottom (plantar) portion of the foot when the shoe is worn. The sockliner may be removable, as for wearer preference or for washing the sockliner and/or the shoe, or may be unitary to the shoe. A sockliner may provide cushioning, warmth, improved fit, or other benefits. Ideally, the sockliner fits tightly inside the shoe. If the sockliner is too large, it may wrinkle or pucker. If the sockliner is too small, it may move within the shoe during donning or wear. In either case, an ill-fitting sockliner may be uncomfortable and/or unsightly. If the sockliner is sized to fit precisely into the shoe, the function and appearance of the sockliner improves, but the sockliner may be difficult to position into the shoe during manufacture.

<CIT> describes a shoe insole with a reinforcement layer enclosed between a top layer and a base and a method for making the insole with less number of procedures and suitable for mass production.

<CIT> describes a footwear system having a sock and a shoe for interfacing with the sock.

<CIT> describes a method for producing three-dimensional insoles with support for shoe, which involves compressing only one of elastic material layers into deeper level of depth of base walls of shaped mold cavities, during compression of material in cavities.

The claimed invention is defined by the features set out in the independent claim. Particular embodiments of the claimed invention are defined by the dependent claims. This brief summary is provided as a general overview of the more detailed disclosure which follows. It is not intended to identify key or essential elements of the disclosure, or to define the claim in isolation from the remainder of the disclosure, including the drawings.

The present disclosure references the attached drawing figures, wherein:.

As used herein, "sockliner" refers to a layer of material inside a shoe, on top of an insole or possibly in lieu of an insole, which may be unitary to and irremovable from the shoe or removable from the shoe. As used herein, "sockliner" does not refer to a stocking or other thin garment which may be worn against the foot and under a sock, the sock being worn over both the foot and the stocking.

As used herein, "shoe" may include a broad range of footwear, including, without limitation, boots (including, without limitation, dress boots, snow boots, ski boots, equestrian boots, work boots, and the like), flats, pumps, wedges, athletic shoes (including, without limitation, soccer shoes, baseball shoes, basketball shoes, golf shoes, running shoes, walking shoes, and the like), studio shoes (including, without limitation, dance shoes and studio wraps), slippers, and casual or fashion shoes. The sockliner described herein could be adapted for variations of any of these kinds of shoe, as well as some styles of sandals.

<FIG> shows an exemplary sockliner <NUM> according to aspects of this disclosure. The view is a sectional side view, with the solid lines indicating the shape of the sockliner <NUM> when it has conformed to the interior of a shoe (an "in-use conformation" <NUM>), and the dashed lines indicating the shape of the sockliner <NUM> in a relaxed conformation <NUM>. The relaxed conformation <NUM> may reflect the shape in which the sockliner <NUM> is manufactured, as described below. When placed inside a shoe, the sockliner <NUM> may take on an in-use conformation <NUM>. The relaxed conformation <NUM> and the in-use conformation <NUM> are different conformations that may be assumed under different conditions by the same sockliner <NUM>.

As shown, in the relaxed conformation <NUM>, sockliner <NUM> has a medial side <NUM>, which runs between an upper medial edge <NUM> and a lower medial edge <NUM>. The medial side <NUM> corresponds to the medial side of a right foot (e.g., a human foot). A sockliner for a left foot could be substantially a mirror image of the sockliner <NUM>. In the relaxed conformation <NUM>, medial side <NUM>, as shown, has a generally concave curvature relative to a center of the sockliner <NUM>. When pressed or placed into a shoe or shoe sole, as described in greater detail below, the sockliner <NUM> may assume in-use conformation <NUM>, having medial side 159B which runs between an upper medial edge 151B and a lower medial edge 153B. In the in-use conformation <NUM>, medial side 159B, as shown, is generally flat, and might even be slightly convex. Similarly, in the relaxed conformation <NUM>, sockliner <NUM> has a lateral side <NUM> which runs between an upper lateral edge <NUM> and a lower lateral edge <NUM>. In the relaxed conformation <NUM>, lateral side <NUM> may have a surface which is generally concave relative to a center of sockliner <NUM>. In the in-use conformation <NUM>, the lateral side 163B may be generally flat or even slightly convex, and may run between upper lateral edge 157B and lower lateral edge 155B.

Sockliner <NUM> further has a bottom-facing side or bottom surface <NUM>, which, in the relaxed conformation <NUM> runs between lower medial edge <NUM> and lower lateral edge <NUM>, and may be generally concave relative to a center of sockliner <NUM>. In the in-use conformation <NUM>, bottom surface 161B runs between lower medial edge 153B and lower lateral edge 155B, and may be generally flat or even slightly convex. Sockliner <NUM> has a top-facing (e.g., foot-facing) side or top surface <NUM>, which, in the relaxed conformation <NUM> runs between upper medial edge <NUM> and upper lateral edge <NUM>, and may be generally flat. In the in-use conformation <NUM>, top-facing side or top surface 165B runs between upper medial edge 151B and upper lateral edge 157B, and may be generally concave relative to a center of sockliner <NUM>.

As shown in <FIG>, an exemplary shoe <NUM> may have an upper <NUM> and a sole <NUM>. Upper <NUM> may include a number of subunits, such as a tongue, a closure, padding or cushioning, and the like. Many variations of uppers, in structure and material, are known in the art and could be used with the sockliner described herein. Sole <NUM> may comprise two or more layers, such as an outsole, midsole, and/or insole (if an insole separate from sockliner <NUM> is present). An outsole typically includes the ground-contacting surface of shoe <NUM> when the shoe is worn. The outsole may provide traction, water-resistance or water-proofing, wear- and/or puncture-resistance, stability, and/or other protection for the foot or ankle. A midsole, which might or might not be visible in the finished shoe, generally provides cushioning. Some midsole structures may use combinations of materials, possibly including stiffening materials, to provide variable support and cushioning over the width and/or length of the shoe. A midsole may also contribute to the stability of the foot within the shoe.

An insole, which might or might not be visible in the finished shoe, or might be visible only when viewing interior <NUM> of shoe <NUM>, may provide additional cushioning, arch support, or other support and/or comfort. A sockliner <NUM> may be used with an insole, or may be used in lieu of an insole. Sockliner <NUM> may provide additional warmth, cushioning (e.g., impact attenuation), moisture management, microbial control, and/or arch support. In some embodiments, sockliner <NUM> may be used as a post-production and/or customizable insert. Post-production inserts are placed by a user into a shoe which may already have an insole. In this sense, sockliner <NUM> may be added to a shoe, e.g., by a user or wearer, even if the shoe has a built-in insole/sockliner.

Sole <NUM>, or one or more of the layers of sole <NUM>, may be joined to upper <NUM> using seam <NUM>. Seam <NUM> may be any suitable joint, including joints formed via adhesives, cohesives, welding (heat, ultrasound, UV, etc.), sewing, other mechanical attachments, or combinations thereof. Seam <NUM> may be a strobel-type joint, a series of layers of material from or attached to upper <NUM> and one or more layers of sole <NUM> which are stitched together to hold sole <NUM> to upper <NUM>. Seam <NUM>, is shown in <FIG> as a strobel-type joint. Seam <NUM> may be positioned inside shoe <NUM>, and may be covered by sockliner <NUM> so that the seam <NUM> is not visible and/or any texture from the seam does not irritate or press against the foot when shoe <NUM> is worn. Alternately, seam <NUM> may be visible and/or perceptible by touch inside shoe <NUM>. In some aspects, sockliner <NUM> may be cemented into shoe <NUM>. In some aspects, sockliner <NUM> may be purposefully excluded from seam <NUM>, i.e., not joined into seam <NUM>, so that sockliner <NUM> can be removed from shoe <NUM>. The ability to remove sockliner <NUM> may make it easier to clean and/or dry the sockliner if it becomes soiled or wet, and may facilitate the use of specialty insoles or orthotics, if desired.

<FIG> provides a schematic illustration of a conventional, flat sockliner <NUM>. When looking down on the top (foot-facing) surface of the conventional, flat sockliner <NUM>, it has a perimeter <NUM> which generally follows the interior contours of a partially or fully assembled shoe, or the general shape of a foot. When looking at a cross-section <NUM> along axis A-A, conventional, flat sockliner <NUM> has a relatively uniform thickness across the width of the sockliner. Conventional, flat sockliner <NUM> may also be uniform in thickness along a toe-to-heel length of the sockliner.

<FIG> is a schematic illustration of an alternative conventional sockliner <NUM> having a non-uniform thickness. Alternative conventional sockliner <NUM> has a perimeter <NUM> which may closely approximate that of conventional, flat sockliner <NUM>, because both are intended to fit closely to the interior contours of a shoe. However, when a cross-section <NUM> of alternative conventional sockliner <NUM> is viewed along axis B-B, it can be seen that alternative conventional sockliner <NUM> has a varying thickness across the width of the sockliner. The thickness of alternative conventional sockliner <NUM> may also vary along a toe-to-heel length of the sockliner. Alternative conventional sockliner <NUM> is typically formed by injection or closed cast molding processes, and is molded to have the shape that is desired when alternative conventional sockliner <NUM> is placed in the shoe. That is, if alternative conventional sockliner <NUM> has an arch support feature <NUM> characterized by a greater thickness in the generally central portion of the width and/or length of the alternative conventional sockliner <NUM> than along perimeter <NUM>, then alternative conventional sockliner <NUM> would have a raised arch support feature <NUM> when molded, and would have a raised arch support feature <NUM> if removed from the shoe. The conformation of sockliner <NUM> does not change, or does not change significantly, whether it is in a shoe or in a relaxed state.

<FIG> show an exemplary sockliner <NUM> in accordance with aspects of this disclosure, from the top and bottom, respectively. When sockliner <NUM> is placed in a shoe as intended, a first surface, top surface <NUM> is the foot-facing surface of sockliner <NUM>, and a second, contoured surface opposing the first surface, bottom surface <NUM> faces sole <NUM>. Sockliners <NUM>, <NUM>, and <NUM> are designed for the same shoe. However, unlike conventional sockliners <NUM> and <NUM>, sockliner <NUM> has a perimeter <NUM> for the top surface <NUM> which deviates from the general shape of the interior of a shoe, shown in dotted lines as second perimeter <NUM>. Perimeter <NUM> may correspond to the perimeter of the bottom surface <NUM>. The deviation between perimeter <NUM> and perimeter <NUM> may be relatively small, and the width of sockliner <NUM> measured along a curve (e.g., the arc length across a contoured portion of the surface) may be approximately equal to the width of sockliner <NUM> at the corresponding position of the sockliner, but the width of sockliner <NUM> will appear to be wider because the distance is linear across the flat top surface <NUM> of sockliner <NUM>.

Perimeter <NUM> and perimeter <NUM> may be bridged by third and fourth, side surfaces of sockliner <NUM>. The side surfaces may be distinct, with discernible starts and ends along the perimeter, or the side surfaces may meet, e.g., at toe and heel portions, with or without a discernible distinction. However, the sockliner <NUM> has two sides, a medial side <NUM> corresponding to the inside or instep of the foot, and a lateral side <NUM> to the outside of the foot, and each side has a side surface bridging an edge of the top surface <NUM> of sockliner <NUM> and an edge of the bottom surface <NUM> of sockliner <NUM>. The third and fourth side surfaces, shown as lateral side <NUM> and medial side <NUM> may be linear, or approximately linear, or contoured. If contoured, at least a portion of the sockliner <NUM> between the wider perimeter <NUM> of top surface <NUM> and the narrower perimeter <NUM> of bottom surface <NUM> may be thinner than an average thickness of the sockliner <NUM> within perimeter <NUM>. The contour of bottom surface <NUM> and/or one or both side surfaces may include steps, arcs, curves, or other non-linear shapes. As used herein, "contour" does not include a linear-shaped (e.g., flat, planar) surface. A contour may be oriented transversely or laterally, e.g., parallel to an axis running between the medial and lateral sides of the sockliner, or a contour may be oriented lengthwise, e.g., parallel to an axis running between the toe and the heel of the sockliner, or a contour may be oriented diagonally.

As molded, and when in a relaxed state, top surface <NUM> of sockliner <NUM> may be flat. That is, top surface <NUM> of sockliner <NUM> may be substantially planar (e.g., planar within process, material, and measurement variations customary in the industry). Sockliner <NUM> is in a relaxed state when it is placed on a table or other supportive surface under normal room conditions (e.g., approximately 1atm, <NUM>-<NUM>, relative humidity <NUM>-<NUM>%) with no constraints placed on the conformation of the sockliner. If sockliner <NUM> is turned over to view bottom surface <NUM> from above, as shown in <FIG>, it can be seen that bottom surface <NUM> is not planar. Rather, a cross-section of sockliner <NUM> along axis C-C shows that bottom surface <NUM> has two or more different thicknesses across the width of sockliner <NUM>, when sockliner <NUM> is in a relaxed state.

The change in thickness across sockliner <NUM> may occur step-wise, in one or two or more steps <NUM>, with or without filleting or rounding of the step edges. <FIG> shows steps <NUM>, <NUM> without fileting or rounding. Different shapes or numbers of steps may be used in different portions of sockliner <NUM>, and adjacent steps may have different shapes, lengths and/or depths. For example, as shown in <FIG>, steps <NUM> have a lesser width than steps <NUM>. The change in thickness across sockliner <NUM> may follow a curve, with one exemplary curved transition shown in <FIG>. The curve <NUM> may have a uniform arc or variable arc at different portions of the curve, in some aspects potentially resembling a soft S-curve. The arc may vary along the perimeter of the sockliner <NUM>. The change in thickness may be generally arcuate. The curve <NUM> may be concave relative to top surface <NUM> of sockliner <NUM>.

The portions of sockliner <NUM> between perimeter <NUM> and perimeter <NUM> may form laterally extending wings <NUM>, <NUM> which, because of the different thickness and/or material composition, may be noticeably distinct in appearance, flexibility, etc. from the body 580of sockliner <NUM>. In some cases, the wings may be noticeably different only in comparison to a shoe template or general shoe shape. The body <NUM> of sockliner <NUM> may have perimeter <NUM>, generally corresponding to the shape of the interior foot bed of a shoe. Wings <NUM>, <NUM> may extend as a border around at least a portion of the perimeter <NUM> of body <NUM>. Wings <NUM>, <NUM> may be localized to a central portion of sockliner <NUM>, excluding the toe and heel of sockliner <NUM>. Wings <NUM>, <NUM> could extend longitudinally, or both longitudinally and laterally, from body <NUM>. One or more integral wings <NUM>, <NUM> may be formed as a unit with body <NUM>.

Because top surface <NUM> of sockliner <NUM> is substantially planar, it can be formed using open molding tools, such as exemplary mold <NUM>, shown from the side in <FIG>. Exemplary mold <NUM> provides the form <NUM> of bottom surface <NUM> of sockliner <NUM> in an internal cavity. The mold top <NUM> may be open and may be substantially flat or planar. The foam may be introduced into the mold in a flowable or at least malleable state, and may be dried or cured to form a solid, compressible foam sockliner. Mold form <NUM> may be filled with sockliner material, and a straight-edged tool may be used to smooth the material across mold top <NUM>, so that the top surface of sockliner material inside mold <NUM> is smooth and flush with mold top <NUM>. The smooth material, flush with planar top <NUM> of mold <NUM>, yields a substantially flat top surface <NUM> for sockliner <NUM>. A portion of mold form <NUM> corresponding to body <NUM> of sockliner <NUM> may extend a full depth of the mold, from the flat upper surface of the mold to a bottom of the forming surface at its farthest point (measured orthogonally) from the top <NUM> of mold <NUM>. One or more wing portions of mold form <NUM> corresponding to one or more wings <NUM>, <NUM> of sockliner <NUM> may extend less than the full depth of the mold.

Suitable sockliner materials include natural latex rubber, ethylene vinyl alcohol (EVA), styrene-butadiene rubber (SBR), polyurethane, polyethylene, elastomeric foams, and combinations thereof. A frothed foam, such as a mechanically frothed foam, may be used. A mechanically frothed foam having a specific gravity of less than <NUM>. 4gm per cubic centimeter and a hardness of <NUM>-<NUM> Asker "C" in polyurethane or blends of natural and synthetic rubber have been found to provide a particularly good balance of compressibility and resistance to compression (e.g., cushioning or support) for athletic shoes, with or without a builder. Different materials could be used for different portions of sockliner <NUM>. For example, mold <NUM> could be partially filed with a first material and then filled with second, third, fourth, and/or fifth materials, yielding different properties through the depth of sockliner <NUM>. As another example, the portion of a mold <NUM> corresponding to wings <NUM>, <NUM> may be filled with a first material as the body portion of the mold is filled with a second material. The body, the wings, or both, could additionally have layers of different materials at different depths. In some aspects, mold <NUM> is filled completely, or even over-filled and leveled off, to ensure a flat, planar top surface in the molded part. Alternately, or in addition, care may be taken to keep mold <NUM> oriented such that while the sockliner material is still flowable, mold <NUM> is oriented and stabilized to maintain the top of the sockliner material inside mold <NUM> at an acceptable angle.

A shoe <NUM> may be formed on a last that includes an allowance for a sockliner. The allowance for the sockliner keeps open a space for inserting the sockliner between upper <NUM> and sole <NUM> after the upper <NUM> is joined to sole <NUM> and the joined shoe parts are removed from the last. The sockliner may be inserted into shoe <NUM> after upper <NUM> has been joined to sole <NUM>. Only sole <NUM> is shown in <FIG> to provide a clear view of the fit between sockliner <NUM> and sole <NUM>. As sockliner <NUM> is pressed into sole <NUM>, wings <NUM>, <NUM> are pressed upward and inward by sole <NUM> and upper <NUM>. Bottom surface 161B of sockliner <NUM> will typically conform to sole <NUM>, because sockliner <NUM> will be more compressible and/or conformable than sole <NUM>. As bottom surface <NUM> of sockliner <NUM> is pressed against sole <NUM> and upper <NUM> (not shown), the upward and inward pressure on wings <NUM>, <NUM> will modify the topography of top surface <NUM>, forming a contoured foot bed. Even as the top surface <NUM> of sockliner <NUM> changes significantly, it may remain smooth, e.g., free of or substantially free of wrinkles.

The smoothness of the top surface <NUM> may contribute to a comfortable sockliner <NUM>, with reduced pressure points on the foot, e.g., from wrinkles or abrupt changes in thickness or shape. The smoothness of the surface may also make the interior of the shoe more aesthetically pleasing. A wrinkled, puckered, or unfamiliar surface shape or texture may cause a consumer to question whether the shoe is of good quality, was well-assembled, will be durable, and/or will be comfortable, even if the wrinkles or surface features would not cause discomfort. In general, dependent upon the combination of the materials and contours of the sockliner as well as the shape of the shoe, top surface <NUM> of sockliner <NUM> may remain substantially free of wrinkles after being placed in a shoe if the material used can be compressed by at least <NUM>% in any linear direction.

Some compression of the sockliner may help hold it in place if it is not otherwise secured into the shoe. While it may be useful to be able to remove the sockliner, it is also useful for the sockliner to fit securely in the shoe, so that the sockliner moves as little as possible relative to other components of the shoe and/or a wearer's foot. In some aspects, the sockliner may be cemented, glued, or otherwise adhered to the inside of the shoe. In some aspects, the sockliner may be sewn or otherwise joined to the inside of the shoe.

When wings <NUM>, <NUM> are lifted and sockliner <NUM> is deformed from the relaxed conformation <NUM> to an in-use conformation <NUM>, the bottom surface <NUM> may change configuration, too. Bottom surface <NUM> may have a linear or convex shape relative to top surface <NUM> in the relaxed conformation <NUM>. Bottom surface 161B may have a linear or concave shape relative to top surface 165B when wing or wings <NUM>, <NUM> are lifted and sockliner <NUM> is in an in-use conformation <NUM>. If bottom surface <NUM> has a linear relaxed state, it may have a concave shape in the in-use state. If bottom surface <NUM> has a linear assembled state, it may have a convex shape in the relaxed state. This is shown in a side view in <FIG> shows sockliner <NUM> in a relaxed conformation <NUM>, and <FIG> shows sockliner <NUM> in an in-use conformation <NUM>.

The dimensions of sockliner <NUM> may be determined by starting from the desired shape of sockliner <NUM> in the in-use conformation <NUM>. For existing shoes using a conventional sockliner, the desired dimensions can be measured from an existing sockliner. For new shoes, the desired shape and dimensions can be calculated using, without limitation, one or more of the shape of the interior of the shoe, desired support points within the shoe, and desired cushion points within the shoe. Desired support and/or cushion points may depend upon the kind of shoe and its intended purpose. For example, soccer shoes may require different distributions of cushioning and/or support than running shoes.

<FIG> shows an exemplary sockliner <NUM> in a relaxed conformation. Sockliner <NUM> has centerline D. The dimensions of sockliner <NUM> in the relaxed conformation can be measured or calculated from the sockliner in an in-use conformation, as shown in <FIG>. For example, an arc length <NUM> from the upper medial edge 151B to centerline D may be measured or calculated, if working from an intangible design rather than an actual sockliner or physical model. Similarly, arc length <NUM> may be measured or calculated from centerline D to the upper lateral edge 157B. These arc lengths may be reapplied as linear lengths <NUM> and <NUM> for the flat top surface <NUM> of sockliner <NUM>, as shown in a relaxed conformation in <FIG>. Likewise, lengths <NUM> and <NUM> may be measured or calculated between centerline D and the lower medial edge 153B and the lower lateral edge 155B, respectively, in the in-use conformation shown in <FIG> to determine the lengths <NUM>, <NUM> from centerline D to lower medial edge <NUM> and lower lateral edge <NUM>, respectively, in the relaxed conformation shown in <FIG>.

The thickness of sockliner <NUM> can be measured as arc length <NUM> in the in-use conformation in <FIG>, and reapplied as linear length <NUM> in the relaxed configuration in <FIG>. The radius of curvature of arc <NUM>, if present, in the in-use conformation in <FIG> can then be used as a starting point for the radius of curvature of arc 1060A in the relaxed configuration in <FIG>. The radius of curvature of arc 1060A may be adjusted to account for the use of different materials or different densities of a material, appreciating that the density of a material may be varied intentionally (e.g., to modify cushioning or support), or the density of a material may vary as a function of variations in the raw material, process conditions, normal process variation and tolerances, and the like.

This conversion of the desired sockliner configuration to a pattern for a sockliner <NUM> that can be manufactured using a flat-top, open cast mold, such as mold <NUM> may simplify the manufacture of the sockliner and/or a shoe. The mold tooling for cast foam molding may be less complicated and/or less expensive than mold tooling for other molding processes. For example, cast foam molding may require only a single mold form, as opposed to a clamshell or multi-part mold for other molding processes. Cast foam molding may generate less waste compared, for example, to other molding processes, or to cutting or forming sockliners from a larger sheet or block of material. Cast foam molding may also permit the use of different materials, which may provide opportunities to improve cost, flexibility, support, cushioning, or other aspects of the sockliner. Further, a flexible, flat-surfaced (in the relaxed conformation) sockliner as described herein facilitates incorporating the sockliner into the shoe prior to or while joining the upper to the sole, simplifying manufacturing and potentially reducing the number of components. For example, the sockliner can be joined into the seam or joint between the upper and sole, securing the sockliner in place within the shoe while eliminating the need for a glue or adhesive. As another example, the sockliner may be joined to the upper or the sole prior to joining the upper to the sole.

If it is desired to join sockliner <NUM> to seam <NUM>, sockliner <NUM> may be placed between upper <NUM> and sole <NUM> and at least a portion of an edge of sockliner <NUM> may be incorporated into seam <NUM>. For example, at least a portion of the perimeter edge of bottom surface <NUM> of sockliner <NUM> may be sewn into a strobel-type seam <NUM>, joining sockliner <NUM> to both upper <NUM> and sole <NUM>.

In some aspects, a skirt <NUM> may be attached to sockliner <NUM> to facilitate joining sockliner in seam <NUM>, as shown in <FIG>. Skirt <NUM> then provides a margin for gluing, welding, sewing, or otherwise joining skirt <NUM> into seam <NUM> and/or to any component of upper <NUM> and/or sole <NUM>. Skirt <NUM> may be present along at least a portion of the perimeter of sockliner <NUM>, or along the entire perimeter of sockliner <NUM>, or along the entire bottom surface <NUM> of sockliner <NUM>, or may be present in some parts of sockliner <NUM> and not in others. For example, skirt <NUM> may be present discontinuously around the perimeter of most of sockliner <NUM>, or may be present along the toe-portion of sockliner <NUM>, or along the heel-portion of sockliner <NUM>, or along the arch portion of sockliner <NUM>, or some combination thereof, with gaps in between. If skirt <NUM> is discontinuous, it may be present as one skirt which does not extend uniformly to the perimeter of sockliner <NUM> in all directions, or may be present as two or more distinct skirts. If two or more distinct skirts are used, they may be of the same or different materials.

Skirt <NUM> may include any material suitable for embedding in or attaching to sockliner <NUM> and joining to other shoe materials, as at seam <NUM>. The nature of the other shoe materials and the nature of the seam or joint will influence the choice of the skirt material. In general, suitable skirt materials include, without limitation, fabrics, woven, knitted or nonwoven, of synthetic or natural fibers, or combinations thereof. Netting, webs, or films may be used as fabrics if they are of sufficient strength to secure the sockliner in seam <NUM> or to other components of shoe <NUM>.

Body <NUM> of sockliner <NUM> may have a central portion and a periphery. The central portion may be adjacent to a longitudinal centerline of sockliner <NUM>, or a lateral centerline of sockliner <NUM>, or both. The periphery <NUM> may be a margin or border along at least a portion of the perimeter <NUM> of body <NUM>. The periphery may extend between about <NUM> and about <NUM> from the edge of body <NUM> along perimeter <NUM>. Skirt <NUM> may have a central portion <NUM> and a periphery <NUM>. The central portion <NUM> may be adjacent to a longitudinal centerline of skirt <NUM>, or a lateral centerline of skirt <NUM>, or both. The periphery <NUM> may be a margin or border along at least a portion of the outer perimeter of skirt <NUM>. The periphery <NUM> may extend between about <NUM> and about <NUM> from the outer perimeter of skirt <NUM>.

Body <NUM> of sockliner <NUM> may be joined to skirt <NUM> along a central portion of bottom surface <NUM>, leaving at least a portion of the periphery <NUM> of skirt <NUM> loose from at least a portion of the periphery <NUM> of body <NUM> of sockliner <NUM>. The periphery <NUM> of skirt <NUM> may be loose from all of the periphery <NUM> of body <NUM> of sockliner <NUM>, or may be loose from the periphery of body <NUM> in all portions of body <NUM> where skirt <NUM> is present. Skirt <NUM> may extend along substantially all (e.g., <NUM>% or more) or all of the periphery <NUM> of body <NUM>.

<FIG> provides an example of how a skirt can be incorporated into sockliner <NUM> during the process of molding sockliner <NUM>. Mold <NUM> is shown in cross-section, so that the interior of the mold is visible. Mold <NUM> has a mold form <NUM>, with a forming surface <NUM> defining a cavity inside mold <NUM> for receiving sockliner material. A skirt <NUM> can be placed adjacent to or against the forming surface <NUM> of mold form <NUM>, and sockliner material may be added on top of skirt <NUM>. Skirt <NUM> and/or the sockliner material may be selected and/or treated such that sockliner material, in its moldable state, will at least partially wet or impregnate skirt <NUM>, such that when the sockliner material cures, skirt <NUM> is integral to or at least securely attached to sockliner <NUM>.

One or more portions of skirt <NUM>, shown as arcs <NUM>, may be treated with a release agent. (Arcs <NUM> are arcuate because of the shape of the exemplary forming surface in mold <NUM>. The periphery of skirt <NUM> may have other shapes, including straight lines or alternative contours. ) A release agent may leave a margin of skirt <NUM> free of sockliner <NUM>, which may make it easier to join skirt <NUM> in seam <NUM> or to other portions of shoe <NUM>. Suitable release agents may prevent skirt <NUM> from being wetted or impregnated by the sockliner material, or may facilitate peeling those margins of skirt <NUM> away from sockliner <NUM>. Periphery of skirt <NUM> may diverge from or not lie flat against the periphery of body <NUM> of sockliner <NUM>. Periphery of skirt <NUM> may diverge from or not lie flat against the periphery of body <NUM> of sockliner <NUM> particularly, but not exclusively, when body <NUM> is an in-use conformation (e.g., when wings <NUM>, <NUM> have been lifted away from bottom surface 161B of body <NUM>).

Exemplary release agents include, but are not limited to waxes, silicones, oils, and combinations thereof. Release agents generally lower the surface energy and/or increase the contact angle of the treated portion of skirt <NUM> relative to the untreated portion of skirt <NUM>. Alternately, or in addition, portions of skirt <NUM>, such as the central portion <NUM> of skirt <NUM>, may be treated with a wetting agent or treatment to facilitate wetting of skirt <NUM> by the sockliner material during molding. Wetting agents or treatments generally increase the surface energy and/or lower the contact angle of the treated portion of skirt <NUM> relative to the untreated portion of skirt <NUM>.

Claim 1:
A mold (<NUM>) for forming a sockliner (<NUM>) with an integrated fabric skirt (<NUM>), the mold (<NUM>) comprising: a forming surface (<NUM>) defining a cavity within the mold (<NUM>), the forming surface (<NUM>) having a central portion and a periphery; and one or more indentations (<NUM>) in the central portion of the forming surface (<NUM>), the one or more indentations (<NUM>) permitting fluid communication of a flowable foam from the cavity into the one or more indentations (<NUM>), wherein the periphery of the forming surface (<NUM>) of the mold (<NUM>) has no indentations.