Shoe with insole as part sole filler and method of making same

Abstract

A method of manufacture of footwear and the footwear comprising the steps of providing a last with an upper thereon, providing a mold insert on the bottom of the last, providing a mold having a mold cavity for a tread sole, disposing the last and upper against the mold with the mold insert disposed within the mold cavity, forming a sole in the mold cavity having a depression therein in the shape of the mold insert, providing an insole with a first portion in the shape of the depression and a second portion substantially in the shape of the sole and securing the first portion of the insole in the depression. The tread sole and insole are formed of materials preferably having different physical properties. The tread sole can include one of tongues and grooves and the insole would then have the other of tongues and grooves, said tongues and grooves mating with each other. The step of providing an insole can include removing the mold insert from the mold cavity, disposing the last spaced from the tread sole and then forming the insole in the cavity formed by the removal of the weight relief and the spacing of the last from the tread sole.

1 - 14 . (canceled)  
   
   
       15 . Footwear comprising: 
 (a) a tread sole having a toe region at one end thereof and a heel region at an opposing end thereof and an upper secured to said tread sole;    (b) said tread sole including a cavity therein extending continuously from said toe region and beneath the ball of a wearer's foot to said heel region and beneath the wearer's heel, and wherein said cavity in the heel region is of substantially greater depth than other portions of said cavity; and    (c) an insole with a portion in the shape of said tread sole cavity, said insole portion disposed in said cavity and extending continuously from said toe region and beneath the ball of a wearer's foot to and beneath the wearer's heel to provide support under a wearer's heel.    
   
   
       16 . Footwear as recited in  claim 15  and wherein said insole includes a lip portion integral therewith and external of said cavity over said tread sole.  
   
   
       17 . Footwear as recited in  claim 15  and wherein said insole includes a contoured outer surface.