Method of construction and footware using mated components

Abstract

A method and apparatus for forming footwear, such as a sandal, with a footstrap secured to a sole by way of engagement of an insertion portion with a recess. The recess may be molded into a portion of the sole with an exposed opening at the outer surface of the sole leading to the recess formed in the sole interior. The exposed opening may be smaller in area than an area of the recess within the sole, and may be smaller that a largest cross-sectional area of the insertion portion. Thus, the insertion portion may be forced through the exposed opening, e.g., by deforming the insertion portion and/or the sole portion at the exposed opening, and received within the recess. The sole and/or insertion portion may be formed of a molded foam, e.g., that is resilient and water resistant.

1 . A method for forming footwear, comprising: 
 providing a footstrap having an insertion portion, the footstrap being constructed and arranged to extend over at least a portion of a wearer's foot and secure the wearer's foot to the footwear;    providing a sole of the footwear having a recess molded into a portion of the sole and an opening at an outer surface of the sole leading to the recess, a top portion having a footbed arranged to contact a wearer's foot and a bottom portion arranged to contact a surface on which the wearer stands when wearing the footwear, the sole portion having the recess being constructed and arranged to receive the insertion portion and secure the footstrap to the sole, the recess being formed in the sole without requiring a throughhole being formed in the sole; and    securing the insertion portion in the recess to attach the footstrap to the sole by passing the insertion portion through the opening and into the recess, attachment of the insertion portion in the recess being suitable to maintain engagement of the footstrap with the sole during intended wearing of the footwear by a wearer.    
   
   
       2 . The method of  claim 1 , wherein the insertion portion and the recess are formed so that the opening in the sole leading into the recess is smaller in area than a largest cross-sectional area of the insertion portion.  
   
   
       3 . The method of  claim 1 , wherein the insertion portion and the recess are formed so that the entire insertion portion is received in the recess and is positioned within an outer surface of the sole.  
   
   
       4 . The method of  claim 1 , wherein the insertion portion is permanently bonded in the recess.  
   
   
       5 . The method of  claim 1 , wherein the insertion portion is integrally molded with the footstrap.  
   
   
       6 . The method of  claim 5 , wherein the insertion portion and footstrap are molded from a foam material.  
   
   
       7 . The method of  claim 1 , wherein the footstrap is integrally molded with a portion of the sole.  
   
   
       8 . The method of  claim 1 , wherein the sole is formed as a unitary member molded from a foam material.  
   
   
       9 . The method of  claim 1 , wherein the footstrap includes a toe bar and lateral and medial rear strap portions, and one of the toe bar and lateral and medial rear strap portions includes the insertion portion at a distal end.  
   
   
       10 . The method of  claim 9 , wherein all of the toe bar and lateral and medial rear strap portions include an insertion portion at a respective distal end, and the step of securing includes securing the insertion portion for the toe bar and lateral and medial rear strap portions in a respective recess in the sole.  
   
   
       11 . Footwear comprising: 
 a sole constructed and arranged to support a wearer's foot, the sole including a top portion having a footbed arranged to contact a wearer's foot and a bottom portion arranged to contact a surface on which the wearer stands when wearing the footwear, the sole including a recess molded into a portion of the sole and formed without requiring a throughhole being formed in the sole; and    a footstrap constructed and arranged to secure a wearer's foot to the sole, the footstrap including an insertion portion secured to the sole within the recess and arranged to securely attach the footstrap to the sole.    
   
   
       12 . The footwear of  claim 11 , wherein the insertion portion and the recess are formed so that an opening in the sole leading into the recess is smaller in area than a largest cross-sectional area of the insertion portion.  
   
   
       13 . The footwear of  claim 11 , wherein the insertion portion and the recess are formed so that the entire insertion portion is received in the recess and is positioned within an outer surface of the sole.  
   
   
       14 . The footwear of  claim 11 , wherein the insertion portion is permanently bonded in the recess.  
   
   
       15 . The footwear of  claim 11 , wherein the insertion portion is integrally molded with the footstrap.  
   
   
       16 . The footwear of  claim 15 , wherein the insertion portion and footstrap are molded from a foam material.  
   
   
       17 . The footwear of  claim 11 , wherein the footstrap is integrally molded with a portion of the sole.  
   
   
       18 . The footwear of  claim 17 , wherein the footstrap and sole are molded from a foam material.  
   
   
       19 . The footwear of  claim 11 , wherein the footstrap includes a toe bar and lateral and medial rear strap portions, and one of the toe bar and lateral and medial rear strap portions includes the insertion portion at a distal end.  
   
   
       20 . The footwear of  claim 19 , wherein all of the toe bar and lateral and medial rear strap portions include an insertion portion at a respective distal end, and the step of securing includes securing the insertion portion for the toe bar and lateral and medial rear strap portions in a respective recess in the sole.  
   
   
       21 . The footwear of  claim 11 , wherein an opening leading into the recess is formed in a top of the sole.  
   
   
       22 . The footwear of  claim 11 , wherein the sole is integrally molded from a foam material.  
   
   
       23 . The footwear of  claim 11 , wherein the recess is formed in a central portion of a footbed portion of the sole.  
   
   
       24 . The footwear of  claim 11 , wherein the recess is formed near a lateral or medial side of the sole.  
   
   
       25 . The footwear of  claim 11 , wherein the insertion member includes a disc-like shape.  
   
   
       26 . The footwear of  claim 11 , wherein the insertion member includes a cylinder-like shape.  
   
   
       27 . Footwear comprising: 
 a sole constructed and arranged to support a wearer's foot, the sole being molded of a foam material as a single unitary member and including a top portion having a footbed arranged to contact a wearer's foot and a bottom portion arranged to contact a surface on which the wearer stands when wearing the footwear, the sole including a recess molded into a portion of the sole and formed without requiring a throughhole being formed in the sole; and    a footstrap constructed and arranged to secure a wearer's foot to the sole, the footstrap being molded from a foam material and including an insertion portion secured to the sole within the recess and arranged to securely attach the footstrap to the sole;    wherein an opening in the sole leading into the recess is smaller in area than a largest cross-sectional area of the insertion portion and the entire insertion portion is received in the recess and is positioned within an outer surface of the sole.