Molded insole for welted footwear

Abstract

The present disclosure provides an improved welted footwear and related method of manufacture. The welted footwear and related method of manufacturing is directed to a molded foot support platform that provides a number of advantageous features.

1 . A welted footwear comprising:
 an upper portion configured to hold the footwear to a person's foot, the upper portion including a lower peripheral edge;   a molded foot support platform including a first surface and a second surface, the foot support platform including a rib extending downwardly from the second surface adjacent a periphery edge of the foot support platform, wherein the rib is integrally molded to the foot support platform, the foot support platform including a toe cap retaining structure;   a welt configured to extend around at least a portion of the peripheral edge of the upper portion of the footwear;   a stitch that extends through at least a portion of the peripheral edge of the upper portion, the welt, and the rib of the foot support platform;   an outsole including a portion configured to engage the ground surface, the outsole including a portion that is attached to the foot support platform;   a pliable material molded to the rib;   a toe cap positioned on the foot support platform and engaged with the toe cap retaining structure; and   a securing layer positioned over at least a portion of a flange of the toe cap and at least a portion of the toe cap retaining structure.   
     
     
         2 . The welted footwear of  claim 1 , wherein the stitch that extends through the peripheral edge of the upper, the welt, and the rib also extends through the pliable material. 
     
     
         3 . The welted footwear of  claim 1 , wherein a pliable material covers an exterior surface of the rib. 
     
     
         4 . The welted footwear of  claim 1 , wherein the outsole is molded to the foot support platform. 
     
     
         5 . The welted footwear of  claim 4 , wherein the outsole includes a shock absorption portion that is molded into a cavity between the portion of the outsole that is configured to engage the ground surface and the second surface of the foot support platform. 
     
     
         6 . The welted footwear of  claim 5 , further comprising a pliable fabric material molded to the second surface of the foot support platform and wherein the shock absorption portion of the outsole is molded to the pliable fabric material. 
     
     
         7 . The welted footwear of  claim 1 , wherein the foot support platform includes a hindfoot zone, a forefoot zone, and a midfoot zone, and wherein the foot support platform is at least ten percent stiffer in the midfoot zone than the hindfoot zone. 
     
     
         8 . The welted footwear of  claim 7 , wherein the forefoot zone includes a toe support area and a metatarsal support area, wherein the metatarsal support area is between the toe support area and the midfoot zone, and wherein the toe support area of the foot support platform is at least ten percent stiffer than the metatarsal support area. 
     
     
         9 . The welted footwear of  claim 2 , wherein at least some of the stitches extend through the pliable material on both an inner side portion and an outer side portion of the rib. 
     
     
         10 . The welted footwear of  claim 1 , wherein the toe cap retaining structure includes a ridge that engages the flange to limit the movement of the toe cap within the footwear. 
     
     
         11 . A foot support platform comprising:
 a main body including a first surface and a second surface;   a rib extending downwardly from the second surface adjacent a periphery edge of the main body, the rib being integrally molded to the main body;   a pliable material molded to the second surface and to at least a portion of the rib; and   wherein the main body includes a hindfoot zone, a forefoot zone, and a midfoot zone; and   wherein the forefoot zone includes a toe support area and a metatarsal support area, wherein the metatarsal support area is between the toe support area and the midfoot zone, and wherein the toe support area of the main body is at least ten percent stiffer than the metatarsal support area.   
     
     
         12 . The foot support platform of  claim 11 , wherein the rib has an inside surface and an outside surface, wherein the outside surface has a curved cross-sectional profile. 
     
     
         13 . The foot support platform of  claim 11 , wherein the main body includes a wherein the foot support platform is at least ten percent stiffer in the midfoot zone than the hindfoot zone. 
     
     
         14 . (canceled) 
     
     
         15 . The foot support platform of  claim 11 , wherein the pliable material is located on both an inner side portion and an outer side portion of the rib and wherein the pliable material includes fabric. 
     
     
         16 . The foot support platform of  claim 11 , wherein the rib includes notches in a forefoot portion. 
     
     
         17 . The foot support platform of  claim 14 , further comprises a ramp shaped toe cap retaining structure molded to the toe support area of the main body. 
     
     
         18 - 22 . (canceled) 
     
     
         23 . A footwear comprising:
 an upper;   an outsole below the upper;   a foot support platform connected above the outsole, wherein the foot support portion includes a toe cap retaining structure having at least an edge;   a protective toe cap supported on the foot support platform, the protective toe cap including a flange engaged with the edge of the toe cap retaining structure.   
     
     
         24 . The footwear of  claim 23 , wherein the toe cap retaining structure is ramp shaped and integrally molded to the foot support platform. 
     
     
         25 . The footwear of  claim 23 , wherein the front edge of the toe cap retaining structure defines an arc shape. 
     
     
         26 . The footwear of  claim 23 , further comprising a securing layer cemented over at least a portion of a flange of the toe cap and at least a portion of the toe cap retaining structure.