Combined midsole/insole

Abstract

Described herein are devices and techniques for solving the problems, such as high costs and intensive labor, associated with individual cutting and lamination of each component of a multilayered article of manufacture, particularly a footwear article. The combined midsole/insole described herein is cut from a layered composition having a Strobel (or insole board) layer, a cushioning layer, and a textile layer. The Strobel layer, the cushioning layer, and the textile layer are needle-punched or laminated together to form the layered composition. The layered composition may be produced as a sheet of material or be produced as a roll of material without delamination or separation of the layers.

What is claimed is: 
     
         1 . A layered composition comprising three or more layers suitable for combined midsole/insole production comprising:
 i) a first layer comprising a Strobel or insole board;   ii) a second layer comprising a cushioning material; and   iii) a third layer comprising a textile material, wherein the first layer, second layer, and third layer are needle-punched or laminated together so as to form a layered composition, the layered composition being cuttable to produce at least one combined midsole/insole.   
     
     
         2 . The layered composition of  claim 1 , wherein the cushioning material comprises at least one of polyester needle-punch, recycled fiber, viscose fibers, ethylene vinyl acetate (EVA), rubber, neoprene, or polyurethane. 
     
     
         3 . The layered composition of  claim 1 , wherein the Strobel or insole board comprises at least one of a non-woven, stitch-bounded, fibrous material, polyester, polypropylene, cotton, nylon, wool, or viscose fibers. 
     
     
         4 . The layered composition of  claim 1 , wherein the textile material comprises at least one of a woven textile, a non-woven textile, a knit textile, polyester, nylon, cotton, or wool. 
     
     
         5 . The layered composition of  claim 1 , wherein the second layer is positioned between the first layer and the third layer. 
     
     
         6 . The layered composition of  claim 1 , wherein the first layer is positioned between the second layer and the third layer. 
     
     
         7 . The layered composition of  claim 1 , wherein a minimum diameter of a cylinder around which the layered composition is rollable without delamination or separation is less than 40 millimeters. 
     
     
         8 . The layered composition of  claim 1 , wherein the at least one combined midsole/insole is configured for assembly with at least one of an outsole and an upper to produce a shoe. 
     
     
         9 . A method for making a combined midsole/insole comprising:
 i) providing a first layer comprising a Strobel or insole board;   ii) providing a second layer comprising a cushioning material;   iii) providing a third layer comprising a textile material; and   iv) needle-punching or laminating the first layer, the second layer, and the third layer together to form a layered composition.   
     
     
         10 . The method of  claim 9 , further comprising cutting the layered composition to produce at least one combined midsole/insole. 
     
     
         11 . The method of  claim 10 , wherein the step of cutting further comprises die-cutting. 
     
     
         12 . The method of  claim 10 , further comprising assembling the at least one combined midsole/insole with at least one additional component to produce a shoe. 
     
     
         13 . The method of  claim 12 , wherein the at least one additional component is at least one of an outsole or an upper. 
     
     
         14 . The method of  claim 12 , wherein the shoe comprises one of the at least one combined midsole/insole, an outsole, and an upper. 
     
     
         15 . A shoe comprising:
 i) an outsole;   ii) a combined midsole/insole comprising:
 i. a first layer comprising a Strobel or insole board; 
 ii. a second layer comprising a cushioning material; and 
 iii. a third layer comprising a textile material, wherein the first layer, second layer, and third layer are needle-punched or laminated together so as to form a layered composition, the layered composition being cuttable to a desired shape; and 
   iii) an upper.   
     
     
         16 . The shoe of  claim 15 , wherein the third layer of the combined midsole/insole is a footbed. 
     
     
         17 . The shoe of  claim 15 , wherein the outsole and the combined midsole/insole are at least one of needle punched, glued, laminated, or sewn together. 
     
     
         18 . The shoe of  claim 15 , wherein the upper and the combined midsole/insole are at least one of needle punched, glued, laminated, or sewn together.