Footwear with built-in intrinsic midsole

Abstract

Footwear with enhanced wearing comfortability, stability and orthotic foot support are disclosed. The footwear comprises built-in intrinsic midsole, anatomically shaped footbed having a functional arch concavity on a medial side, and deep heel cup. The built-in intrinsic midsole provides ideal foot support and function. Raised sidewalls accentuate a deep heel cup, which controls and matches the natural anatomic shape of the foot. The midsole is made by direct single density injection with integrated orthotic contour. The direct injection midsole to upper creates a strong bond, and resolves a potential of delaminating soles. Furthermore, it eliminates the need and cost of cementing, and improves instant fit/comfort.

1 . A unibody midsole for enhanced wearing comfortability and orthotic foot support, the unibody midsole comprising:
 an anatomically shaped footbed integrated with a concaved heel cup and a contoured arch support having a functional arch concavity on a medial side;   a raised sidewall fully around the footbed; and   a bottom surface comprising a plurality of grooves.   
     
     
         2 . The unibody midsole of  claim 1  wherein the midsole is made with thermoplastic polyurethane (TPU), polyethylene (PU), or Ethylene-vinyl acetate (EVA). 
     
     
         3 . The unibody midsole of  claim 1  wherein the unibody midsole is constructed as a single density midsole. 
     
     
         4 . The unibody midsole of  claim 1  wherein the unibody midsole is constructed as a dual density midsole. 
     
     
         5 . The unibody midsole of  claim 1  wherein the contoured arch support is higher than the heel cup. 
     
     
         6 . The unibody midsole of  claim 1 , further comprising 1 st  ray relief. 
     
     
         7 . A footwear with integrated orthotic foot support, the footwear comprising:
 an upper comprising a heel contour;   a unibody midsole directly injected to the upper, the midsole having an anatomically shaped footbed integrating a concaved heel cup and a contoured arch support having a functional arch concavity on a medial side.   
     
     
         8 . The footwear of  claim 7  wherein the midsole is made with thermoplastic polyurethane (TPU), polyethylene (PU), or Ethylene-vinyl acetate (EVA). 
     
     
         9 . The footwear of  claim 7  wherein the unibody midsole further comprises a raised sidewall as a closed contour. 
     
     
         10 . The footwear of  claim 7  wherein the contoured arch support is higher than the heel cup. 
     
     
         11 . The footwear of  claim 7  wherein the heel cup transitions seamlessly into the heel counter. 
     
     
         12 . The footwear of  claim 7  wherein the footwear further comprises a strobel sock having a surface contour substantially matched the footbed. 
     
     
         13 . The footwear of  claim 12  wherein the molded strobel sock is made with perforated memory foam layer. 
     
     
         14 . The footwear of  claim 7  wherein the unibody midsole has a bottom surface comprising a plurality of grooves. 
     
     
         15 . The footwear of  claim 14  further comprising at least one insert attached on the bottom surface. 
     
     
         16 . The footwear of  claim 15  wherein the at least one insert is a carbon rubber or a blown rubber. 
     
     
         17 . The footwear of  claim 14  wherein the unibody midsole has a medial concavity on the bottom surface. 
     
     
         18 . The footwear of  claim 14  wherein the midsole has reinforcement on the bottom surface and beneath the contoured arch support for increased lateral torsional support. 
     
     
         19 . The footwear of  claim 7 , wherein the midsole includes 1 st  ray relief. 
     
     
         20 . A method for making a footwear with orthotic foot support comprising:
 providing a unibody midsole with an anatomically shaped footbed, the footbed integrating an orthotic arch support having a functional arch concavity on a medial side, and deep heel cup; and   directly bonding the midsole to a one-piece upper.   
     
     
         21 . The method of  claim 20  further comprising attaching a molded strobel sock on the footbed of the midsole, the strobel sock being a perforated memory foam layer. 
     
     
         22 . The method of  claim 20  wherein the unibody midsole comprises a raised side wall around the footbed to enhance the bonding between the midsole and the upper.