Footbeds with improved cushioning, stability and comfort and methods of making same

Abstract

Disclosed is an insole or footbed for footwear that optimizes the comfort and performance of the footbed via a modified construction to the shoe's upper and midsole to accommodate a preferred footbed construction.

What is claimed: 
     
         1 . A shoe comprising:
 a shoe upper;   a midsole having at least one cavity formed in an upper surface thereof;   an insole having at least one projecting interlocking feature formed in a lower surface thereof; and   a lasting board coupled to the shoe upper, the lasting board having at least one cutout for accepting the at least one projecting interlocking feature, the at least one cutout being aligned with the at least one cavity of the midsole.   
     
     
         2 . The shoe of  claim 1 , wherein the at least one cavity includes two cavities, the at least one projecting interlocking feature includes two projecting interlocking features, and the at least one cutout includes two cutouts. 
     
     
         3 . The shoe of  claim 2 , wherein the two projecting interlocking features include a first projecting interlocking feature adjacent a heel region and a second projecting interlocking feature adjacent a forefoot region. 
     
     
         4 . The shoe of  claim 3 , wherein the first projecting interlocking feature and the second projecting interlocking feature include thicknesses that are greater than thickness of remaining portions of the insole. 
     
     
         5 . The shoe of  claim 3 , wherein the first projecting interlocking feature and the second projecting interlocking feature include at least one rectangular-shaped pod. 
     
     
         6 . The shoe of  claim 3 , wherein the first projecting interlocking feature and the second projecting interlocking feature include at least one dome-shaped pod. 
     
     
         7 . The shoe of  claim 1 , wherein the at least one cutout and the at least one cavity have a same perimeter. 
     
     
         8 . The shoe of  claim 1 , wherein the at least one cavity is configured to accept and mate with the at least one projecting interlocking feature. 
     
     
         9 . A shoe comprising:
 a midsole having at least one cavity formed in an upper surface thereof; and   an insole having at least one projecting interlocking feature formed in a lower surface thereof, the at least one projecting interlocking feature having a complementary shape to that of the a least one cavity and being configured to aligned therewith.   
     
     
         10 . The shoe of  claim 9 , wherein the at least one cavity includes two cavities, and the at least one projecting interlocking feature includes two projecting interlocking features. 
     
     
         11 . The shoe of  claim 10 , wherein the two projecting interlocking features include a first projecting interlocking feature adjacent a heel region and a second projecting interlocking feature adjacent a forefoot region. 
     
     
         12 . The shoe of  claim 11 , wherein the first projecting interlocking feature and the second projecting interlocking feature include thicknesses that are greater than thickness of remaining portions of the insole. 
     
     
         13 . The shoe of  claim 11 , wherein the first projecting interlocking feature and the second projecting interlocking feature include at least one rectangular-shaped pod. 
     
     
         14 . The shoe of  claim 11 , wherein the first projecting interlocking feature and the second projecting interlocking feature include at least one dome-shaped pod. 
     
     
         15 . The shoe of  claim 9 , further comprising a lasting board disposed between the midsole and the insole, the lasting board having at least one cutout defining a cross-support, the at least one cutout being configured to accept the at least one projecting interlocking feature of the insole and align with the at least one cavity of the midsole. 
     
     
         16 . The shoe of  claim 15 , wherein the at least one cutout and the at least one cavity have a same perimeter. 
     
     
         17 . A method of manufacturing footwear, comprising:
 providing a shoe upper;   providing a midsole having at least one cavity formed in an upper surface thereof;   providing an insole having at least one projecting interlocking feature formed in a lower surface thereof; and   providing a lasting board, the lasting board having at least one cutout for accepting the at least one projecting interlocking feature.   
     
     
         18 . The method of  claim 17 , further comprising coupling the lasting board to the shoe upper. 
     
     
         19 . The method of  claim 17 , further comprising aligning the at least one cutout of the lasting board to the at least one cavity of the midsole. 
     
     
         20 . The method of  claim 17 , further comprising receiving the at least one projecting interlocking feature of the insole within the at least one cutout of the lasting board and the at least one cavity of the midsole.