Orthotic devices for providing arch support for the foot are disclosed. The orthotic device includes a base member, an arch support portion, and a covering for coupling the arch support portion to the base member. A method of providing continuous contact with the plantar surface of the foot during all phases of the gait cycle is also disclosed. In addition, methods of assembling and using the orthotic device are also disclosed.

A procedure for making a shoe including steps of weaving/construction of an upper, forming the upper in which two previously constructed stockings are a tube that is closed on one side while the other end of the tube remains open, subjecting the upper to a steam jet that dampens and softens a thermosetting polymer yarn, and passing the upper through a high-temperature kiln. Construction of the sole entails inserting the upper into a shoe-tree of a mould, positioning the shoe-tree with the upper and closure between two rings of the mould for polyurethane injection. Because of the presence of the arch structure a barrier that limits the passage thereof to the inner part of the upper, with filling of the mould, passage of predetermined quantities of polyurethane only through the slots of the arch structure permitting joint points to be created between the sole and upper and with the inner.

A procedure for making a shoe including steps of weaving/construction of an upper, forming the upper in which two previously constructed stockings are a tube that is closed on one side while the other end of the tube remains open, subjecting the upper to a steam jet that dampens and softens a thermosetting polymer yarn, and passing the upper through a high-temperature kiln. Construction of the sole entails inserting the upper into a shoe-tree of a mould, positioning the shoe-tree with the upper and closure between two rings of the mould for polyurethane injection. Because of the presence of the arch structure a barrier that limits the passage thereof to the inner part of the upper, with filling of the mould, passage of predetermined quantities of polyurethane only through the slots of the arch structure permitting joint points to be created between the sole and upper and with the inner.

In one aspect, a textile component including bulking yarn is disclosed. In embodiments, the textile component is a knitted component. In one embodiment, an article of footwear includes a knitted component arch support configured to reduce the rate of pronation. A support structure may include a fusible yarn adjacent to an external surface of the arch support, a bulking yarn, and a nonfusible yarn. In certain embodiments, an arch support includes compartments and flex lines. In another aspect, an article having a knitted component includes a rigid material, a bulking yarn, and a flexible material. The rigid material may be fusible yarn. Methods for forming a textile component are provided. One embodiment involves knitting a first section comprising a fusible yarn, a second section comprising a bulking yarn, and a third section comprising a nonfusible yarn, and heating.

In one aspect, a textile component including bulking yarn is disclosed. In embodiments, the textile component is a knitted component. In one embodiment, an article of footwear includes a knitted component arch support configured to reduce the rate of pronation. A support structure may include a fusible yarn adjacent to an external surface of the arch support, a bulking yarn, and a nonfusible yarn. In certain embodiments, an arch support includes compartments and flex lines. In another aspect, an article having a knitted component includes a rigid material, a bulking yarn, and a flexible material. The rigid material may be fusible yarn. Methods for forming a textile component are provided. One embodiment involves knitting a first section comprising a fusible yarn, a second section comprising a bulking yarn, and a third section comprising a nonfusible yarn, and heating.

A sole structure for an article of footwear includes a unitary sole with a first cushioning body having a first hardness and a second cushioning having a second hardness greater than the first hardness. Both the first and the second cushioning bodies are exposed at a periphery of the sole. The second cushioning body may have a wedge surface that interfaces with a lateral extremity of the first cushioning body and angles laterally outward toward a lateral side exterior surface of the sole from a lower extent to an upper extent of the wedge surface. The second cushioning body may underlie the first cushioning body in a portion of a forefoot region of the sole such that the first cushioning body establishes a foot-facing exterior surface and the second cushioning body establishes a ground-facing exterior surface of the sole where the first cushioning body overlies the second cushioning body.

A sole structure for an article of footwear includes a unitary sole with a first cushioning body having a first hardness and a second cushioning having a second hardness greater than the first hardness. Both the first and the second cushioning bodies are exposed at a periphery of the sole. The second cushioning body may have a wedge surface that interfaces with a lateral extremity of the first cushioning body and angles laterally outward toward a lateral side exterior surface of the sole from a lower extent to an upper extent of the wedge surface. The second cushioning body may underlie the first cushioning body in a portion of a forefoot region of the sole such that the first cushioning body establishes a foot-facing exterior surface and the second cushioning body establishes a ground-facing exterior surface of the sole where the first cushioning body overlies the second cushioning body.

An article of footwear includes an outsole, an upper secured to the outsole and defining a foot-receiving cavity and an ankle opening, and a unitary, full-length midsole having a forefoot region, a midfoot region, and a heel region, and configured to be removably inserted into the foot-receiving cavity through the ankle opening. The midsole includes a first cushioning body having a first hardness and a second cushioning body having a second hardness greater than the first hardness. The midsole has a lateral side, a medial side, a forwardmost extent disposed in the forefoot region, and a rearmost extent disposed in the heel region. The second cushioning body includes a lateral segment that extends through the lateral side in the forefoot region, and a portion of the lateral segment of the second cushioning body is closer to the forwardmost extent than to the midfoot region.

An article of footwear includes an outsole, an upper secured to the outsole and defining a foot-receiving cavity and an ankle opening, and a unitary, full-length midsole having a forefoot region, a midfoot region, and a heel region, and configured to be removably inserted into the foot-receiving cavity through the ankle opening. The midsole includes a first cushioning body having a first hardness and a second cushioning body having a second hardness greater than the first hardness. The midsole has a lateral side, a medial side, a forwardmost extent disposed in the forefoot region, and a rearmost extent disposed in the heel region. The second cushioning body includes a lateral segment that extends through the lateral side in the forefoot region, and a portion of the lateral segment of the second cushioning body is closer to the forwardmost extent than to the midfoot region.

An insole having, a base layer, a top layer fixedly secured to the base layer, a middle layer comprised of the base layer and the top layer positioned between the base layer and the top layer, a pressure projection extending upwardly from within the middle layer and extending past an upper surface of the upper layer, the projection including a disc fixedly secured within the middle layer, an annular ring fixedly secured atop the disc, a circular metal insert fixedly secured atop the disc within the annular ring, the circular metal insert having a horseshoe-shaped aperture therein. The insole may also include projections either positioned proximate an inside arch and/or positioned proximate an outside arch. The insole may also comprise a projection positioned proximate to a midfoot region.