A sole structure for an article of footwear includes a first midsole body and a second midsole body. The first midsole body defines a ground-facing surface and a foot-facing surface opposite the ground-facing surface and includes a first midsole material, which has a first hardness. The second midsole body extends through the first midsole body. As such, the second midsole body extends beyond the ground-facing surface of the first midsole body. The second midsole body includes a second midsole material, which has a second hardness, and the first hardness is greater than the second hardness.

An insulating shoe insert, as for use in an athletic shoe, comprises a core layer to cushion and to resist moisture, comprising a honeycomb-like cellular material, and a top layer and a bottom layer positioned on opposing sides of the core layer, the top layer and bottom layer to resist the transfer of heat through the insulating shoe insert. The top layer and bottom layer comprise an aromatic polyamide, in some embodiments a long-chain synthetic polyamide in which at least 85% of the amide linkages are attached directly to two aromatic rings, in some specific embodiments NOMEX or a similar meta amarid material. The core layer generally includes a honeycomb-like cellular material with irregularly shaped and spaced cells, often a vegetable-based honeycomb-like cellular material. The top layer and bottom layer are bonded to the core layer by an adhesive.

A flexible shoe snugging fitment is oblong with a thickness providing pad that is carried on top of a foot, preferably held in place against the foot with hosiery, which underlies and spaces a top part, e.g., vamp, of an article of footwear, e.g., shoe or boot, from the foot snugging the footwear on the foot improving fit and helping prevent relative movement therebetween. A preferred fitment is oblong and transversely oriented relative to a lengthwise fore-aft extent of the foot. Fitment has a central portion from which flaps extend oppositely outwardly that each extend around part of a corresponding side of the foot helping to prevent side-to-side relative movement between the foot and footwear worn on the foot. One preferred fitment is an assembly with a smaller adjuster pad slidably received in a pocket in a pad carrier with the pad extendable to adjust thickness and width of the assembly.

Selectively textured footbeds for athletic footwear are described. A footbed includes a rearfoot portion and a plurality of discrete raised areas extending from the rearfoot portion. The discrete raised areas are constructed and arranged to engage a rearfoot region of a plantar surface of a foot. The footbeds provide a sensory input to the plantar surface to allow a user to determine whether and/or how to adjust his or her gait.

A method of forming a castless orthotic for a patient's foot in need thereof. The method comprises preparing an orthotic template for the foot wherein the template extends between a heel end and a toe end. In preparing the template the steps of attaching a three-quarter length or full length upper thermoplastic material to a or three-quarter length lower thermoplastic material, or providing a thermoplastic material having a variable thickness such that said thickness decreases from said heel end to said toe end is provided. Then attaching an outer lower layer to the lower thermoplastic material and attaching an outer upper layer to the upper thermoplastic material, or attaching an outer layer to each face of the variable thickness thermoplastic material and heating the prepared orthotic template for a predetermined period of time at a predetermined temperature to soften the orthotic template. A wrap is then placed on top of the foot foam and the foot of the patient is placed on top of the wrap and foot foam. The patient's foot is lifted and the heated orthotic template is placed on top of the wrap and then placing the patient's foot on top of the heated orthotic template. The wrap is placed about the longitudinal axis of the foot to retain the heated orthotic template intermediate the sole of the foot and the foot foam whereby the sides of the orthotic template are particularly supported by the wrap. The method further includes ensuring the foot is positioned over a cuboid support and a medial longitudinal arch support wherein the cuboid support is disposed on the outside of the bottom of the foot and the cuboid support is moved to push the foot upwardly until a resistance is felt, and where the foot is also positioned over the medial longitudinal arch support which is then pushed and pulled upwardly until the foot is moved into a neutral position or if it is unable to be translated or rotated due to until it reaches its end range of motion. At this time, the heel of the patient's foot is lifted to place their weight substantially on the front of their foot and a coolant is applied to at least the heel end of the orthotic template.

A shoe includes an outsole having a room defined in the top thereof. A vamp is connected to the peripheral wall of the room. An air pad and an insole are located in the room. The air pad includes a front pad and a rear pad. A tube is connected between the front and rear pads. The front pad includes an inflatable support portion and a resilient support section which is located at the front portion of the front pad. The resilient support section has multiple buffering portions. A plate is located on the front pad and between the inflatable support portion and the insole. The plate restricts the deformation area on the inflatable support portion to deform the insole.

An article of footwear may include a sole structure fixedly attached to an upper defining an internal cavity configured to receive a foot of a wearer. The sole structure may include an exposed outer member configured to contact the ground, the exposed outer member including a first aperture, and a sensory feedback member disposed at least partially within the first aperture in the outer member, the sensory feedback member including a first end and a second end. The first end of the sensory feedback member may include a projection extending through the first aperture and configured to contact the ground. In addition, the second end of the sensory feedback member may include a plurality of flexible bristles extending through a portion of the sole structure and exposed to the internal cavity.

An article of footwear may include a sole structure fixedly attached to an upper defining an internal cavity configured to receive a foot of a wearer. The sole structure may include an exposed outer member configured to contact the ground, the exposed outer member including a first aperture, and a sensory feedback member disposed at least partially within the first aperture in the outer member, the sensory feedback member including a first end and a second end. The first end of the sensory feedback member may include a projection extending through the first aperture and configured to contact the ground. In addition, the second end of the sensory feedback member may include a plurality of flexible bristles extending through a portion of the sole structure and exposed to the internal cavity.

An orthopedic shoe appliance includes a pad for providing support for midfoot arches, the second metatarsal, and the third metatarsal of a foot, wherein the pad does not provide substantial support under a heel of the foot or under the first metatarsal, the fourth metatarsal, and the fifth metatarsal. A method for manufacturing an orthopedic appliance includes obtaining a pad; and shaping the pad to provide support for midfoot arches, the second metatarsal, and the third metatarsal of a foot, but not provide substantial support under a heel of the foot or under the first metatarsal, the fourth metatarsal, and the fifth metatarsal.

The present invention relates to a process for producing a flexible polyurethane foam thermally recyclable by fusion, and to hybrid materials made of flexible polyurethane foam and compact thermoplastic elastomer and/or expanded thermoplastic polyurethane.