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.

An orthopedic shoe may include a shoe having an upper and a sole, the upper having a multi-compartment toe box at a forefront of the shoe, the multi-compartment toe box including a separate compartment for the big toe; and an elevating portion at a location corresponding to a big toe. Further another orthopedic shoe may include a shoe having an upper and a sole; and an elevating portion, wherein an outsole of the sole has a groove formed therein at a location corresponding to a base of the elevating portion which contacts the sole at the location where the big toe bends. Further yet another orthopedic shoe may include a shoe having an upper and a sole; and an elevating portion, wherein the upper comprises a toe box, and wherein the toe box has a peak height above the sole at a location above the elevating portion.

The present disclosure relates to a dual-density insole (or sock liner) for a shoe. According to aspects set forth herein, the insole includes a carrier with two cavities. Two inserts with a density or hardness level that is different from that of the carrier are positioned in the cavities for increased performance. The disclosed insole further exhibits a molded geometry marked with shaped protrusions.

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.

A plurality of orthotic systems are provided. One bi-layer system is constructed from a single sheet of fabric that is molded into two layers. One tri-layer system includes a base layer; a mid-layer; and an upper layer. The upper layer is joined to the mid-layer and the mid-layer is joined to the base layer. The coupling of the base layer, the mid-layer and the upper layer create a rear spring section, a mid-spring section and a front spring section in which the upper layer is suspended over the mid-layer and the heel portion is suspended on the proximal heel end of the base layer.

FIG. 1 illustrates a shoe with a support structure for a bunion foot, according to one embodiment of the present invention. As disclosed, a shoe with a support for allaying a bunion foot comprising a leather lining, a stretchable fabric and an arch support. The leather lining forms a support structure around the feet of a user. The stretchable fabric is stitched in-line with the leather lining. The arch support is connected inside the leather lining to support a sole of the shoe. The stretchable fabric is attached an inner lining of the shoe. The shoe further comprises a heel counter attached between the inner lining and an upper.

The present disclosure is directed to a toe box insert configured to provide support between a wearer's toes and the end of a footwear. An exemplary toe box insert comprises a compressible material. The compressible material can be characterized by a firmness, a flexibility, and a springback. The firmness can provide rigidity to the footwear even when a force is applied on the toe box insert by a wearer. The flexibility can cause the toe box insert to indent in response to a force applied on the toe box insert by the wearer. The springback can cause the toe box insert to return to an original shape after a force applied by a wearer ceases.

The present disclosure is directed to a toe box insert configured to provide support between a wearer's toes and the end of a footwear. An exemplary toe box insert comprises a compressible material. The compressible material can be characterized by a firmness, a flexibility, and a springback. The firmness can provide rigidity to the footwear even when a force is applied on the toe box insert by a wearer. The flexibility can cause the toe box insert to indent in response to a force applied on the toe box insert by the wearer. The springback can cause the toe box insert to return to an original shape after a force applied by a wearer ceases.

The new apparatus is an orthopedic foot bed created using multiple materials to provide maximum comfort for an individual. The apparatus is composed of a flexible material such as, for example, memory foam on top of another material such as an impact absorbing material and an arch-support foot bed made of, for example, antimicrobial energy returning foam, with the entire apparatus covered in a stretchy suede textile in one embodiment.

Provided are footbeds having multiple points of contact and varying compression rates for use in articles of footwear. In one embodiment, a footbed may include apertures (for example, ovals) arranged in a varying grid density. In another embodiment, a footbed may include a lattice having edges that define polygons arranged in a constant grid density. In another embodiment, a footbed may include a lattice having edges that define polygons arranged in a constant grid density and having protruding structures within each polygon.