The present invention describes a shaped footwear device intended to be used as a supportive insole or orthotic and a system and methods for making the same. The footwear device includes a top foam layer, a light-cured composite material layer, and a bottom textile layer. The footwear device is created by conforming a pre-cured insole assembly to the plantar surface of a foot or foot mold and then exposing the pre-cured insole assembly to light to create a shaped footwear device with a light-cured composite material support plate.

An insulating shoe insert including a core layer formed of a cellular material, and a top layer and a bottom layer bonded to opposing sides of the core layer, respectively, the top layer and the bottom layer being configured as thin sheets of aromatic polyamide material such that the top layer and bottom layer cooperate with the core layer to create a heat transfer resistance sufficient to resist transfer of heat through the core layer.

Footwear with vertically lapped nonwoven layers in upper and sole structures for enhanced breathability and moisture wicking is disclosed. Exemplary vertically lapped nonwoven dual layers comprise one or more hydrophobic layers and one or more hydrophilic layers that are adhered to each other by a plurality of methods and are further integrated into the inside of the upper and sole of the footwear so that the hydrophilic layer is in direct contact with the feet. The hydrophilic part of the dual layer wicks sweat or bodily fluid from the wearer into the nonwoven and transports the moisture to the hydrophobic layer for fast evaporation, thus keeping the feet dry. The nonwoven footwear is environmentally friendly as the nonwoven layers can be made of recycled materials and may be fully recyclable.

An insole and/or outsole for a shoe such as an athletic shoe or cleat that includes a multilayer channeled assembly designed at preventing the transfer of heat from extremely hot ground surfaces, most notably synthetic turf, to the foot. In one embodiment, the insole includes a channeled layer of solid material with a very low thermal conductivity, preferably silicon or cork, as the base material beneath a layer of heat resistant felt preferably made of oxidized polyacrylonitrile fibers. The channeling in the base layer allows for air pockets to be created within the insole itself that makes the heat resistant felt more resistant to (i.e., more efficient at preventing) the transfer of heat. In another embodiment, the outsole for a shoe such as an athletic shoe or cleat includes a base layer of channeled solid material with low thermal conductivity, preferably silicon, cork, or polystyrene, below a layer of heat resistant felt preferably made of oxidized polyacrylonitrile fibers. This assembly is encased within a solid plastic mold that extends up to the base of the upper of the shoe or cleat and allows for little or no pressure to be put on the assembly itself. The studs for the cleats are preferably molded out of the plastic encasing itself.

An insole configured to be disposed in a shoe worn by a person, in particular during a walking period of the person. The insole includes a force and/or pressure measurement unit configured to acquire at least one representative measurement of the force and/or pressure exerted on the insole by the person, a motion measurement acquisition unit configured to acquire at least one measure representative of a motion of the person’s foot, and a processing unit configured to receive the force and/or pressure measurement and the motion measurement, to compute at least one walking parameter and to control the emission of stimulation at a walking moment according to the value of the walking parameter.

The present disclosure provides an insole, including a base having a front surface for corresponding to the foot sole of a wearer of a shoe with the insole and a rear surface for corresponding to an inner sole of the shoe; wherein the insole further includes a plurality of protrusions evenly arranged on the front surface; the protrusions have the same heights, each protrusion includes a column fixed on the base and a height of the column protruding out from the base ranges from 1 to 7 mm, and a coverage rate of the protrusions on the base ranges from 30% to 70%.

A footbed having at least one of a thickness adjustment panel and a lateral adjustment fin, each configured to be moved between a first configuration and a second configuration, the first and second configurations providing different fits of a shoe into which the footbed is inserted.

Designs and compositions of insoles for footwear are described herein. The insoles may be customized for a given foot. In some examples, the insole (100) includes a base comprising a variable thickness component (205), a directional stiffness component, a stability component, and a reinforcement component. The base may be a single composition that is manufactured using additive manufacturing techniques.

A force or pressure sensing device comprises one or more magnets resiliently held spaced from one or more magnetic sensors such that pressure on the device displaces the magnets relative to the magnetic field sensors. The device may be incorporated into an insole of a shoe, or integrated into a shoe, or integrated into a seat, cushion, mattress or saddle. The device includes one or more magnetic focussing elements on the opposite side of the magnetic field sensor from the magnets to focus and condition the magnetic field passing through the sensor. The magnetic focussing elements may be permanent magnets or magnetic materials having a high magnetic permeability such as mu-metals. Additional magnetic focussing elements may be placed adjacent to the magnets. Plural magnetic field sensors can be arranged in a symmetrical arrangement in a plane below the one or more magnets so that shear forces applied to the device causes lateral relative displacement of the magnet and magnetic field sensors changing the magnetic field sensed by the magnetic field sensors. The device can also include a motion detector such as an accelerometer which may be integral with the magnetic field sensor.

In certain aspects, the inventive subject matter is directed to production of constructs of footwear and components thereof by jet extrusion. The inventive subject matter contemplates novel processes for making such constructs using jets or streams of materials that solidify as fibers, and which form into two- or three-dimensional webs as they are collected. The webs may be in the nature of films, membranes, or mats. In some embodiments, the inventive subject matter generally relates to nonwoven textiles consisting of webs of superfine fibers, i.e., fibers with diameters in nanoscale or micronscale ranges.