Method of fabricating custom-fitted footbed

Abstract

A method and article of manufacture for fabricating a footbed for an article of footwear includes the use of a moldable gel material which is shaped by having the wearer place his/her foot on the upper surface of the footbed. The thus-molded gel material is then subjected to sunlight for at least a predetermined time period to permanently solidify the thus-molded gel material in conformity to the shape of the wearer's foot.

1 . A method for fabricating a custom-fitted footbed for use in an article of footwear, said method comprising the steps of: 
 a) providing a foot-shaped member comprising a formable material that becomes set and solidified after exposure to sunlight for at least a predetermined time;    b) placing the wearer's foot onto said member so that an impression of the wearer's foot is formed in said formable material; and    c) after removing the foot from said member exposing said member and the molded formable material to sunlight for at least said predetermined time so that said molded formable material is set permanently to conform to the shape of the wearer's foot.    
     
     
         2 . The method of  claim 1 , in which said member includes a first layer and a second layer, said formable material being disposed intermediate said first and second layers.  
     
     
         3 . The method of  claim 1 , in which said formable material is a gel-like substance.  
     
     
         4 . The method of  claim 3 , in which said gel-like substance is contained in at least one container disposed between said first and second layers  
     
     
         5 . The method of  claim 1 , in which said formable material comprises a polyester resin including a photo catalyst or an ultraviolet catalyst.  
     
     
         6 . The method of  claim 2 , in which one of said first and second layers is transparent to sunlight and UV rays and the other of said first and second layers is opaque to sunlight.  
     
     
         7 . The method of  claim 2 , in which said first and second layers are each transparent.  
     
     
         8 . The method of  claim 2 , in which at least one of said first and second layers is transparent.  
     
     
         9 . The method of  claim 2 , in which the wearer's foot is placed on the then upper, opaque one of said first and second layers to form said impression, and further comprising the steps of inverting the footbed after said impression is formed and then exposing the then upper, transparent one of said first and second layers to sunlight.  
     
     
         10 . The method of  claim 1 , in which said predetermined time is at least two minutes.  
     
     
         11 . The method of  claim 1 , in which said predetermined time is between 4 and 6 minutes in bright sunlight, 6 and 8 minutes for partial sun, and 8 and 20 minutes for a light overcast.  
     
     
         12 . An article of manufacture for use in fabricating an article of footwear custom fit to a wearer, said article including an upper layer and a lower layer, at least one of said upper and lower layers being transparent, and a formable material disposed intermediate said upper and lower layers and having the property of being set and solidified after exposure to sunlight for at least a predetermined time.  
     
     
         13 . The article of  claim 12 , in which said formable material is gel-like in form.  
     
     
         14 . The article of  claim 13 , in which said gel-like formable material is contained in at least one container disposed between said upper and lower layers.  
     
     
         15 . The article of  claim 12 , in which said formable material includes a polyester resin and a styrene polymer.  
     
     
         16 . The article of  claim 15 , in which said polyester resin includes a photo catalyst or an ultraviolet catalyst.  
     
     
         17 . The article of  claim 12 , in which said lower layer is transparent and said upper layer is opaque  
     
     
         18 . The article of  claim 12 , in which said upper and lower layers are each transparent.  
     
     
         19 . A sandal, shoe or boot fabricated according to the method of  claim 1 .  
     
     
         20 . A sandal, shoe or boot made using the article of  claim 12.