Articles of footwear including unitary sole and footbed components and methods of manufacturing the same

Abstract

A method of manufacturing an article of footwear includes providing an upper and an insole of the article of footwear, connecting the upper to the insole to provide a combined upper and insole having a foot-receiving chamber and a footbed-receiving opening, providing a unitary combined sole and footbed of the article of footwear, the unitary combined sole and footbed including at least a portion of a sole having an upper surface, a first portion of a footbed connected to the portion of the sole, and a second portion of the footbed connected to the first portion of the footbed, the second portion of the footbed having a lower surface detached from the upper surface of the portion of the sole, passing the second portion of the footbed through the footbed-receiving opening and into the foot-receiving chamber, and securing the insole to the portion of the sole.

The following is claimed: 
     
         1 . A method of manufacturing an article of footwear, comprising:
 providing an upper of the article of footwear;   providing an insole of the article of footwear;   connecting the upper to the insole to provide a combined upper and insole, the combined upper and insole having a foot-receiving chamber and a footbed-receiving opening coupled to the foot-receiving chamber;   providing a unitary combined sole and footbed of the article of footwear, the unitary combined sole and footbed including at least a portion of a sole having an upper surface, a first portion of a footbed connected to the portion of the sole, and a second portion of the footbed connected to the first portion of the footbed, the second portion of the footbed having a lower surface detached from the upper surface of the portion of the sole;   passing the second portion of the footbed through the footbed-receiving opening and into the foot-receiving chamber; and   securing the insole to the portion of the sole.   
     
     
         2 . The method of  claim 1 , wherein providing the unitary combined sole and footbed includes forming the unitary combined sole and footbed via an injection molding process. 
     
     
         3 . The method of  claim 1 , wherein connecting the upper to the insole to provide the combined upper and insole includes connecting the upper and the insole via strobel stitching. 
     
     
         4 . The method of  claim 1 , wherein the portion of the sole includes the midsole. 
     
     
         5 . The method of  claim 1 , wherein the unitary combined sole and footbed further includes a third portion of the footbed connected to the first portion of the footbed, the third portion of the footbed having a lower surface detached from the upper surface of the portion of the sole, and further comprising passing the third portion of the footbed through the footbed-receiving opening and into the foot-receiving chamber. 
     
     
         6 . The method of  claim 5 , wherein the first portion of the footbed includes an arch-supporting portion, the second portion of the footbed includes a forefoot-supporting portion, and the third portion of the footbed includes a heel-supporting portion. 
     
     
         7 . The method of  claim 1 , wherein the first portion of the footbed includes an arch-supporting portion and the second portion of the footbed includes a forefoot-receiving portion. 
     
     
         8 . The method of  claim 1 , wherein the first portion of the footbed includes a heel-supporting portion and the second portion of the footbed includes an arch-receiving portion. 
     
     
         9 . The method of  claim 1 , wherein securing the insole to the portion of the sole includes adhering the insole to the portion of the sole. 
     
     
         10 . An article of footwear, comprising:
 a combined upper and insole having a foot-receiving chamber and a footbed-receiving opening coupled to the foot-receiving chamber;   a unitary combined sole and footbed including:
 at least a portion of a sole; 
 a first portion of a footbed connected to the portion of the sole; and 
 a second portion of the footbed connected to the first portion of the footbed, the second portion of the footbed extending through the footbed-receiving opening and disposed within the foot-receiving chamber. 
   
     
     
         11 . The article of footwear of  claim 10 , wherein the portion of the sole includes an upper surface adhered to the insole. 
     
     
         12 . The article of footwear of  claim 10 , wherein the first portion of the footbed includes an arch-supporting portion and the second portion of the footbed includes a forefoot-receiving portion. 
     
     
         13 . The article of footwear of  claim 10 , wherein the first portion of the footbed includes a heel-supporting portion and the second portion of the footbed includes an arch-receiving portion. 
     
     
         14 . A method of manufacturing an article of footwear, comprising:
 providing a mold including a first molding chamber and a second molding chamber coupled to the first molding chamber at an interface;   providing a first molten material to the first molding chamber, the first molten material having a first property;   providing a second molten material to the second molding chamber such that the second molten material and the first molten material engage each other at the interface, the second molten material having a second property, and the second property being different than the first property; and   permitting the first molten material and the second molten material to cure and thereby provide a unitary portion of the article of footwear.   
     
     
         15 . The method of  claim 14 , wherein the first molten material forms a first portion of the unitary portion of the article of footwear, the first property provides the first portion with a first hardness, the second molten material forms a second portion of the unitary portion of the article of footwear, the second property provides the second portion with a second hardness, and the second hardness is different than the first hardness. 
     
     
         16 . The method of  claim 14 , wherein the first property is a first color, and the second property is a second color, and the second color is different than the first color.