Shoe Construction and Method of Manufacture

Abstract

A shoe construction and method of manufacture a shoe that provides an improved arch support that is customized and self-adjusted to provide maximum comfort and support, even when the shape of the arch changes during movement. The shoe construction includes an outsole layer, a midsole layer, a cushion layer and a lining layer. The arch support of the shoe is formed with a midsole layer made of a relatively soft material that increasing its width from the outsole layer such that the arch support flexes when pressure from a foot is placed on it.

What I claim is: 
     
         1 . A shoe having an arch support, comprising:
 a. an outsole layer having a predetermined width;   b. a midsole layer above said outsole layer;   c. a lining layer above said midsole layer having a predetermined width wider than said outsole layer;   wherein said midsole layer increasing its width from said outsole layer to said lining layer to form the arch support; and   wherein said midsole layer is made of a material having a hardness of between around 65-70 durometers, such that the arch support flexes when pressure is placed on it and the arch support returns to its original position when pressure is removed from it.   
     
     
         2 . The shoe of  claim 1  further comprising a cushion layer between said midsole layer and said lining layer. 
     
     
         3 . The shoe of  claim 1  wherein said outsole layer is made of a thermoplastic polyurethane. 
     
     
         4 . The shoe of  claim 1  wherein said outsole layer is made of a thermoplastic elastomer. 
     
     
         5 . The shoe of  claim 1  wherein said midsole layer is made of polyurethane. 
     
     
         6 . The shoe of  claim 1  wherein said midsole layer is made of ethylene vinyl acetate. 
     
     
         7 . The shoe of  claim 1  wherein said midsole layer is made of rubber. 
     
     
         8 . The shoe of  claim 2  wherein said cushion layer is made of memory foam. 
     
     
         9 . The shoe of  claim 2  wherein said cushion layer is made of cork filler. 
     
     
         10 . The shoe of  claim 1  wherein said lining layer is made of soft leather. 
     
     
         11 . The method of manufacturing a shoe having an arch support, comprising the steps of:
 a. providing an outsole having a predetermined width;   b. providing a shoe last having a convex lower surface;   c. providing a midsole layer having a hardness of between around 65-70 durometers, above said outsole layer;   d. providing a lining layer above said midsole layer having a predetermined width wider than the outsole layer; and   e. forming the midsole layer with a concave surface with said shoe last and with increasing width from the outsole layer to the lining layer to form the arch support.   
     
     
         12 . The method of  claim 11  further comprising the step of providing a cushion layer between said midsole layer and said lining layer. 
     
     
         13 . The method of  claim 11  wherein said outsole layer is made of thermoplastic polyurethane. 
     
     
         14 . The method of  claim 11  wherein said outsole layer is made of thermoplastic elastomer. 
     
     
         15 . The method of  claim 11  wherein said midsole layer is made of polyurethane. 
     
     
         16 . The method of  claim 11  wherein said midsole layer is made of ethylene vinyl acetate. 
     
     
         17 . The method of  claim 11  wherein said midsole layer is made of rubber. 
     
     
         18 . The method of  claim 12  wherein said cushion layer is made of memory foam. 
     
     
         19 . The method of  claim 12  wherein said cushion layer is made of cork filler. 
     
     
         20 . The method of  claim 11  wherein said lining layer is made of soft leather.