Cushioned stabilizing sock and method

Abstract

A cushioned stabilizing sock is described, having an inner fabric component, a midfoot stiffening component, a cushion heel component, and an outer fabric component. The sock may also have an attached or removable outer resin component. A method of making the sock comprises laying up the components upon a mold base covered by a release sheet.

What is claimed is: 
     
         1 . A footwear apparatus, comprising:
 an inner fabric component;   a stiffening component adjacent to and outside a portion of the inner fabric component;   a resilient heel component outside a portion of the fabric component;   an outer fabric component surrounding the inner fabric component, the stiffening component and the heel component; and   a resin component outside at least a portion of the outer fabric component.   
     
     
         2 . The footwear apparatus of  claim 1 , wherein the inner fabric component is shaped to cover a foot. 
     
     
         3 . The footwear apparatus of  claim 2 , wherein the stiffening component is a midfoot stiffing component and is made of carbon fiber and is located at least at a midfoot region of the apparatus. 
     
     
         4 . The footwear apparatus of  claim 2 , wherein the heel component is made of resilient material and is located at least at a heel portion of the apparatus. 
     
     
         5 . The footwear apparatus of  claim 4 , wherein the heel component partially directly overlies the stiffening component. 
     
     
         6 . The footwear apparatus of  claim 4 , wherein the heel component partially directly overlies the inner fabric component. 
     
     
         7 . The footwear apparatus of  claim 4 , wherein the heel component partially directly overlies the stiffening component and partially directly overlies the inner fabric component. 
     
     
         8 . The footwear apparatus of  claim 5 , wherein the outer fabric component completely surrounds an outside of the assembly comprising the inner fabric component, the stiffening component, and the resilient heel component. 
     
     
         9 . The footwear apparatus of  claim 6 , wherein the resin component partially surrounds an outside of the outer fabric component. 
     
     
         10 . The footwear apparatus of  claim 7 , wherein the resin component is bonded to the outer fabric component. 
     
     
         11 . The footwear apparatus of  claim 7 , wherein the resin component is separable from the outer fabric component. 
     
     
         12 . The footwear apparatus of  claim 10 , wherein the outer fabric component and the inner fabric component are sewn together at both a toe portion and an ankle portion respectively thereof. 
     
     
         13 . The footwear apparatus of  claim 12 , wherein the outer fabric component and the inner fabric component form a chamber enclosing the stiffening component and the resilient heel component. 
     
     
         14 . The footwear apparatus of  claim 13 , wherein the stiffening component is made of a more stiff material than the material of the resilient heel component. 
     
     
         15 . A method of manufacturing a footwear apparatus, comprising:
 providing a mold base;   covering at least partially the mold base with a release sheet;   covering at least partially the release sheet with an inner fabric component;   covering partially the inner fabric component with a stiffening component;   covering partially at least one of the inner fabric component and/or the stiffening component with a resilient heel component;   covering the stiffening component and resilient heel component with an outer fabric component;   sewing the inner fabric component and the outer fabric component together at a respective toe portions and ankle portions thereof to form an enclosure enclosing the stiffening component and the resilient heel component; and   removing the assembly comprising the inner fabric component, the stiffening component, the heel component and the outer fabric component from the assembly comprising the mold base and release sheet.   
     
     
         16 . The method according to  claim 15 , further comprising:
 covering partially the outer fabric component with a resin component.   
     
     
         17 . The method of  claim 16 , wherein the process of covering partially the outer fabric component with a resin component further comprises bonding the resin component to the outer fabric component. 
     
     
         18 . The method of  claim 16 , wherein the process of covering partially the outer fabric component with a resin component further comprises placing a second release sheet over the outer fabric component. 
     
     
         19 . The method of  claim 18 , wherein the resin component is removable from the outer fabric component. 
     
     
         20 . The method of  claim 19 , wherein the resin component covers at least a heel and midfoot portion of the footwear apparatus.