Conformable and pressure-spreading footbeds, methods of manufacture thereof, and articles containing the footbed

Abstract

A footbed for use in an article of footwear, the footbed comprising a conforming layer having an initial, substantially uniform thickness of 3 to 9 millimeters, and comprising a foam that permanently conforms to a shape of a foot after wear; and a pressure-spreading layer disposed on the conforming layer, having a thickness of 2 to 4 millimeters, and comprising a resilient foam.

What is claimed is: 
     
         1 . A footbed for use in an article of footwear, the footbed comprising:
 a conforming layer having an initial, substantially uniform thickness of 3 to 9 millimeters, and comprising a foam that permanently conforms to a shape of a foot after wear; and   a pressure-spreading layer disposed on the conforming layer, having a thickness of 2 to 4 millimeters, and comprising a resilient foam.   
     
     
         2 . The footbed of  claim 1 , wherein the conforming layer has a thickness of 4 to 8 millimeters. 
     
     
         3 . The footbed of  claim 1 , wherein the pressure-spreading layer has a thickness less than the thickness of the conforming layer. 
     
     
         4 . The footbed of  claim 1 , wherein the pressure-spreading layer has a thickness of 2.5 to 3.5 millimeters. 
     
     
         5 . The footbed of  claim 1 , wherein the conforming layer comprises ethylene-vinyl acetate, a polyethylene, polyethylene-polypropylene blend, polystyrene, neoprene, chloroprene, polyurethane, or a combination comprising at least one of the foregoing. 
     
     
         6 . The footbed of  claim 1 , wherein the conforming layer comprises ethylene-vinyl acetate. 
     
     
         7 . The footbed of  claim 1 , wherein the pressure-spreading layer comprises polyurethane, polypropylene, or a combination comprising at least one of the foregoing. 
     
     
         8 . The footbed of  claim 1 , wherein the pressure-spreading layer comprises a microcellular polyurethane foam. 
     
     
         9 . The footbed of  claim 1 , wherein the pressure-spreading layer reduces a pressure point on a foot of a wearer. 
     
     
         10 . The footbed of  claim 1 , wherein the conforming layer has an Asker C hardness of 5 to 20 before use of the footbed by a wearer. 
     
     
         11 . The footbed of  claim 1 , wherein the pressure-spreading layer has an Asker C hardness of 10 to 40 before use of the footbed by a wearer. 
     
     
         12 . The footbed of  claim 1 , wherein the pressure-spreading layer has a compression set of 0 to 20% at 25° C. before use of the footbed by a wearer. 
     
     
         13 . The footbed of  claim 12 , wherein the compression set is 1 to 10%. 
     
     
         14 . The footbed of  claim 1 , wherein the pressure-spreading layer extends substantially the entire length of the conforming layer. 
     
     
         15 . The footbed of  claim 1  further comprising a fabric layer disposed on a side of the pressure-spreading layer opposite the conforming layer. 
     
     
         16 . The footbed of  claim 1  further comprising an adhesive layer disposed between the pressure relieving and the conforming layer, or between the fabric layer and the pressure-spreading layer. 
     
     
         17 . A method for the manufacture of the footbed of  claim 1 , comprising laminating the conforming layer and the pressure-spreading layer to provide the footbed. 
     
     
         18 . A footbed made by the method of  claim 17 . 
     
     
         19 . An article of footwear comprising an outsole, an upper attached to the outsole, and the conforming layer of the footbed of  claim 1  disposed on the outsole. 
     
     
         20 . The article of  claim 19  further comprising a midsole, an insole, or a combination comprising at least one of the foregoing. 
     
     
         21 . A method for the manufacture of the footbed of  claim 1 , comprising forming the pressure relieving layer on the conforming layer, or forming the conforming layer on the pressure relieving layer to provide the footbed. 
     
     
         22 . A footbed made by the method of  claim 21 .