Footwear with unitary insole and strap

Abstract

Unitary insole/strap layers for articles of footwear and methods for making such unitary insole/strap layers are provided. The insole/strap layers are transformed from a two-dimensional patterned base into a three-dimensional insole/strap layer, which simplifies the manufacturing process. The insole/strap layer is then secured to an outsole structure to form an article of footwear, such as a flip flop or sandal.

What is claimed is: 
     
         1 . A method for making a unitary insole/strap layer of an article of footwear, the method comprising:
 forming a patterned base having an insole portion and a strap portion, wherein the insole portion includes an aperture in a toe region and the strap portion comprises at least two straps each extending from either a midfoot region or a heel region of the insole portion and having a distal end;   folding the at least two straps relative to the insole portion and passing the distal end of each strap through the aperture;   folding the distal end of each strap passed through the aperture in opposite directions relative to the insole portion; and   securing the folded distal end of each strap to the insole portion.   
     
     
         2 . The method according to  claim 1 , wherein the at least two straps comprise a first strap and a second strap, wherein the first strap has a first side and a second side and the second strap has a first side and a second side, and wherein folding the two straps relative to the insole portion comprises:
 folding the first strap to form a first arch;   folding the second strap to form a second arch; and   aligning the distal end of each strap so that the second side of the first strap is adjacent to the second side of the second strap to form a thong.   
     
     
         3 . The method according to  claim 2 , wherein folding the distal end of each strap in opposite directions relative to the insole portion comprises:
 folding the distal end of the first strap passed through the aperture toward the insole portion; and   folding the distal end of the second strap passed through the aperture toward the insole portion.   
     
     
         4 . The method according to  claim 3 , wherein securing the folded distal end of each strap to the insole portion comprises;
 applying an adhesive to the first side of the folded distal end of the first strap adjacent the insole portion and applying pressure to the distal end of the first strap and the insole portion; and   applying an adhesive to the first side of the folded distal end of the second strap adjacent the insole portion and applying pressure to the distal end of the second strap and the insole portion.   
     
     
         5 . The method according to  claim 1 , wherein securing the folded distal end of each strap to the insole portion comprises applying an adhesive to the distal end of each strap adjacent the insole portion and applying pressure to the distal end of each strap and the insole portion. 
     
     
         6 . The method according to  claim 1 , wherein the at least two straps are formed as substantially rectangular shapes. 
     
     
         7 . The method according to  claim 1 , wherein the patterned base is made from a flexible material. 
     
     
         8 . The method according to  claim 7 , wherein the flexible material comprises neoprene. 
     
     
         9 . An article of footwear comprising:
 an outsole structure; and   a unitary insole/strap layer secured to the outsole structure, wherein the insole/strap layer comprises an insole portion and a strap portion, wherein the insole portion includes an aperture in a toe region, wherein the strap portion comprises at least two straps each extending from either a midfoot region or a heel region of the insole portion and having a distal end, wherein the at least two straps are folded relative to the insole portion and the distal end of each strap is passed through the aperture and the distal end of each strap passed through the aperture is folded in opposite directions relative to the insole portion and secured to the insole portion.   
     
     
         10 . The article of footwear according to  claim 9 , wherein the insole/strap layer is made from a flexible material. 
     
     
         11 . The article of footwear according to  claim 10 , wherein the flexible material comprises neoprene. 
     
     
         12 . A method for making a unitary insole/strap layer of an article of footwear, the method comprising:
 forming a patterned base having an insole portion and a strap portion, wherein the insole portion comprises a heel portion and a toe portion and the strap portion extends between the heel portion and the toe portion; and   wrapping the toe portion over and around the heel portion or the heel portion over and around the toe portion until a heel facing edge of the toe portion is aligned with a toe facing edge of the heel portion, such that the toe portion and heel portion form the insole portion and the strap portion is arched over the insole portion.   
     
     
         13 . The method according to  claim 12 , wherein a bottom surface of the insole portion can be secured to an outsole structure of an article of footwear. 
     
     
         14 . The method according to  claim 12 , wherein the strap portion is substantially rectangular in shape. 
     
     
         15 . The method according to  claim 12 , wherein the patterned base is made from a flexible material. 
     
     
         16 . The method according to  claim 15 , wherein the flexible material comprises neoprene. 
     
     
         17 . An article of footwear comprising:
 an outsole structure; and   an insole/strap layer secured to the outsole structure, wherein the insole/strap layer comprises an insole portion and a strap portion, wherein the insole portion comprises a heel portion and a toe portion and the strap portion extends between the heel portion and the toe portion such that the toe portion is wrapped over and around the heel portion or the heel portion is wrapped over and around the toe portion until a heel facing edge of the toe portion is aligned with a toe facing edge of the heel portion, such that the toe portion and heel portion form the insole portion and the strap portion is arched over the insole portion.   
     
     
         18 . The article of footwear according to  claim 17 , wherein the insole/strap layer is made from a flexible material. 
     
     
         19 . The article of footwear according to  claim 18 , wherein the flexible material comprises neoprene.