Abstract: A shoe sole having improved cushioning characteristics is disclosed. The sole includes a midsole having a top layer of material and a bottom layer of material. In one embodiment, the top layer of material may be harder than the bottom layer of material. A pattern of lugs defining a wave may be formed on the bottom layer of material. The wave may generally be in the shape of sine wave so as to provide improved cushioning characteristics for the sole. An outsole may also be formed on the bottom layer of material and an upper may be connected to the top layer of material, such that a shoe is formed.

Abstract: A variety of devices for protecting a user's foot from injury are disclosed. In one instance, the device is an external metatarsal protection device for a shoe or boot, having a sole with a first surface for supporting a wearer's foot and a second surface for contacting a ground area, an upper affixed to the sole, and an integral toe cap. An interior surface of the upper and the first surface of the sole define a receptacle for receiving the wearer's foot. The external protection device is incorporated along an exterior surface of the upper and is positioned to protect at least a metatarsal region of the wearer's foot. In an instance, the external protection device has injection-molded first and second layers of material, with the cushioning elements formed on a surface of the first layer and a plurality of grooves defined on a surface of the second layer.

Abstract: A method of constructing footwear includes providing a mold having an inner cavity, injecting an expandable material into the inner cavity, removing the expandable material from the inner cavity such that the material expands to form a footwear-shaped shell having an inner cavity and at least one recessed area offset from an inner surface of the shell, and inserting a chassis within the inner cavity of the expanded shell. The chassis has one or more components adapted to protect a user's foot from injury. The insertion of the chassis within the shell permanently affixes the one or more components within the at least one recessed area of the shell.

Abstract: A footwear system is disclosed, which includes a shell having an inner cavity and at least one recessed area offset from an inner surface of the shell, and a chassis having one or more components adapted to protect a user's foot from injury. In one embodiment, the chassis is insertable into the inner cavity of the shell, such that the one or more components of the chassis are securely retained (e.g., permanently affixed) within the at least one recessed area of the shell. Methods of forming the aforementioned footwear system using expandable materials are also disclosed.

Abstract: A variety of devices for protecting a user's foot from injury are disclosed. In one embodiment, the device may be a metatarsal protection device, which may include a first layer of material having top and bottom surfaces, with at least one of such surfaces including a series of cones or a pattern of hexagons thereon. The metatarsal protection device may also include a second relatively rigid layer of material overlying the first layer, and the first layer may be shaped to conform to the metatarsal region of the user's foot, such that the device is configured to protect the metatarsal region against injury. Other configurations and variations of a metatarsal protection device are also disclosed, as are other uses for the principles of the invention(s) disclosed herein (e.g., protection devices for other areas of the foot, etc).

Abstract: A shoe sole having improved cushioning characteristics is disclosed. The sole includes a midsole having a top layer of material and a bottom layer of material. In one embodiment, the top layer of material may be harder than the bottom layer of material. A pattern of lugs defining a wave may be formed on the bottom layer of material. The wave may generally be in the shape of sine wave so as to provide improved cushioning characteristics for the sole. An outsole may also be formed on the bottom layer of material and an upper may be connected to the top layer of material, such that a shoe is formed.