MOLDED FOOTBED WITH INTEGRALLY FORMED MASSAGING DOMES

Abstract

A footbed according to an embodiment of the present disclosure includes: a top surface; a bottom surface; a plurality of domes formed in the footbed, the plurality of domes protruding at the top surface; each of the plurality of domes having an outer diameter at the top surface and a cavity formed under the dome, the cavity extending to the bottom surface; a first set of the plurality of domes each having a first outer diameter at the top surface; a second set of the plurality of domes each having a second outer diameter at the top surface; wherein the first outer diameter is larger than the second outer diameter, and wherein the footbed is a single piece of injection molded foam material.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/585,299 filed Nov. 13, 2017, which is incorporated by reference herein in its entirety for all purposes.

TECHNICAL FIELD

Embodiments of the present disclosure relate generally to footwear, and more particularly to a footbed and outsole construction and assembly.

BACKGROUND

Existing massaging footbeds often include stiff protrusions that often sacrifice foot massaging performance for overall comfort. Massaging footbed elements are often solid nubs can cause irritation and discomfort, particularly for users whose feet are not accustomed to such footbeds.

SUMMARY

Example 1

A footbed according to an embodiment of the present disclosure includes: a top surface; a bottom surface; a plurality of domes formed in the footbed, the plurality of domes protruding at the top surface; each of the plurality of domes having an outer diameter at the top surface and a cavity formed under the dome, the cavity extending to the bottom surface; a first set of the plurality of domes each having a first outer diameter at the top surface; a second set of the plurality of domes each having a second outer diameter at the top surface; wherein the first outer diameter is larger than the second outer diameter, and wherein the footbed is a single piece of injection molded foam material.

Example 2

The footbed of Example 1, the first set of the plurality of domes each having a first inner diameter at the bottom surface, wherein the first inner diameter is smaller than the first outer diameter.

Example 3

The footbed of any of Examples 1 to 2, the second set of the plurality of domes each having a second inner diameter at the bottom surface, and wherein the first inner diameter is larger than the second inner diameter.

Example 4

The footbed of any of Examples 1 to 3, wherein the top surface comprises a heel region, a midfoot region, and a forefoot region, the heel region configured to engage a user's heel and the forefoot region configured to engage a user's forefoot during use of the footbed; wherein the heel region comprises more of the first set of the plurality of domes than the second set of the plurality of domes.

Example 5

The footbed of any of Examples 1 to 4, wherein the heel region does not include any of the second set of the plurality of domes, and wherein the forefoot region does not include any of the first set of the plurality of domes.

Example 6

The footbed of any of Examples 1 to 5, further comprising: a third set of the plurality of domes each having a third outer diameter at the top surface, wherein the second outer diameter is larger than the third outer diameter.

Example 7

The footbed of any of Examples 1 to 6, wherein the top surface comprises a heel region, a midfoot region, and a forefoot region, the heel region configured to engage a user's heel and the forefoot region configured to engage a user's forefoot during use of the footbed, the midfoot region situated between the heel region and the forefoot region; wherein the heel region comprises more of the first set of the plurality of domes than the second and third sets of the plurality of domes; wherein the forefoot region comprises more of the second set of the plurality of domes than the first and third sets of the plurality of domes; and wherein the midfoot region comprises more of the third set of the plurality of domes than the first and second sets of the plurality of domes.

Example 8

The footbed of any of Examples 1 to 7, wherein, along a length from a heel end toward a toe end of the footbed, the heel region comprises a first third of the length, the midfoot region comprises a second third of the length, and the forefoot region comprises a third third of the length.

Example 9

The footbed of any of Examples 1 to 8, wherein the first set of the plurality of domes is situated only at the heel region or between the heel region and the midfoot region; wherein the second set of the plurality of domes is situated only at the forefoot region or between the forefoot region and the midfoot region and between the midfoot region and the heel region; and wherein the third set of the plurality of domes is situated only at the midfoot region or between the midfoot region and the heel region or between the midfoot region and the forefoot region.

Example 10

The footbed of any of Examples 1 to 9, wherein the first outer diameter is at least five millimeters, and wherein the first outer diameter is fifteen to seventy-five percent larger than the second outer diameter.

Example 11

The footbed of any of Examples 1 to 10, wherein the first inner diameter is at least four millimeters.

Example 12

The footbed of any of Examples 1 to 11, wherein a thickness of each of the plurality of domes between the top surface and the cavity is between 1 and 2.5 millimeters.

Example 13

The footbed of any of Examples 1 to 12, wherein a bottom surface of each of the plurality of domes is flush with the top surface.

Example 14

A footwear system according to an embodiment of the present disclosure comprises a footbed comprising: a footbed top surface; a footbed bottom surface; a plurality of domes formed in the footbed, the plurality of domes protruding at the footbed top surface; each of the plurality of domes having an outer diameter at the top surface and a cavity formed under the dome, the cavity extending to the footbed bottom surface; a first set of the plurality of domes each having a first outer diameter at the footbed top surface; a second set of the plurality of domes each having a second outer diameter at the footbed top surface; wherein the first outer diameter is larger than the second outer diameter, and wherein the footbed is a single piece of injection molded foam material; and an outsole comprising: an outsole top surface; and an outsole bottom surface, wherein the outsole top surface is adhered to the footbed bottom surface such that the cavity of each of the plurality of domes entraps air in the cavity during use.

Example 15

The footwear system of any of Examples 1 to 14, wherein the cavity of each of the plurality of domes permanently entraps air, such that the entrapped air provides greater resistance to deformation of each of the plurality of domes than each of the plurality of domes would exhibit without such air entrapment.

Example 16

The footwear system of any of Examples 1 to 15, wherein each cavity of the plurality of domes is not in fluid communication with other cavities of the plurality of domes.

Example 17

The footwear system of any of Examples 1 to 16, wherein the top surface comprises a heel region, a midfoot region, and a forefoot region, the heel region configured to engage a user's heel and the forefoot region configured to engage a user's forefoot during use of the footbed; wherein the forefoot region does not include any of the first set of the plurality of domes.

Example 18

The footwear system of any of Examples 1 to 17, further comprising: a third set of the plurality of domes each having a third outer diameter at the top surface, wherein the second outer diameter is larger than the third outer diameter.

Example 19

The footwear system of any of Examples 1 to 18, wherein the top surface comprises a heel region, a midfoot region, and a forefoot region, the heel region configured to engage a user's heel and the forefoot region configured to engage a user's forefoot during use of the footbed, the midfoot region situated between the heel region and the forefoot region; wherein the heel region comprises more of the first set of the plurality of domes than the second and third sets of the plurality of domes; wherein the forefoot region comprises more of the second set of the plurality of domes than the first and third sets of the plurality of domes; and wherein the midfoot region comprises more of the third set of the plurality of domes than the first and second sets of the plurality of domes.

Example 20

The footwear system of any of Examples 1 to 19, wherein the first set of the plurality of domes is situated only at the heel region or between the heel region and the midfoot region; wherein the second set of the plurality of domes is situated only at the forefoot region or between the forefoot region and the midfoot region or between the midfoot region and the heel region; and wherein the third set of the plurality of domes is situated only at the midfoot region or between the midfoot region and the heel region or between the midfoot region and the forefoot region.

While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a front perspective view of a footbed according to an embodiment of the present disclosure.

FIG. 2 illustrates a top view of the footbed of FIG. 1, according to an embodiment of the present disclosure.

FIG. 3 illustrates a bottom view of the footbed of FIG. 1, according to an embodiment of the present disclosure.

FIG. 4 illustrates a front view of the footbed of FIG. 1, according to an embodiment of the present disclosure.

FIG. 5 illustrates a back view of the footbed of FIG. 1, according to an embodiment of the present disclosure.

FIG. 6 illustrates an inner side view of the footbed of FIG. 1, according to an embodiment of the present disclosure.

FIG. 7 illustrates an outer side view of the footbed of FIG. 1, according to an embodiment of the present disclosure.

FIG. 8 illustrates a top view of the footbed of FIG. 1, with cross-sectional annotations, according to an embodiment of the present disclosure.

FIG. 9 illustrates a partial cross-sectional view of the footbed of FIGS. 1 and 8 taken along line A-A of FIG. 8, according to an embodiment of the present disclosure.

FIG. 10 illustrates a partial cross-sectional view of the footbed of FIGS. 1 and 8 taken along line B-B of FIG. 8, according to an embodiment of the present disclosure.

FIG. 11 illustrates a partial cross-sectional view of the footbed of FIGS. 1 and 8 taken along line C-C of FIG. 8, according to an embodiment of the present disclosure.

FIG. 12 illustrates an exemplary pressure diagram for a foot.

FIG. 13 illustrates an adhesive agent being applied to a top surface of an insole, according to an embodiment of the present disclosure.

FIG. 14 illustrates an adhesive agent being applied to a bottom surface of a footbed, according to an embodiment of the present disclosure.

FIG. 15 illustrates a footbed being joined with an outsole according to an embodiment of the present disclosure.

FIG. 16 illustrates a back elevation partial cross-sectional view of a system having a combined footbed and outsole, with a user's heel stepping on the system, according to an embodiment of the present disclosure.

FIG. 17 illustrates a top view of a footbed according to another embodiment of the present disclosure.

FIG. 18 illustrates a top view of a footbed according to yet another embodiment of the present disclosure.

FIG. 19 illustrates an exemplary cross-sectional diagram of the footbed of FIG. 18, according to an embodiment of the present disclosure.

FIG. 20 is a legend illustrating six different dome and cavity configurations for the footbed of FIGS. 18 and 19, according to an embodiment of the present disclosure.

While embodiments of the disclosure are amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the invention to the particular embodiments described. On the contrary, the invention is intended to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

FIGS. 1-7 illustrate a footbed 10 according to an embodiment of the present disclosure. The footbed 10 may include a top surface 50, a bottom surface 60, and a plurality of domes 20 formed in the footbed. The footbed 10 may further include corresponding cavities 70 at the bottom surface 60 under one or more of the domes 20. The plurality of domes 20 protrudes at the top surface 50. The domes 20 may be formed of different sizes; for example, a first dome or set of domes 22 may have a first outer diameter at the top surface 50; a second dome or set of domes 24 may have a second outer diameter at the top surface 50 that is smaller than the outer diameter of the domes 22; and a third dome or set of domes 26 may have a third outer diameter at the top surface 50 that is smaller than the outer diameter of domes 24, according to an embodiment of the present disclosure. Footbed 10 may also include a protruding island 32 that extends under the base of the toes of the wearer, as well as a hole 34 configured to receive a toe bar, for example as used with sandal-type footwear. The top surface 50 may further include a raised bump pattern 36. The footbed 10 may further include a large heel dome 40 with an optional corresponding cavity 42 on the bottom surface 60, according to an embodiment of the present disclosure.

According to an embodiment of the present disclosure, and as illustrated in FIGS. 8-11, each of the plurality of domes 20 has an outer diameter at the top surface and a cavity 70 formed under the dome, the cavity 70 extending to the bottom surface 60. A first set of the plurality of domes 22 may each have a first outer diameter OD1 at the top surface 50; a second set of the plurality of domes 24 may each have a second outer diameter OD2 at the top surface 50; and the first outer diameter OD1 may be larger than the second outer diameter OD2.

As illustrated, the footbed 10 is a single piece of injection molded foam material; in other words, the footbed 10 and each of the plurality of domes 20 and cavities 70 is formed integrally as a single piece of injection molded foam material. Footbed 10 may alternatively be described as unitary, monolithic, homogeneous, and/or integral, according to embodiments of the present disclosure. In one embodiment of the present disclosure, all elements shown in FIGS. 1-11 are formed integrally as a single piece of injection molded foam material, and, in some embodiments, all elements shown in FIGS. 1-11 are unitary, monolithic, homogeneous, and/or integral. In an embodiment of the present disclosure, forming the footbed 10 as a single piece of molded foam material adds comfort and durability while permitting the integrally formed domes to perform massaging and/or cushioning functions.

FIG. 12 illustrates an exemplary pressure profile for a human foot while standing, during the act of walking. When comparing the heel area, the midfoot area, and the forefoot area, the highest pressure concentration is in the heel area, followed by the forefoot area, followed by the midfoot area. Given this typical pressure profile, an embodiment of the footbed 10 of the present disclosure includes domes having a larger outer diameter at the top surface in the heel area (where FIG. 12 indicates “big bubbles”), includes domes having a smaller outer diameter at the top surface in the forefoot area (where FIG. 12 indicates “medium bubble”), and includes domes having an even smaller outer diameter at the top surface in the midfoot area (where FIG. 12 indicates “small bubbles”). The larger the domes, which may alternatively be referred to as bubbles and/or air pockets and/or gas pockets, the greater the degree of cushioning effect applied to the bottom of the user's foot when the user steps on and/or is using the footbed 10. The smaller the domes, the lesser the degree of cushioning effect applied to the bottom of the user's foot when the user steps on and/or is using the footbed 10. As such, using large domes at the heel area, medium domes at the forefoot area, and small domes at the midfoot area provides a massaging effect on the bottom of the foot, while simultaneously providing cushioning and relative pressure distribution across the footbed 10 from heel to midfoot to forefoot, according to an embodiment of the present disclosure.

FIG. 8 illustrates examples of outer diameters for various domes. For example, outer diameter OD1 of domes 22 may be 9.98 millimeters (mm), outer diameter OD2 of domes 24 may be 8.46 mm, and outer diameter OD3 of domes 26 may be 5.81 mm. Other dimensions, ranges of dimensions, and/or relative dimensions are both possible and contemplated by the present disclosure. According to an embodiment of the present disclosure, the first set of the plurality of domes 22 may each have a first inner diameter ID1 at the bottom surface 60, and the first inner diameter ID1 may be smaller than the first outer diameter OD1. For example, FIG. 9 shows a first inner diameter ID1 as 8.24 mm, although other dimensions, ranges of dimensions, and/or relative dimensions are both possible and contemplated by the present disclosure.

FIG. 9 further shows that a height H1 of the cavity 70 formed under dome 22 may be 16.13 mm, and the thickness T1 of dome 22 may be 1.99 mm, although other dimensions, ranges of dimensions, and/or relative dimensions are both possible and contemplated by the present disclosure. FIG. 10 shows that an inner diameter ID2 may be 6.62 mm, height H2 of the cavity 70 formed under dome 24 may be 11.25 mm, and the thickness T2 of dome 24 may be 2.36 mm, although other dimensions, ranges of dimensions, and/or relative dimensions are both possible and contemplated by the present disclosure. FIG. 11 shows that an inner diameter ID3 may be 4.51 mm, height H3 of the cavity 70 formed under dome 26 may be 8.53 mm, and the thickness T3 of the dome 26 may be 1.30 mm, although other dimensions, ranges of dimensions, and/or relative dimensions are both possible and contemplated by the present disclosure.

According to an embodiment of the present disclosure, the second set of the plurality of domes 24 each has a second inner diameter ID2 at the bottom surface 60, and the first inner diameter ID1 is larger than the second inner diameter ID2.

As illustrated by the boundary lines 80, 82 of FIG. 2, the top surface 50 of the footbed 10 may include a heel region 90, a midfoot region 94, and a forefoot region 92. Boundary 80 illustrates an exemplary boundary between the heel region 90 (or heel section 90 or heel portion 90) and the midfoot region 94 (or midfoot section 94 or midfoot portion 94). Boundary 82 illustrates an exemplary boundary between the midfoot region 94 and the forefoot region 92 (or forefoot section 92 or forefoot portion 92), according to an embodiment of the present disclosure. One of ordinary skill in the art, based on the present disclosure, will understand that such imaginary boundaries 80, 82 may be situated in different places depending on the type and size of footbed, while still serving as boundaries between such heel, midfoot, and forefoot areas as understood by one of ordinary skill in the art. As another non-limiting example, along a length from a heel end 84 toward a toe end 86 of the footbed, the heel region comprises a first third of the length, the midfoot region comprises a second third of the length, and the forefoot region comprises a third third of the length.

The heel region 90 is configured to engage a user's heel and the forefoot region 92 is configured to engage a user's forefoot during use of the footbed 10, according to an embodiment of the present disclosure. According to one embodiment, the heel region 90 includes more of the first set of the plurality of domes 22 than the second set of the plurality of domes 24. According to some embodiments of the present disclosure, the heel region 90 does not include any of the second set of the plurality of domes 24, and the forefoot region 92 does not include any of the first set of the plurality of domes 22. According to some embodiments of the present disclosure, boundaries 80 and/or 82 are straight.

According to an embodiment of the present disclosure, the footbed 10 includes a third set of the plurality of domes 26 each having a third outer diameter ID3 at the top surface 50. According to such embodiments, the second outer diameter OD2 is larger than the third outer diameter OD3.

As described above, the top surface 50, and/or the footbed itself 10, comprises a heel region 90, a midfoot region 94, and a forefoot region 92, the heel region 90 configured to engage a user's heel and the forefoot region 92 configured to engage a user's forefoot during use of the footbed, the midfoot region 94 situated between the heel region 90 and the forefoot region 92, according to an embodiment of the present disclosure. The heel region 90 may include more of the first set of the plurality of domes 22 than the second 24 and third sets of the plurality of domes 26; and the forefoot region 92 may include more of the second set of the plurality of domes 24 than the first 22 and third sets of the plurality of domes 26; and the midfoot region may include more of the third set of the plurality of domes 26 than the first 22 and second sets of the plurality of domes 24, according to an embodiment of the present disclosure.

According to an embodiment of the present disclosure, the first set of the plurality of domes 22 is situated only at the heel region 90 or between the heel region 90 and the midfoot region 94; he second set of the plurality of domes 24 is situated only at the forefoot region 92 or between the forefoot region 92 and the midfoot region 94 and between the midfoot region 94 and the heel region 90; and the third set of the plurality of domes 26 is situated only at the midfoot region 94 or between the midfoot region 94 and the heel region 90 or between the midfoot region 94 and the forefoot region 92, for example as shown in FIGS. 1-8.

According to an embodiment of the present disclosure, the first outer diameter OD1 is at least five millimeters, and the first outer diameter OD1 is fifteen to seventy-five percent larger than the second outer diameter OD2. According to another embodiment of the present disclosure, the first outer diameter OD1 is at least four millimeters. According to another embodiment of the present disclosure, the first outer diameter OD1 is fifteen to twenty-five percent larger than the second outer diameter OD2. According to another embodiment of the present disclosure, the first outer diameter OD1 is ten to thirty percent larger than the second outer diameter OD2. According to an embodiment of the present disclosure, the first inner diameter ID1 is at least four millimeters. According to an embodiment of the present disclosure, first outer diameter OD1 is sixty-five to eighty percent larger than the third outer diameter OD3. According to an embodiment of the present disclosure, the first outer diameter OD1 is sixty to eighty-five percent larger than the third outer diameter OD3.

According to some embodiments of the present disclosure, a thickness of each of the plurality of domes between the top surface and the cavity (for example, T1, T2, and/or T3) is between 1 and 2.5 millimeters. According to some embodiments of the present disclosure, a thickness of each of the plurality of domes between the top surface and the cavity (for example, T1, T2, and/or T3) is between 0.5 and 3.0 millimeters. According to some embodiments of the present disclosure, a bottom surface 72 of each of the plurality of domes 20 is flush with the top surface 50. According to some embodiments of the present disclosure, a ratio of an overall height (for example, H1, H2, and/or H3) of each cavity 70 with respect to a thickness (for example, T1, T2, and/or T3) of the dome at the top of each cavity 70 is between four and eight. According to some embodiments of the present disclosure, a ratio of an overall height (for example, H1, H2, and/or H3) of each cavity 70 with respect to a thickness (for example, T1, T2, and/or T3) of the dome at the top of each cavity 70 for the highest instance of each cavity 70 of the sets 22, 24, 26 is between four and eight.

As illustrated by FIGS. 1-11 and 16, a footwear system 100 according to an embodiment of the present disclosure includes a footbed 10 including a footbed top surface 50, a footbed bottom surface 60, a plurality of domes 20 formed in the footbed 10, with the plurality of domes 20 protruding at the footbed top surface 50. The plurality of domes may each include an outer diameter at the top surface 50 and a cavity 70 formed under the dome 20, the cavity 70 extending to the footbed bottom surface 60. In some embodiments, a first set of the plurality of domes 22 each has a first outer diameter OD1 at the footbed top surface 50 and a second set of the plurality of domes 24 each has a second outer diameter OD2 at the footbed top surface 50. According to such embodiments, the first outer diameter OD1 is larger than the second outer diameter OD2, and the footbed 10 is a single piece of injection molded foam material. A footbed system 100 according to an embodiment of the present disclosure may further include an outsole 101 including an outsole top surface 102, and an outsole bottom surface 104. As illustrated in FIG. 16, the outsole top surface 102 is adhered to the footbed bottom surface 60 such that the cavity 70 of each of the plurality of domes 20 entraps air in the cavity during use.

According to an embodiment of the present disclosure, the cavity 70 of each of the plurality of domes 20 permanently entraps air, such that the entrapped air provides greater resistance to deformation of each of the plurality of domes 20 than each of the plurality of domes 20 would exhibit without such air entrapment. FIG. 16 illustrates a user's heel UH compressing the plurality of domes 20 and the footbed 10 as the user steps on the footbed 10 while the footbed is adhered to the outsole 101. According to one embodiment of the present disclosure, FIG. 16 shows the cavities 70 and the air or gas therein being compressed by the weight of the user as transmitted through the user's heel UH (which may also be referred to as the user's foot). As shown in FIG. 16, a compression force applied to the top of the system 100 causes the overall height of one or more of the domes 20 to decrease, and/or causes the dome portion over each cavity 70 to become compressed and/or deformed such that it becomes flush or closer to flush with a top surface 50 of the footbed 10, according to one embodiment of the present disclosure. According to some embodiments of the present disclosure, the cavities 70 of entrapped or entrained air or gas exhibit a greater resistance to deformation than the injection molded foam material in the footbed 10 surrounding such cavities 70, thus permitting the domes 20 and the cavities 70 over which the domes 20 extend to exhibit both a cushioning and a massaging quality or performance with respect to the bottom of the user's foot.

According to an embodiment of the present disclosure, each cavity 70 of the plurality of domes 20 is not in fluid communication with other cavities 70 of the plurality of domes 20. According to some embodiments of the present disclosure, the top surface 50 comprises a heel region 90, a midfoot region 94, and a forefoot region 92, the heel region 90 being configured to engage a user's heel and the forefoot region 92 being configured to engage a user's forefoot during use of the footwear system 100. According to such embodiments, the forefoot region 94 does not include any of the first set of the plurality of domes 22.

FIGS. 13-15 illustrate a method of creating footwear system 100, according to an embodiment of the present disclosure. After the outsole 101 and footbed 10 are molded, for example via an injection (e.g. a single injection) molding process, an adhesive or bonding agent may be applied (e.g. brushed) onto a top surface 102 of the outsole 101, as illustrated in FIG. 13. An adhesive or bonding agent may be applied (e.g. brushed) onto a bottom surface 60 of footbed 10, as illustrated in FIG. 14. The footbed 10 may be placed onto the outsole 101 as illustrated in FIG. 15, in which the bottom surface 60 of footbed 10 is placed into contact with the top surface 102 of outsole 101. An optional step or steps may include activating the adhesive via light, for example ultraviolet light, and/or via other energy source such as ultrasonic energy or heat, according to an embodiment of the present disclosure. In one embodiment, the adhesive or bonding agent is activated by ambient air and/or by one or more chemicals applied to the bottom surface 60 and/or top surface 102 and/or contained within the adhesive or bonding agent. According to embodiments of the present disclosure, other methods may be used to join or couple the bottom surface 60 of the footbed 10 with the top surface 102 of the outsole 101. Such joining or coupling creates an air-tight or hermetic seal around the cavity 70 of one or more, or the entire plurality of, domes 20, according to an embodiment of the present disclosure. According to an alternative embodiment of the present disclosure, the seal between the bottom surface 60 and the top surface 102 is not hermetic and/or is not sufficient, for any or necessarily all of the cavities 70, to prevent passage of gas (e.g. air) into or out of the cavity 70 upon compression or expansion of (e.g. walking on) the domes 20 of the footbed 10, but which still creates a deformation resistance of the cavity 70 that is greater than the deformation resistance of the cavity 70 had the bottom surface 60 not have been joined to the top surface 102.

According to an embodiment of the present disclosure, the footwear system 100 includes a third set of the plurality of domes 26 each having a third outer diameter OD3 at the top surface 50, with the second outer diameter OD2 being larger than the third outer diameter OD3. According to some embodiment of the present disclosure, the footwear system 100 includes a heel region 90, a midfoot region 94, and a forefoot region 92, the heel region 90 being configured to engage a user's heel and the forefoot region 94 being configured to engage a user's forefoot during use of the footbed 10, the midfoot region 92 situated between the heel region 90 and the forefoot region 92; wherein the heel region 90 includes more of the first set of the plurality of domes 22 than the second 24 and third 26 sets of the plurality of domes, wherein the forefoot region 92 includes more of the second 24 set of the plurality of domes than the first 22 and third 26 sets of the plurality of domes, and wherein the midfoot region 94 includes more of the third 26 set of the plurality of domes than the first 22 and second 24 sets of the plurality of domes.

According to some embodiments of the present disclosure, the first 22 set of the plurality of domes is situated only at the heel region 90 or between the heel region 90 and the midfoot region 94, the second set 24 of the plurality of domes is situated only at the forefoot region 92 or between the forefoot region 92 and the midfoot region 94 or between the midfoot region 94 and the heel region 90, and the third set 26 of the plurality of domes is situated only at the midfoot region 94 or between the midfoot region 94 and the heel region 90 or between the midfoot region 94 and the forefoot region 92.

FIGS. 17-20 illustrate another embodiment of the present disclosure in which the outer diameter of the domes decreases from the heel end toward the toe end, for example from a “low pressure” (large outer diameter domes) region near the heel region, a “mid pressure” (medium outer diameter domes) region near the midfoot region, and a “high pressure” (smaller diameter domes) region near the forefoot region. FIG. 18 illustrates six different outer diameter sized sets of domes (decreasing in outer diameter from the heel end toward the toe end), and FIG. 19 illustrates an exemplary cross-sectional view of such footbed. FIG. 20 illustrates examples of each of the six different outer diameter sized sets of domes of FIGS. 17-19, according to an embodiment of the present disclosure.

According to embodiments of the present disclosure, the cavities 70 and/or the domes 20 above them, formed in the footbed 10, are resilient, such that they resume their original shape after foot pressure is released (e.g. after being compressed). According to some embodiments, they do so even after repeated cycles, for example in a dynamic compression set test of 500,000 cycles of compression. According to another embodiment of the present disclosure, they footbed 10 does not become delaminated from the outsole 101 during use, including after repeated cycles, for example after one hundred thousand cycles of flexing of the footbed to an angle of sixty degrees at a temperature of twenty-three degrees Celsius. According to an embodiment of the present disclosure, the inclusion of a plurality of domes 20 and corresponding cavities 70 under the domes 20 results in a footbed 10 that is at least fifteen percent lighter, in other words weighs at least fifteen percent less, than if the cavities 70 had been filled in with molded foam material, for example with the same molded foam material out of which the rest of the footbed 10 has been constructed. The presence of a plurality of domes 20 further promotes air ventilation below the foot, for example by creating air channels below the foot and above the top surface 50, according to an embodiment of the present disclosure. Molding the footbed 10 as a single piece of molded material, for example a closed-cell foam material, also promotes durability, ease of cleaning and drying, and/or odor resistance.

The footbed 10 and/or the outsole 101 may be injection molded, for example each with a two- or three-piece spring loaded injection mold, with resin molded foam, for example with ethylene vinyl acetate (EVA), according to an embodiment of the present disclosure. Such foam molding process may result in the footbed 10 and/or outsole 101 expanding immediately following injection, prior to contraction and/or cooling, for example. Footbed 10 and/or outsole 101 may alternatively be injection molded, and/or molded, via other molding processes as would be appreciated by one of ordinary skill in the art, based on the present disclosure.

Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. For example, while the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.

Claims

1. A footbed comprising:

a top surface;

a bottom surface;

a plurality of domes formed in the footbed, the plurality of domes protruding at the top surface;

each of the plurality of domes having an outer diameter at the top surface and a cavity formed under the dome, the cavity extending to the bottom surface;

a first set of the plurality of domes each having a first outer diameter at the top surface;

a second set of the plurality of domes each having a second outer diameter at the top surface;

wherein the first outer diameter is larger than the second outer diameter, and

wherein the footbed is a single piece of injection molded foam material.

2. The footbed of claim 1, the first set of the plurality of domes each having a first inner diameter at the bottom surface, wherein the first inner diameter is smaller than the first outer diameter.

3. The footbed of claim 2, the second set of the plurality of domes each having a second inner diameter at the bottom surface, and wherein the first inner diameter is larger than the second inner diameter.

4. The footbed of claim 1, wherein the top surface comprises a heel region, a midfoot region, and a forefoot region, the heel region configured to engage a user's heel and the forefoot region configured to engage a user's forefoot during use of the footbed; wherein the heel region comprises more of the first set of the plurality of domes than the second set of the plurality of domes.

5. The footbed of claim 4, wherein the heel region does not include any of the second set of the plurality of domes, and wherein the forefoot region does not include any of the first set of the plurality of domes.

6. The footbed of claim 1, further comprising:

a third set of the plurality of domes each having a third outer diameter at the top surface, wherein the second outer diameter is larger than the third outer diameter.

7. The footbed of claim 6, wherein the top surface comprises a heel region, a midfoot region, and a forefoot region, the heel region configured to engage a user's heel and the forefoot region configured to engage a user's forefoot during use of the footbed, the midfoot region situated between the heel region and the forefoot region; wherein the heel region comprises more of the first set of the plurality of domes than the second and third sets of the plurality of domes; wherein the forefoot region comprises more of the second set of the plurality of domes than the first and third sets of the plurality of domes; and wherein the midfoot region comprises more of the third set of the plurality of domes than the first and second sets of the plurality of domes.

8. The footbed of claim 7, wherein, along a length from a heel end toward a toe end of the footbed, the heel region comprises a first third of the length, the midfoot region comprises a second third of the length, and the forefoot region comprises a third third of the length.

9. The footbed of claim 7, wherein the first set of the plurality of domes is situated only at the heel region or between the heel region and the midfoot region; wherein the second set of the plurality of domes is situated only at the forefoot region or between the forefoot region and the midfoot region and between the midfoot region and the heel region; and wherein the third set of the plurality of domes is situated only at the midfoot region or between the midfoot region and the heel region or between the midfoot region and the forefoot region.

10. The footbed of claim 1, wherein the first outer diameter is at least five millimeters, and wherein the first outer diameter is fifteen to seventy-five percent larger than the second outer diameter.

11. The footbed of claim 10, wherein the first inner diameter is at least four millimeters.

12. The footbed of claim 1, wherein a thickness of each of the plurality of domes between the top surface and the cavity is between 1 and 2.5 millimeters.

13. The footbed of claim 1, wherein a bottom surface of each of the plurality of domes is flush with the top surface.

14. A footwear system comprising:

a footbed comprising: a footbed top surface; a footbed bottom surface; a plurality of domes formed in the footbed, the plurality of domes protruding at the footbed top surface; each of the plurality of domes having an outer diameter at the top surface and a cavity formed under the dome, the cavity extending to the footbed bottom surface; a first set of the plurality of domes each having a first outer diameter at the footbed top surface; a second set of the plurality of domes each having a second outer diameter at the footbed top surface; wherein the first outer diameter is larger than the second outer diameter, and wherein the footbed is a single piece of injection molded foam material; and

an outsole comprising: an outsole top surface; and an outsole bottom surface, wherein the outsole top surface is adhered to the footbed bottom surface such that the cavity of each of the plurality of domes entraps air in the cavity during use.

15. The footwear system of claim 14, wherein the cavity of each of the plurality of domes permanently entraps air, such that the entrapped air provides greater resistance to deformation of each of the plurality of domes than each of the plurality of domes would exhibit without such air entrapment.

16. The footwear system of claim 14, wherein each cavity of the plurality of domes is not in fluid communication with other cavities of the plurality of domes.

17. The footwear system of claim 14, wherein the top surface comprises a heel region, a midfoot region, and a forefoot region, the heel region configured to engage a user's heel and the forefoot region configured to engage a user's forefoot during use of the footbed; wherein the forefoot region does not include any of the first set of the plurality of domes.

18. The footwear system of claim 14, further comprising:

a third set of the plurality of domes each having a third outer diameter at the top surface, wherein the second outer diameter is larger than the third outer diameter.

19. The footwear system of claim 18, wherein the top surface comprises a heel region, a midfoot region, and a forefoot region, the heel region configured to engage a user's heel and the forefoot region configured to engage a user's forefoot during use of the footbed, the midfoot region situated between the heel region and the forefoot region; wherein the heel region comprises more of the first set of the plurality of domes than the second and third sets of the plurality of domes; wherein the forefoot region comprises more of the second set of the plurality of domes than the first and third sets of the plurality of domes; and wherein the midfoot region comprises more of the third set of the plurality of domes than the first and second sets of the plurality of domes.

20. The footwear system of claim 19, wherein the first set of the plurality of domes is situated only at the heel region or between the heel region and the midfoot region; wherein the second set of the plurality of domes is situated only at the forefoot region or between the forefoot region and the midfoot region or between the midfoot region and the heel region; and wherein the third set of the plurality of domes is situated only at the midfoot region or between the midfoot region and the heel region or between the midfoot region and the forefoot region.