CONFORMABLE AND PRESSURE-SPREADING FOOTBEDS, METHODS OF MANUFACTURE THEREOF, AND ARTICLES CONTAINING THE FOOTBED
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.
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 .