GB2517189A

GB2517189A - Footwear and methods of making footwear

Info

Publication number: GB2517189A
Application number: GB1314575.0A
Authority: GB
Inventors: Max Dinmahamed; Richard James Swift
Original assignee: BRITANNIA FOOTWEAR UK Manufacturing Ltd
Current assignee: BRITANNIA FOOTWEAR UK Manufacturing Ltd
Priority date: 2013-08-14
Filing date: 2013-08-14
Publication date: 2015-02-18
Anticipated expiration: 2033-08-14
Also published as: GB201510860D0; GB2529521A; GB2517189B; GB201314575D0

Abstract

An item of footwear, and a method of making footwear, comprises a shoe with a footbed portion 22 in direct mechanical interlock with an outsole portion 100. The outsole portion comprises upper (10, Fig 4) and lower (40, Fig 4) faces, the lower face being in contact with a ground surface during use and the upper surface mechanically engaging with the footbed portion. The footbed portion is mechanically engaged with the upper surface of the outsole on a first lower face and engaging with the bottom surface of a foot on its opposing upper face. In one embodiment the lower footbed face or upper outsole face comprises one or more projecting elements (20,21, Fig 3) which extend outwardly its surface and engage with one or more recesses (11, Fig 3) in the respective outsole or footbed portion. The projecting elements may form an interference fit or snap fit with the recesses. An upper 80 may be provided which is optionally affixed within a groove 41 in the outer peripheral edge of the outsole portion.

Description

FOOTWEAR AND METHODS OF MAKING FOOTWEAR

STATEMENT OF INVENTION

The present invention relates to footwear, methods of manufacturing footwear, and complementary outsole and insole components for use in said footwear.

BACKGROUND

Conventional shoe constructs generally comprise a sole portion, the bottom of which contacts the ground in use, a footbed (also known as an insock or sock liner) above the sole onto which the foot is directly placed in use, and an upper which wraps across the top of the foot to hold the sole in place on the bottom of the foot.

In conventional shoe constructs, the sole portion typically comprises a number of layers (see, e.g. Figure 7). For instance, conventional shoe soles comprise an outsole 71, insole 72 and a midsole 73 placed between the outsole and insole. The outsole acts as a durable base for contacting a ground surface in use and may be a single piece or comprise a number of separate pieces, which may be different materials. The insole layer forms the interior surface of the shoe located directly beneath the footbed. The insole layer acts to provide a planar supporting layer for placement of the footbed and toot and provides a layer under which the upper 74 can be wrapped when affixing the sole to the upper. The midsole is a layer of material affixed between the outsole and insole layers, usually with the function of providing additional comfort and support, for instance having a shock-absorptive capacity. A number of midsole layers may be provided depending on the intended purpose of the shoe.

The footbed 75 is the part of the shoe that comes into direct contact with the base of the foot in use and is situated directly on top of the insole. The footbed functions to add extra cushioning and I or to control the shape, moisture and I or odour of the shoe. It may also be beneficial for health reasons, e.g. to correct or mitigate irregularities in the shape or positioning of the foot during standing or walking.

In conventional shoe construction, it is usual to attach the footbed 75 to the shoe insole 72 by use of adhesives and I or stitching. Alternatively, as often adopted in modern leisure-type footwear, the footbed may be simply positioned loosely into the shoe, i.e. by resting on the insole surface and following the profile and periphery of the inside base of the shoe upper 74. It should be noted that such footbeds are sometimes referred to in the art as "insoles" (mostly in the US), but such "insoles" are distinct from the true insole base layer 72 of the shoe, which is in fact the interior bottom surface of the shoe above the outsole and midsole layers onto which the footbed (insole") 75 is placed.

A benefit of using adhesives and / or stitching to affix the footbed to the insole is that the footbed adheres firmly to the insole layer and is thus resistant to movement within the shoe both in a horizontal (sliding) and vertical (lifting) planes. However, a problem with these methods is that it is often difficult or impossible to remove the footbed cleanly in the event that it becomes damaged, worn or malodorous. The usual result therefore is that attempts to remove the footbed leave irregular "clumps" of the base footbed material attached to the insole, particularly in the toe area, which cannot be easily reached in a conventional shoe, even by a professional shoe repair merchant.

Thus, the end result is that the whole shoe may need replacing to solve the problem.

Footbeds that are positioned loosely onto the insole and rely on a relative "periphery" fit have the benefit of being easily removed and replaced. However, the lack of any substantial coupling between the insole and footbed means that, under general wear, foot movement and downward pressure can distort the footbed shape and lead to the footbed "riding up" the wall of the shoe upper. This is particularly the case in sports shoes, where the footbed is subject to dynamic changes in pressure and direction.

Foot sweating can also cause the footbed to adhere to the bottom surface of the foot and dislodge it to such a degree that it becomes necessary after use for the wearer to have to remove the footbed and re-position it. This need to re-position the footbed is undesirable and, over time, this action can lead to a permanently damaged or distorted footbed that no longer conforms to its original shape or function and needs replacing.

Many attempts have been made to mitigate these problems by modification of the shoe insole and / or footbed parts of shoes. For instance, UK Patent Application GB2209922A discloses a non-slip insole base (i.e. insole) for insertion into a shoe beneath the footbed (the footbed is referred to as an "insole" in this document, see e.g. page 2, lines 32 to page 3 lines 5). The insole base contains a number of raised ridges that are intended to engage the footbed to reduce lateral shear and thus reduce lateral movement ofthefootbed in use (see, e.g. Figures 1-4). Such solutions thus typically require the addition of new material layers to conventional shoe constructs, adding undesired bulk to the shoe. In the case of UK Patent Application GB2209922A, the intended engagement of ridges projecting from the insole base into the footbed body, particularly in the key pressure areas of the heel and forefoot will also have a detrimental effect on comfort in the key areas that need it most. This is because the parts of the footbed in engagement with the projecting ridges in use would experience reduced thickness and thus reduced cushioning compared to a conventional footbed. It would therefore be necessary to provide an even bulkier footbed layer to provide the same level of comfort compared to an analogous conventional footbed, thus adding further to the undesired bulk. Moreover, whilst such projections into the footbed designs may mitigate lateral movement of the footbed in use, they do little to prevent vertical lift of the footbed from the insole base, resulting for example, from adhesion of the footbed to the underside of the foot.

There is thus a need to provide new footwear and new methods of manufacturing footwear that obviate or mitigate the problems described above.

SUMMARY OF INVENTION

Broadly speaking, the present invention provides a new footwear construction comprising a shoe footbed in direct mechanical engagement with the shoe outsole.

This direct engagement between outsole and footbed brings about a number of advantages as discussed below.

The invention also provides a method of making a shoe by mechanically engaging the footbed with the outsole.

DESCRIPTION OF THE INVENTION

In a first aspect is provided a shoe comprising an outsole portion in direct mechanical engagement with a footbed portion.

In particular, the first aspect of the invention may thus provide a shoe comprising an outsole portion and a footbed portion: the outsole portion comprising upper and lower outsole faces, the lower outsole face configured to contact a ground surface when in use and the upper outsole face configured to mechanically engage the footbed portion; and the footbed portion comprising upper and lower footbed faces, the upper footbed face configured to contact the bottom surface of a foot when in use and the lower footbed face configured to mechanically engage the upper outsole face; wherein the outsole portion is in mechanical engagement with the footbed portion. Suitably, such mechanical engagement is wherein the upper outsole face is in mechanical engagement with the lower footbed face.

The present invention thus provides a new shoe construction based on direct mechanical engagement of the footbed portion with the outsole portion.

The mechanical engagement between the footbed and outsole portions has the benefit of restricting movement of the footbed within the shoe in use without the need for conventional adhesives and / or stitching. Such footbed movement is particularly problematic in conventional shoes during vigorous (e.g. sporting) activity.

Furthermore! the direct engagement of the outsole portion with the footbed portion allows for a substantially streamlined I lightweight shoe design, since conventional midsole and I or insole layers are not required. These advantages would thus be particular beneficial in a sports shoe (e.g. running shoe).

The result is a substantially simplified and potentially streamlined shoe design which can be manufactured more efficiently and without the need for additional footbed-fixing steps, such as sewing or gluing.

Mechanical engagement In the shoes of the present invention, the outsole portion is in mechanical engagement with the footbed portion. Suitably, the upper outsole face is in mechanical engagement with the lower footbed face.

The term "engagement" refers to a mutual physical interaction between the respective outsole and footbed portions whereby the movement of the footbed relative to the outsole is restricted in at least one dimension. Suitably, the mechanical engagement restricts movement of the footbed portion in at least one dimension in the horizontal plane relative to the respectively engaging faces of the outsole and footbed portions (i.e. in a plane parallel to the respective outsole and footbed faces, thus restricting sliding movement between the respective outsole and footbed portions in one, or typically both, horizontal dimensions). Preferably, the mechanical engagement also restricts movement of the footbed portion relative to the outsole portion in the vertical plane relative to the mutually interacting faces of the respective outsole and footbed portions (i.e. in a plane generally orthogonal to the respective outsole and footbed faces, thus restricting the footbed portion from lifting away from the outsole portion).

In embodiments at least one of the footbed and outsole portions comprises one or more projecting elements extending outwardly from the surface (i.e. in a plane orthogonal to the respective footbed I outsole face) and in mechanical engagement with one or more recesses in the body of the respective outsole or footbed portion.

Thus, whilst benefiting from a frictional engagement between the outsole and footbed body portions, the engagement also includes mechanical engagement of one or more projecting elements into recesses in the respective footbed or outsole portion.

Suitably, at least one of the lower footbed face and upper outsole face may comprise one or more projecting elements extending outwardly from the respective surface and in mechanical engagement with one or more recesses in the respective upper outsole face or lower footbed face.

In embodiments, both of the footbed and outsole portions comprise one or more projecting elements extending outwardly from their respective surfaces and in mechanical engagement with one or more recesses in the respective outsole and footbed portions. Suitably, both of the lower footbed face and upper outsole face may therefore comprise one or more projecting elements extending outwardly from their respective surfaces and in mechanical engagement with one or more recesses in the respective upper outsole face and lower footbed face.

Typically only one of the footbed and outsole portions comprises one or more projecting elements extending outwardly from its surface in mechanical engagement with one or more recesses in the respective outsole or footbed portion. Thus, typically only one of the lower footbed face and upper outsole faces comprises one or more projecting elements extending outwardly from its surface in mechanical engagement with one or more recesses in the respective upper outsole face or lower footbed face.

In embodiments, the outsole portion comprises one or more projecting elements extending outwardly from its surface in mechanical engagement with one or more recesses in the footbed portion. Suitably, the upper outsole face may therefore complise one or more projecting elements extending outwardly from its surface (i.e. in a plane orthogonal to the upper outsole face) in mechanical engagement with one or more recesses in the lower footbed face (i.e. recesses in the body of the footbed portion). In preferred embodiments, a shoe of the first aspect or any embodiment above is provided wherein the footbed portion comprises one or more projecting elements extending outwardly from its surface in mechanical engagement with one or more recesses in the outsole portion. For instance, in preferred embodiments, the lower footbed face comprises one or more projecting elements extending outwardly from its surface (i.e. in a plane orthogonal to the lower footbed face) in mechanical engagement with one or more recesses in the upper outsole face (i.e. recesses in the body of the outsole portion). In particularly preferred embodiments, only the footbed portion comprises the one or more projecting elements (i.e. which are in mechanical engagement with one or more recesses in the outsole portion) as described above.

Preferably, therefore, only the lower footbed face comprises the one or more projecting elements.

In other words, in a preferred embodiment of the first aspect is provided a shoe comprising an outsole portion and a footbed portion: the outsole portion comprising a lower outsole face configured to contact a ground surface when in use and an upper outsole face comprising one or more recesses (i.e. recesses in the outsole body); and the footbed portion comprising an upper footbed face configured to contact the bottom surface of a foot when in use and a lower footbed face comprising one or more projecting elements extending outwardly from the footbed surface (i.e. in a plane orthogonal to the lower footbed face); wherein one or more projecting elements of the footbed portion are in mechanical engagement with one or more recesses of the outsole portion.

An advantage of providing the projecting elements (male parts) on the footbed portion in mechanical engagement with recesses (female parts) on the outsole portion is that the projecting elements act to provide additional thickness to the footbed compared to conventional shoe designs and compared to the reverse arrangement where the projecting elements (male parts) are provided on the outsole portion. Typically, outsole materials are more rigid than footbed materials as required for their different functions. In the present preferred embodiment, the projecting elements thus allows for replacement of part of the outsole material with footbed material, which may reduce the overall weight of the shoe. Furthermore, the thickness of the footbed is increased in the region of the projecting elements, thus allowing the level of cushioning (and thus comfort) to be increased in those regions without adding any further bulk to the shoe. By increasing the general width and height (and thus volume) of the projecting elements, a larger volume of outsole may be replaced by footbed material, which may further decrease the overall weight and / or increase the area of additional cushioning. Thus, more lightweight and comfortable shoes result, whilst at the same time keeping a desirable low visible shoe profile.

It is not essential that the mutually engaging portions of the outsole and footbed portions complement each other perfectly in terms of shape and size to achieve restriction of movement of the footbed portion relative to the outsole portion in at least one dimension. In other words, it is not necessary to provide a perfect fit to desirably restrict movement of the footbed portion relative to the outsole portion. For instance, a reasonable (but relatively loose) correspondence between the dimensions of the projecting elements and recesses in a horizontal plane will provide adequate restriction of movement in said horizontal plane. On the other hand, close correspondence between the dimensions of the respective projecting elements and recesses in the vertical plane is less important for restricting movement in the horizontal plane, although close vertical correspondence is likely to increase the force required to displace the footbed in a horizontal direction with respect to the outsole. Thus, it is not necessary to provide a tight-fit engagement to restrict the above described movement. However, it is preferred that the mechanical engagement restricts movement substantially completely in the respective dimension or dimensions (i.e. in the respective horizontal I vertical plane or planes) during normal use. More preferably, the mechanical engagement may restrict movement entirely in said respective plane or planes during normal use.

Thus, in typical embodiments, the mutual mechanically engaging portions of the outsole and footbed are configured to provide a tight-fit engagement. This may be achieved in practice for example by ensuring that the respective sides of the one or more projecting elements are configured to abut the sides of the respective one or more recess walls. A tight-fit in the horizontal direction may have a beneficial effect on restriction of movement of the footbed relative to the outsole in a vertical direction as a result of frictional forces. Where resilient materials are used, an "interference fit" or a "snap fit" engagement may be provided. Such interference and snap fit engagements may thus help to form an interlock.

Suitable recesses and projections are defined further below under the "outsole portion" and "footbed portion" sections.

Thus, in preferred embodiments, the mechanical engagement is a mechanical interlock. For instance, in an embodiment of the invention is provided a shoe comprising an outsole portion in direct mechanical interlock with a footbed portion.

The term "interlock" is intended to include temporary interlocking (i.e. wherein the outsole portion may be parted from the footbed portion using reasonable manual force, such as for semi-permanent I temporary footbed installations) and permanent interlocking (i.e. wherein the resulting interlock ensures that the outsole portion cannot be parted from the footbed portion using reasonable manual force, such as for footbed installations intended to last for the lifetime of the footwear). In preferred embodiments, the interlocking is temporary. The relative permanence of the interlock can be controlled for example by varying the resilience of the materials used and by varying the mutual complementarity of the fit between the male and female portions.

Thus, less resilient materials and a higher degree of complementarity between male and female portions will provide a stronger interlock.

Suitably, one or more of the respective projecting elements of the footbed and I or outsole may suitably be provided with one or more features on its surface such as secondary projecting elements and I or secondary recesses in the projecting element body, etc. which may be beneficial for further increasing friction or fit between the outsole and footbed portions. Similarly, one or more of the inner recess walls I floor may also be provided with one or more surface features such as secondary projecting elements and / or secondary recesses in the projecting element body, etc. which may be beneficial for further increasing friction or fit between the outsole and footbed portions.

Outsole portion The outsole portion is configured to mechanically engage the footbed portion.

Suitably, the outsole portion comprises lower and upper outsole faces (i.e. opposing faces), the lower outsole face configured to contact a ground surface when in use and the upper outsole face (i.e. footbed engaging face) configured to mechanically engage with the footbed portion.

The outsole portion may comprise one or more conjoined pieces. In preferred embodiments, the outsole portion is formed from a single piece, such as a single mouldable (e.g. moulded) piece. In embodiments, the outsole portion comprises an amalgamation of two or more pieces (i.e. conjoined pieces). For instance, the outsole portion may comprise two or more discrete pieces affixed together, e.g. by moulding or gluing. Suitably, said two or more pieces may be arranged side-by-side and I or one above the other, i.e. in layers. For instance, the outsole portion may comprise a lower and upper outsole layers, the lower layer forming the first face for engagement with a ground surface and the upper layer forming the second face configured to mechanically engage the footbed portion.

The outsole portion may comprise any material known to the skilled person to be suitable for use as a shoe outsole. Suitable materials tolerate repeated contact with a ground surface in use, i.e. a material of suitable durability. In embodiments, the outsole portion comprises one or more materials selected from plastics, leather, metal and wood. Suitably, said materials may be selected from plastics and leather.

Preferably, the outsole portion comprises a plastic. Suitable plastics include thermoplastics and thermosetting polymers. Suitable examples of plastics thus include rubbers (including natural rubber, resin rubber and synthetic rubber, e.g. thermoplastic rubber), polyurethane, ethyl vinyl acetate (EVA, i.e. a copolymer of ethylene and vinyl acetate) and polyvinyl chloride. Optionally the plastic may be vulcanised. In the above embodiments, the rubber may suitably be a synthetic rubber. Typical synthetic rubbers include thermoplastic rubbers and vulcanised rubbers. In preferred embodiments, the plastic is polyurethane or ethyl vinyl acetate, more preferably polyurethane, such as vulcanised polyurethane.

In embodiments, at least half and preferably more than half of the total weight of the outsole portion comprises said material. For instance, in embodiments, substantially all of the total weight of the outsole portion comprises said material (i.e. at least 90% wt., such as at least 95% wt., 98% wt. or 99% wt.). Typically, the outsole portion consists of said material.

In embodiments where the outsole portion comprises two or more pieces, each piece may be the same or a different material to that of another piece. Typically, the pieces are not all made of the same material. For example, different materials may be provided at different parts of the outsole, e.g. wherein one or more of the materials has a specialised function (e.g. where a more durable material is provided at the heel).

In embodiments, the outsole portion may suitably comprise a groove for receiving the peripheral edges of the upper (shoe upper described below). The groove may be provided proximal to, or at, the outer peripheral outsole edge and configured to receive the peripheral edge of the upper. Preferably, the groove is provided around the peripheral circumference (i.e. outer edges) of the outsole portion. Suitably, wherein the outsole comprises one or more recesses in the upper outsole surface, the upper may be advantageously stitched into the groove through the inner wall of the one or more recesses providing a stitch that is invisible once the footbed is in place. This simple approach is not possible using conventional shoe constructs, wherein an excess portion of the upper fabric is usually required to be passed between the outsole and insole layers to be held in place under the insole and footbed. The groove feature is thus particularly advantageous because it allows direct attachment of the shoe upper to the outsole (for instance by means of a heavy-duty stitch through outsole groove and upper respectively) thus avoiding the need for further shoe layers to hold the upper part of the shoe in place. This in turn avoids the wastage of excess upper material, which is conventionally wrapped under the insole of shoes during convention shoe manufacture.

Preparation of the outsole The outsole may be manufactured according to any suitable method. In a preferred embodiment, the outsole portion is formed of a single piece of material, such as the outsole materials described above, typically a plastic, such as a rubber (e.g. a thermoplastic rubber), preferably polyurethane or ethyl vinyl acetate, more preferably polyurethane, such as vulcanised polyurethane. Advantageously, wherein the outsole is formed of a single piece, such as a single piece of plastic, it may be printed, moulded and I or sculpted, preferably moulded.

For instance, the outsole may be made from either a) direct injection moulding using thermo polyurethane or thermo plastic rubber, or b) using a vulcanised method comprising use of high temperature and pressure to soften and liquidate sheets or blocks of rubber. This softened rubber will then flow readily into a solid mould that has been machined and engraved to represent the shape size and features of the finished outsole design.

Lower face of the outsole The lower face of the outsole portion is configured to engage a ground surface in use.

The lower outsole face is typically formed of a single piece of material, such as a single moulded piece, typically the same material as the remainder of the outsole portion. In alternative embodiments, the first face may comprise an amalgamation of two or more pieces. For instance, the first face may comprise two or more discrete pieces affixed together, e.g. by moulding or gluing. Suitably, said two or more pieces may be arranged side-by-side to form the lower face and optionally may also overlap, i.e. in layers. Wherein the lower outsole face comprises two or more pieces, they are typically arranged side by side, for instance by moulding or gluing to an outsole base portion.

Typically, the lower outsole face comprises a material as defined above for the outsole portion in general. For instance, the first face may comprise a material selected from plastics, leather, metal and wood. Suitably, said materials may be selected from plastics and leather, preferably plastic, e.g. rubber. The plastic may be defined as described above for the outsole portion in general. In embodiments, at least half and preferably more than half of the total area of the lower outsole face comprises said material. For instance, in embodiments, substantially all of the area of the lower outsole face comprises said material (i.e. at least 90%, such as at least 95%, 98% or 99%). Typically, the total area of the lower outsole face consists entirely of said material.

In embodiments wherein the lower outsole face comprises two or more pieces, each piece may be the same or a different material to that of another piece. Typically, the different pieces are not made of the same material. For example, it is commonplace in conventional shoes for the lower outsole face surface to comprise different materials at different parts of the outsole surface, e.g. wherein one or more of the materials has a specialised function.

In embodiments of the present invention where a shoe heel is provided at the lower outsole face, the heel may be the same or a different material to the remaining part of the outsole portion. For instance, the lower outsole face in the region of the heel may be of a different material to the remainder of the lower outsole face. In suitable embodiments, the outsole portion may comprise a more durable material at the forefoot and I or heel parts of the lower outsole face compared to the remaining material of the first outsole face. In specific embodiments, the heel part of the lower outsole face comprises a rubber or steel plate, and the forefoot part of the first outsole face is a different material selected from rubber and leather.

Suitably, the outsole portion may comprise features at the lower outsole face that improve the engagement of the shoe to a ground surface. For instance, contours, grooves spikes and I or studs (such as in sports shoes) may be provided. Such features may be formed as a single piece with lower outsole face or may be separate pieces affixed to the lower outsole face, e.g. by screwing, gluing and or moulding.

Suitably, additional reinforcing plates may be affixed to the first outsole face (such as in the heel region). Suitable materials for such features include the materials described above for the outsole portion.

In a preferred embodiment, the outsole portion is formed of a single piece of material, typically a plastic, such as a rubber (e.g. a thermoplastic rubber), preferably polyurethane or ethyl vinyl acetate, more preferably polyurethane, such as vulcanised polyurethane.

Upper face of the outsole In the first aspect and embodiments above, the upper (i.e. footbed engaging) face of the outsole portion is configured to mechanically engage with the footbed portion.

As described above, the engagement may be by way of mutually interacting projecting elements and recesses. In this regard, typically the outsole portion has a body portion (which is substantially planar). Such projecting elements are intended to refer to elements which project from the body surface and such recesses are intended to refer to recesses in the body surface.

In embodiments the outsole face comprises one or more projecting elements extending outwardly from its surface (i.e. in a plane orthogonal to the upper outsole face) configured to mechanically engage one or more recesses in the footbed portion (i.e. in the lower footbed face) (e.g. recesses in the body of the footbed portion) and / or may comprise one or more recesses in the upper outsole face (i.e. in the upper outsole body portion) configured to mechanically engage one or more projecting elements of the footbed portion (i.e. from the lower footbed face).

Mechanical engagement -recesses in the outsole The upper outsole face preferably comprises one, or in other embodiments more than one, recess (i.e. female part) in the outsole body configured to mechanically engage with one or more projecting elements extending outwardly from the surface of the lower face of the footbed. That is, the upper outsole face may comprise a substantially planar body surface provided with one or more recesses penetrating into the body surface (thus creating one or more female parts suitable for engaging one or more respective male pads of the footbed portion).

Number of recesses Where more than one said recess is provided, the upper outsole surface may comprise 2 or more, suitably 5 or more, 10 or more, 15 or more, 20 or more, 30 or more, or 40 or more recesses. In embodiments, less than 50 recesses are provided, such as less than 40, 30, 20, 15, 10, 5, or less than 4 recesses, typically less than 3.

For instance, in embodiments, 1-40 recesses may be provided, suitably 1-30, 1-20, 1-10 or 1-5, for instance, 1, 2, 3,4 or 5, and preferably one recess may be provided.

In a suitable embodiment, a single recess is provided in the forefoot portion of the upper outsole face and a single recess is provided in the heel portion of the upper outsole face configured to receive complementary projecting elements from the forefoot and heel portions of the respective footbed portion (i.e. from the lower footbed face). In preferred embodiments, a single recess is provided, more preferably wherein the recess spans the forefoot and heel portions of the outsole portion. Even more preferably, a single recess is provided having an outer peripheral recess wall that substantially follows the general contour of the outer periphery of the outsole portion. This thus provides a generally "foot-shaped" projection that advantageously provides cushioning for the foot by thickening the effective footbed.

In embodiments, at least half, and typically more than half, of the upper outsole face portion by area may suitably consist of said one or more recesses. For instance, in suitable embodiments, up to 60%, 70%, 80% or 90% by area of the upper outsole face consists of said one or more recesses.

In embodiments, at least half, and typically more than half, of the outsole portion by volume may suitably consist of said one or more recesses. For instance, in suitable embodiments, up to 50%, 60%, 70%, 80% or 90% by volume of the outsole portion may consists of said one or more recesses.

Recess geometry Referring to Figure 6, the one or more recesses may suitably comprise an upper recess entrance 1 and a recess hollow 4, which is defined by recess side-walls 2 and a recess floor 3. The width at the upper recess entrance may be equal to the largest internal width of the recess hollow (i.e. wherein the recess side walls are parallel, for instance substantially orthogonal to the plane of the lateral surface, see, e.g. Figure 6a), greater than the largest internal width of the recess hollow (wherein the recess side walls narrow from the recess entrance to the recess floor, see, e.g. Figures 6b and Gc) or less than the largest internal width of the recess hollow (wherein the recess walls widen outwardly from the recess entrance at least partially towards the recess floor, see, e.g. Figures 6d and 6e). In embodiments wherein the largest width at the recess entrance is less than the largest internal width of the recess hollow, the one or more recess hollows may comprise any suitable orthogonal cross-sectional shape, including a "dove-tail" shaped hollow cross-section for mutual engagement (e.g. interlock) with a respectively dove-tailed projecting element portion (see e.g. figure 6e), a bulbous cross-section (see e.g. figure 6d) and / or a "lip" may be provided at the recess entrance under which a portion of a projecting element may thus be engaged. For instance, the lip may engage a respective flange portion of a complementarily engaging projecting element in use.

Embodiments wherein the width across the recess entrance is greater than the internal width of the recess hollow provide desirable restriction of horizontal movement. However, such embodiments do not allow for interference or snap-fit engagements with respective male projecting elements and so the footbed may be more prone to peeling-away (e.g. lifting) vertically from the outsole when in use compared to recesses wherein the width of the upper recess entrance is equal to or less than the largest internal width of the recess hollow. Thus, embodiments comprising one or more of said recesses wherein the largest width of the upper recess entrance is equal to or less than the largest internal width of the recess hollow are preferred. More preferred embodiments comprise said one or more recesses wherein the largest width of the upper recess entrance is less than the largest internal width of the recess hollow. It is also preferred that the one or more projecting elements on the complementary footbed or outsole portion complement in size and / or shape said one or more recesses.

In preferred embodiments, one or more of said recesses, suitably more than one, preferably at least half, more preferably more than half, even more preferably substantially all (e.g. at least 90%, 95%, 98% or 99%) and most preferably all of said one or more recesses are recesses wherein the largest width of the upper recess entrance is equal to or less than the largest internal width of the recess hollow.

To provide an "interference" or "snap" fit in such embodiments, it is necessary to provide a projecting element that is of substantially equal or slightly larger width / diameter compared to the width of the recess entrance. Thus, it is essential that either the recess walls and / or the projecting element(s) are resilient in such embodiments to allow the widest part of the projecting element to initially pass through the recess entrance. Compressable materials are particularly preferred for these parts, such as open cell foams, e.g. open celled foams of plastics described above.

Recess depth The one or more recesses in the outsole portion may be of any depth suitable for mechanically engaging said one or more footbed projecting elements. The depth of recess required may typically depend on the engaging materials used. For instance, less resilient materials may require shallower recesses to achieve the desired engaging effect compared to where more resilient materials are used.

In embodiments, one or more of said recesses may penetrate into the surface of the upper outsole face up to 10%, such as up to 20% and suitably up to 30%, 40%, 50%, 60%, 70%, 80% or 90% of the depth of the outsole portion.

The choice of depth will also be limited by the outsole function, as the deeper the recess, the thinner the outsole portion beneath the recess. Thus, there is a balance between the degree of engagement to be achieved and the level of protection provided by the outsole. In running shoes for example, the thickness of the outsole is of comparatively less importance compared to a regular shoe and so the recesses may be deeper in such embodiments.

As explained above, an advantage of the new footbed having male elements projecting from the footbed portion into female recesses of the outsole portion is that the projecting elements act to provide additional thickness to the footbed compared to conventional shoe designs. The projecting elements thus replace pad of the outsole portion with footbed material. Accordingly, the thickness of the footbed is increased (and thus the level of cushioning and comfort may be increased) without adding any further bulk to the shoe (i.e. the footbed replaces part of the outsole). In fact, by replacing part of the outsole material with a suitable footbed material, the overall weight of the shoe may be reduced, whilst at the same time keeping a low visible shoe profile and whilst simultaneously improving comfort for the user.

Thus, deeper recesses will allow for a thicker footbed in the area of the recesses.

Strategic placement of the one or more recesses along with a suitable choice of recess depth will therefore allow for tuning of the cushioning and support provided to the foot when pressure is applied on the footbed portion by the foot in use.

The one or more recesses may suitably be selected independently from grooves (i.e. channels in the surface) and cavities (i.e. pits having a closed mouth portion and a hollow chamber portion). Preferably, one or more of said recesses are cavities. For example, in typical embodiments at least one, suitably more than one, preferably at least half, more preferably more than half, even more preferably substantially all (e.g. at least 90%, 95%, 98% or 99%) and most preferably all of the one or more recesses are cavities. The use of cavities has the advantage that horizontal movement of the respectively engaging projecting element is restricted in two horizontal dimensions rather than just one. This is an advantage over grooves, for example, which do not have a closed mouth and so tend to restrict movement in only one horizontal dimension (i.e. the mutually engaging projecting element may slide freely along the groove in one horizontal dimension).

Thus, in preferred embodiments, the invention provides a shoe comprising an outsole portion and a footbed portion: the outsole portion comprising lower and upper outsole faces, the lower outsole face configured to contact a ground surface when in use and the upper outsole face comprising one or more cavities in the outsole body configured to mechanically engage the footbed portion; and the footbed portion comprising upper and lower footbed faces, the upper footbed face configured to contact the bottom surface of a foot when in use and the lower footbed face comprising one or more projecting elements extending outwardly from the footbed surface (i.e. in a plane orthogonal to the lower footbed face); wherein the one or more projecting elements of the footbed portion are in mechanical engagement with the one or more cavities of the outsole portion.

Mechanical engagement -projecting elements from the outsole In an embodiment of the first aspect, the upper outsole face may comprise only one, or in other embodiments more than one, projecting element (i.e. male part) extending outwardly from its surface (i.e. in a plane orthogonal to the upper outsole face) configured to engage with one or more recesses in the lower footbed face. That is, the upper face may comprise a body surface (typically a substantially planar body) provided with one or more projecting elements extending away from the surface in an orthogonal direction, thus creating one or more male parts.

Number of projecting elements Where more than one said projecting element is provided, the upper surface may comprise 2 or more, suitably 5 or more, 10 or more, 15 or more, 20 or more, 30 or more, or 40 or more projecting elements. In embodiments, less than 50 projecting elements are provided, such as less than 40, 30, 20, 15, 10, 5, or less than 4 projecting elements, typically less than 3. For instance, in embodiments, 1-40 projecting elements may be provided, suitably 1-30, 1-20, 1-10 or 1-5, for instance, 1, 2, 3, 4 or 5, and preferably only one projecting element are provided.

In embodiments, a single projecting element is provided, such as wherein the projecting element spans the forefoot and heel portions of the outsole portion. In embodiments, at least half, and typically more than half, of the upper outsole face portion by area may suitably consist of said one or more projecting elements. For instance, in suitable embodiments, up to 60%, 70%, 80% or 90% by area of the upper outsole face consists of said projecting elements.

Geometry of projecting elements The one or more projecting elements may be of any suitable form for engaging with said one or more recesses on the corresponding footbed portion. For instance, suitable projecting elements include ribs/ridges, substantially flattened projecting pads, pegs, spikes or studs. Each of these elements may engage with recessed grooves in the respective footbed portion, but typically ribs / ridges are not ideal for engaging recesses in the form of cavities.

The projecting element may be shaped to substantially, or completely, complement the corresponding recess shape. Typically, projecting elements comprises a base portion (at the upper outsole face surface), and a tip or head portion removed from the base by an intermediate body portion.

The one or more projecting elements may comprise a regular or irregular cross-section and may have a cross-sectional area at the base of the projecting element that is equal, less or greater than the largest cross-sectional area of the projecting portion, preferably equal or less. For example in embodiments, the cross-sectional area at the base of the projecting element is greater than the largest cross-sectional area of the projecting portion, such as at the tip (outermost part) of the projecting portion, for example wherein the projecting element becomes narrower (tapers) from the base towards the tip, e.g. wherein the projecting element is a spike (e.g. conical, pyramidal, etc). Preferably however, one or more (e.g. at least half, such as more than half, suitably substantially all, preferably all) projecting portions have a cross-sectional area at the base of the projecting element is equal to or less than, more preferably less than, the largest cross-sectional area of the projecting portion, such as at the tip, for example wherein the projecting element becomes narrower (tapers) from tip to base, e.g. in dove-tail shaped projecting elements).

The one or more projecting elements may for example comprise one or more wider portions along the projecting portion to assist with engaging the one or more recesses in the footbed portion. The one or more projecting elements may for instance comprise an enlarged head portion (e.g. formed by a bulbous protrusion, flange or wedge) for improving engagement with the respective recess(es) in the footbed portion.

Embodiments having a projecting element that is narrower at the base (i.e. the part proximal to the outsole base portion) than further along the projecting element (i.e. a part more distal to the base portion of the outsole), such as at the tip have the advantage of allowing an interference or snap fit with one or more complementary recesses, thus improving resistance to vertical lift of the footbed portion from the outsole portion. Thus, in preferred embodiments the projecting element has a dove-tailed cross-section. In embodiments, the projecting element is therefore preferably configured to provide an interference or snap4it with the respective recess(es) in the footbed portion. Thus, in exemplary embodiment, a "dove-tail-shaped cross-section may be provided. This may thus be suitable for mutual engagement with a recess that is respectively dove-tailed recess (see e.g. figure 6e), a bulbous head portion may be provided for mutual engagement with a respectively bulb-shaped recess (see e.g. figure 6d) and / or a flange may be provided in the projecting element to fit under as respective "lip" in the respective recess, thus restricting vertical (lifting) movement of the footbed from the outsole in use.

It is therefore preferred that the one or more projecting elements on the outsole complement in size and I or shape said one or more recesses of the complementary footbed portion.

In preferred embodiments, one or more of said projecting elements, suitably more than one, preferably at least half, more preferably more than half, even more preferably substantially all (e.g. at least 90%, 95%, 98% or 99%) and most preferably all of said one or more projecting elements are projecting elements wherein the largest cross-sectional diameter at the base of the projecting element is less than or equal to the largest cross-sectional area of the projecting portion.

To provide an interference" or "snap" fit in such embodiments, it is necessary to provide a projecting element that is of a slightly larger width I diameter compared to the recess entrance. Thus, it is essential that either the recess walls and / or the projecting element(s) are resilient in such embodiments to allow the widest part of the projecting element to initially pass through the recess entrance. Compressable materials are particularly preferred for these parts, such as open cell foams.

Length of projecting elements The one or more projecting elements in the outsole portion may be of any length suitable for mechanically engaging said one or more footbed recesses. The length of projecting element required may typically depend on the materials used. For instance, less resilient materials may require shorter projecting elements to achieve the desired resistance to movement of the footbed compared to where more resilient materials are used.

In embodiments, one or more of said projecting elements may penetrate into the recesses of the lower footbed face up to 10%, such as up to 20% and suitably up to 30%, 40%, 50%, 60%, 70%, 80% or 90% of the depth of the footbed portion.

The choice of length of projecting element will depend on the choice of depth of recess and vice versa, which will be affected by the footbed function. For instance, the deeper the penetration of the projecting elements into the footbed, the thinner the footbed portion will be above the projections. Thus, there is a balance between the degree of engagement to be achieved and the level of comfort provided by the footbed.

Upper outsole face -construction The upper outsole face is typically formed as a single piece together with the remaining outsole portion, such as a single moulded piece. In alternative embodiments, the upper outsole face may comprise an amalgamation of two or more pieces.

For instance, the upper outsole face may comprise two or more discrete pieces affixed together, e.g. by moulding or gluing. For example, in embodiments wherein the upper outsole face comprises one or more recesses (i.e. female pads) in the outsole body, the edges or walls of one or more recesses may comprise a different material to the outer planar upper outsole surface. For instance, a more durable material may be placed at the edges or walls of a recess to improve longevity of the recess. Likewise, in embodiments wherein the upper outsole face comprises one or more projecting elements (i.e. male parts) extending outwardly from the outsole surface, a part or all of one or more of said projecting elements may comprise a different material to the generally planar upper outsole surface. For instance, a more durable material may be used at the projecting elements compared to the surface to improve longevity of the projecting elements. Suitably, wherein the upper outsole face comprises two or more pieces, the pieces may be joined by moulding or gluing to the outsole base portion.

Typically, the upper outsole face comprises a material selected independently from the materials as defined above for the outsole portion in general. For instance, the upper outsole face may comprise a material selected from plastics, leather, metal and wood. Suitably, said materials may be selected from plastics and leather, preferably plastic, e.g. rubber. The plastic may be defined as described above for the outsole portion in general. In embodiments, at least half and preferably more than half of the total area of the upper face comprises said material. For instance, in embodiments, substantially all of the planar cross sectional area of the upper outsole face comprises said material (i.e. at least 90%, such as at least 95%, 98% or 99%).

Typically, the total area of the upper outsole face consists entirely of said material.

In embodiments wherein the upper outsole face comprises two or more pieces, each piece may be the same or a different material to that of another piece. Typically, the different pieces are not made of the same material.

As mentioned above, it is preferable that the outsole portion is formed of a single piece of material, typically a plastic, such as a rubber (e.g. a thermoplastic rubber), more preferably polyurethane, such as vulcanised polyurethane.

Footbed nortion The footbed portion of the first aspect and embodiments above upper and lower(i.e.

opposing) faces, the upper footbed face configured to contact the bottom surface of a foot when in use and the lower footbed (i.e. upper outsole engaging) face configured to mechanically engage with the upper outsole face.

The footbed portion may be formed as a single piece, such as a single cut or moulded piece. In alternative embodiments, the footbed portion may comprise an amalgamation of two or more pieces. For instance, the footbed portion may comprise two or more discrete pieces affixed together, e.g. by moulding or gluing. Suitably, said two or more pieces may be arranged side-by-side and / or one above the other, i.e. in layers. Wherein the footbed portion comprises two or more pieces, they are preferably arranged in overlapping layers, for instance by moulding or gluing.

The footbed portion may comprise any material known to the skilled person to provide adequate durability for supporting a foot in use. In embodiments, the footbed portion comprises one or more materials selected from textile materials and non-textile materials, typically non-textile materials.

In embodiments, at least half and preferably more than half of the total weight of the footbed portion comprises said material. For instance, in embodiments, substantially all of the weight of the footbed portion comprises said material (i.e. at least 90% wt., such as at least 95% wt., 98% wt. or 99% wt.). Typically, the footbed portion consists of said material. For instance, the footbed may consist of one or more non-textile materials, e.g. one. Alternatively, the footbed may consist of one or more textile materials, e.g. one. In preferred embodiments, the footbed consists of a textile or non-textile material affixed (e.g. glued or laminated) to a non-textile material.

Suitable textile materials include woven and non-woven fabrics, such as comprising natural (e.g. cotton) or synthetic fibres (e.g. polyester). Suitable non-textile materials include natural and non-natural materials, including leather, suede and plastics.

Suitable plastics include thermoplastics and thermosetting polymers. Examples of plastics thus include rubbers (including natural rubber, resin rubber and synthetic rubber, e.g. thermoplastic rubber), polyurethane, ethyl vinyl acetate and polyvinyl chloride. Optionally the plastic may be vulcanised. Suitably, the rubber is a synthetic rubber. Typical synthetic rubbers include thermoplastic rubbers and vulcanised rubbers. In preferred embodiments, the plastic is polyurethane or ethyl vinyl acetate, more preferably polyurethane, such as vulcanised polyurethane.

In preferred embodiments, the footbed comprises a porous material. The porous nature of the material has the advantage of providing improved breathability. Porous materials can also provide added cushioning and thus enhanced comfort. In preferred embodiments, the footbed portion comprises an open-cell foam, such as selected from the plastics listed above, such as an open-cell polyurethane.

In embodiments wherein the footbed portion comprises two or more pieces, each piece may be the same or a different material to that of another piece, typically different. The footbed portion of the present invention may thus comprise a first piece comprising the upper footbed face for engaging the foot in use, and a second piece attached to the first piece, the second piece comprising at least some of and in embodiments at least half of the lower footbed face configured to mechanically engage the outsole portion.

In a preferred embodiment, the footbed portion comprises a layer of open-cell foam (such as an open-cell polyurethane) forming at least part of the lower footbed face for engaging the outsole. attached to a further textile or non-textile layer, such as a leather, suede or plastic layer (e.g. another open cell foam layer), forming the upper footbed face for engaging the foot. In such arrangements, the textile or non-textile portion thus provides a comfortable base for interaction with the foot and the open cell foam provides added cushioning whilst also allowing for a mechanical engagement with the outsole portion.

Preparing the footbed The footbed may be manufactured according to any suitable method. Typically the relevant piece or pieces of the footbed portion may be printed, moulded, cut and I or sculpted. Multiple pieces of the footbed portion may be joined together by moulding or gluing.

Upper footbed face The upper face of the footbed portion is configured to engage the bottom of a foot in use.

The upper footbed face is in suitable embodiments formed from the same piece of material as the remainder of the footbed portion. In preferred embodiments, the upper footbed face is formed of a different material to the remaining footbed body portion. In alternative embodiments, the upper footbed face may be formed by an amalgamation of two or more pieces. For instance, the upper footbed face may comprise two or more discrete pieces affixed together, e.g. by moulding or gluing.

Suitably, said two or more pieces may be arranged side-by-side and I or one above the other, i.e. in overlapping layers.

Typically, the upper face comprises a material as defined above for the footbed portion in general. For instance, the upper face may comprise a material selected from textile materials and non-textile materials, preferably non-textile materials such as leather, suede or plastic, for instance leather or suede. Alternatively the upper face may comprise plastic (such as selected from the plastics mentioned for any embodiment listed above). The upper face may alternatively, or additionally, comprise textile materials, such as a woven fabric.

In embodiments wherein the upper face comprises two or more pieces, each piece may be the same or a different material to that of another piece. Typically, the different pieces are not made of the same material.

As described above, the upper footbed face may comprise the materials mentioned above. In embodiments, at least half and preferably more than half of the total area of the upper footbed face comprises said material(s). For instance, in embodiments, substantially all of the total area of the upper footbed face comprises said material (i.e. at least 90%, such as at least 95%, 98% or 99%). In embodiments, the upper footbed face may thus consist entirely of said material. For instance, the upper footbed face may be formed from a non-textile material (which may be as described according to any embodiment above for the footbed portion in general). Alternatively, the upper footbed face may be formed from a textile material (which may be as described according to any embodiment above for the footbed portion in general). In preferred embodiments, the upper footbed face is formed from leather, suede or a plastic (such as described above). Particularly preferred plastics are open cell foams, such as open cell polyurethane. In embodiments, the upper footbed face is formed from leather or suede, e.g. leather.

The shoe may further comprise one or more additional materials bonded to the foot-side of the upper footbed face. For instance, stickers (typically intended to be temporarily affixed) may be added. Typically, the shoe does not comprise additional materials bonded to the foot-side of the upper footbed face surface of the footbed portion.

Suitably, the footbed portion may comprise features at the upper footbed face that improve the engagement of the shoe to the bottom of the foot. For instance, contours or grooves may be provided. The upper footbed face of the footbed may for example provide supportive structures to complement the general contours of the foot.

A particular advantage of the present invention is that the footbed portion resists sliding and lifting but may be removed manually without damaging the footbed. Thus, the footbed portions are interchangeable and may be easily modified or personalised to an individual's foot contours, and which may be easily inserted into any suitable shoe.

Lower footbed face In the first aspect and embodiments above, the lower footbed (i.e. outsole engaging) face of the footbed portion is configured to mechanically engage with the outsole portion (i.e. with the upper outsole portion).

As described above, the engagement may be by way of mutually interacting projecting elements and recesses. In this regard, typically the footbed portion can be considered as having a body portion. Such projecting elements thus project from the body surface and such recesses are recesses in the body surface.

In embodiments the lower footbed face comprises one or more projecting elements extending outwardly from its surface (i.e. in a plane orthogonal to the lower footbed face) configured to mechanically engage one or more recesses in the outsole portion (i.e. in the upper outsole face) (e.g. recesses in the body of the outsole portion) and / or may comprise one or more recesses in the lower footbed face (i.e. in the lower footbed body portion) configured to mechanically engage one or more projecting elements of the outsole portion (i.e. from the upper outsole face).

Mechanical engagement -projecting elements from the footbed The lower footbed face preferably comprises one, and in other embodiments more than one, projecting element (i.e. male part) extending outwardly from the footbed surface in a plane orthogonal to the lower footbed face and configured to engage with one or more recesses in the upper outsole face. That is, the lower footbed face may comprise a substantially planar body surface provided with one or more projecting elements extending away from the surface in an orthogonal direction, thus creating one or more male parts.

Number of projecting elements Where more than one said projecting element is provided, the lower footbed face may comprise 2 or more, suitably 5 or more, 10 or more, 15 or more, 20 or more, 30 or more, or 40 or more projecting elements. In embodiments, less than 50 projecting elements are provided, such as less than 40, 30, 20, 15, 10, 5, or less than 4 projecting elements, typically less than 3. For instance, in embodiments, 1-40 projecting elements may be provided, suitably 1-30, 1-20, 1-10 or 1-5, for instance, 1, 2, 3, 4 or 5, and preferably one projecting element may be provided.

In particularly preferred embodiments, a single projecting element is provided, such as wherein the projecting element spans the forefoot and heel portions of the footbed portion. In a suitable embodiment, a single projecting element is provided in the forefoot portion of the lower footbed face and a single recess is provided in the heel portion of the lower footbed face configured to engage complementary recesses in the forefoot and heel portions of the respective outsole portion (i.e. from the upper outsole face). In preferred embodiments, a single projecting element is provided is provided, more preferably wherein the single projecting element spans the forefoot and heel portions of the footbed portion. Even more preferably, a single projecting element is provided is having an outer peripheral wall that substantially follows the general contour of the outer periphery of the outer footbed portion. This thus provides a generally "foot-shaped" projection that advantageously provides cushioning for the foot by thickening the effective footbed.

In embodiments, at least half, and typically more than half, of the lower footbed face by area may suitably consist of said one or more projecting elements. For instance, in suitable embodiments, up to 60%, 70%, 80% or 90% by area of the lower footbed face consists of said projecting element(s). By providing a large surface area of projecting elements, this has the advantage of providing additional thickness to the footbed, preferably in the heel and forefoot portions of the footbed, which thus provides additional footbed cushioning and thus comfort.

Geometry of projecting elements The one or more projecting elements may be of any suitable form for engaging with said one or more recesses on the corresponding outsole portion. For instance, suitable projecting elements include ribs/ridges, substantially flattened pads, pegs, spikes or studs. Each of these elements may engage with recessed grooves in the respective outsole portion, but typically ribs / ridges are not suitable for engaging recesses in the form of cavities.

The projecting element may be shaped to substantially, or completely complement the corresponding outsole recess shape. Typically, a projecting element comprises a base portion at the lower footbed face surface, and a tip or head portion removed from the base by a central projecting body portion.

The one or more projecting elements may comprise a regular or irregular cross-section and may have a cross-sectional area at the base of the projecting element that is equal, less or greater than the largest cross-sectional area of the projecting portion, preferably equal or less. For example in embodiments, the cross-sectional area at the base of the projecting element is greater than the largest cross-sectional area of the projecting portion. such as at the tip (outermost part) of the projecting portion, for example wherein the projecting element narrows (tapers) from the base to the tip, e.g. wherein the projecting element is a spike (conical, pyramidal, etc).

Preferably however, one or more (e.g. at least half, such as more than half, suitably substantially all, preferably all) projecting portions have a cross-sectional area at the base of the projecting element is equal to or less than, more preferably less than, the largest cross-sectional area ot the projecting portion, such as at the tip, for example wherein the projecting element narrows (tapers) from tip to base (e.g. in dove-tail shaped projecting elements).

The one or more projecting elements may for example comprise one or more wider portions along the projecting portion to assist with engaging the one or more recesses in the outsole portion. The one or more projecting elements may for instance comprise an enlarged head portion (e.g. fornied by a bulbous protrusion or flange) for improving engagement with the respective recesses in the outsole portion.

Embodiments having a projecting element that is narrower at the base than the tip have the advantage of allowing an interference or snap fit with one or more complementary recesses in the outsole portion, thus improving the resistance to vertical lift of the footbed portion from the outsole portion in use. Thus, in preferred embodiments the projecting element has a cross-sectional area at the base of the projecting element that is less than the largest cross-sectional area of the projecting portion, preferably forming a dove-tail. In embodiments, the projecting element is therefore preferably configured to provide an interference or snap-fit with the respective recess(es) in the footbed portion. Thus, in exemplary embodiment, a "dove-tail-shaped cross-section may be provided for mutual engagement (e.g. interlock) with a respectively dove-tailed recess (see e.g. figure 6e), a bulbous head portion may be provided for mutual engagement with a respectively bulb-shaped recess (see e.g. figure 6d) and I or a flange may be provided in the projecting element to fit under as respective "lip" in the respective recess, thus restricting vertical (lifting) movement of the footbed from the outsole in use.

It is therefore preferred that the one or more projecting elements on the footbed complement in size and I or shape said one or more recesses of the complementary outsole portion.

To provide an "interference" or "snap" fit in such embodiments, it is necessary to provide a projecting element that is of a slightly larger width I diameter compared to the recess entrance. Thus, it is essential that either the recess walls and I or the projecting element(s) are resilient in such embodiments to allow the widest part of the projecting element to initially pass through the recess entrance. Compressable materials are particularly preterred for these parts, such as open cell foams (e.g. foams of plastics described above).

In a preferred embodiment, the one or more projecting elements comprise a resilient material, such as a porous open-cell foam, e.g. polyurethane foam.

Advantageously, when a projecting element comprises a resilient material, the compression of the foot onto the footbed causes the projections to compress into the respective outsole recesses and thus deform slightly and widen to exert a force outward against the recess wall. This may thus assists the mechanical engagement of the projecting element and recess in use. In fact, a tight fit, and even an interlock fit such as an interference fit / snap fit may be actively "induced" in such materials in use even when the width of the projecting element does not substantially match the recess, because the downward pressure by the foot may cause compression and thus widen the projecting element to more tightly engage the recess walls.

In general, the lateral (horizontal) cross-sectional shape of the projecting element may be any shape suitable to fit a respective complementary recess. The one or more projecting element may thus have a cross-sectional shape selected independently from square, round, and elliptical, or something else, e.g. a fanciful design. In the case of projecting elements having a larger cross-sectional area, the lateral cross-section may for example follow the outer periphery of the outsole thus advantageously providing a general foot-shaped projection (for instance for supporting a whole foot).

In preferred embodiments, one or more of said projections has a flat head portion for engaging a recess floor of the respective outsole portion. The flat head portion provides more stability and cushioning when a foot is pressing down on the projecting element, thus distributing the weight of the foot more evenly within the recess.

Length of projecting elements The one or more projecting elements in the footbed portion may be of any length suitable for mechanically engaging said one or more outsole recesses. The length of projecting element required may typically depend on the materials used and the respective recess depth. For instance, less resilient materials may require shorter projecting elements to achieve the desired effect compared to where more resilient materials are used. Preferably, in shoes of the invention, the one or more projections extend to the floor of the respective recess in the outsole portion so the projection can contribute to the additional cushion provided by the footbed potion as a whole between the foot and the outsole portion.

In embodiments, one or more of said projecting elements may penetrate into the recesses of the upper outsole face up to 10%, such as up to 20% and suitably up to 30%, 40%, 50%, 60%, 70%, 80% or 90% of the depth of the outsole portion.

The choice of length of projecting element will depend on the choice of depth of recess and vice versa, which will be affected by the footbed function. For instance, the deeper the penetration of the projecting elements into the footbed, the thicker the footbed portion will be but the thinner the outsole will be below the projections. As described above, it is preferable that the projections extend to the base of the respective recesses rather than hanging freely part way down the recesses. Thus, there is a balance between the degree of engagement to be achieved, the level of comfort provided by the footbed and the level of protection required by the outsole.

Mechanical engagement -recesses in the footbed In alternative embodiments, the lower footbed face may comprise one, and in some embodiments more than one, recess (i.e. female part) in the footbed body configured to engage with one or more projecting elements extending outwardly from the surface of the upper outsole face of the outsole portion. That is, the lower footbed face may comprise a substantially planar body surface provided with one or more recesses penetrating into the body surface (thus creating one or more female parts for engagement with mutual male parts on the outsole portion).

The one or more recesses may be suitably defined as described as above for the recesses in the outsole portion wherein reference to the outsole portion therefore may apply analogously to the footbed portion and reference to the upper face of the outsole portion is therefore may apply analogously to the lower footbed face of the footbed portion.

Lower Footbed Construction The lower footbed face may be formed of a single piece of material, such as a single moulded piece. Alternatively, the lower footbed face may be formed of more than one distinct piece.

The part of the footbed forming the lower footbed face may thus comprise an amalgamation of two or more pieces affixed together, e.g. by moulding or gluing. For example, in embodiments wherein the lower footbed face comprises one or more recesses (i.e. female parts) in its body, the edges and / or walls of one or more recesses may comprise a different material to the outer planar lower surface of the footbed. For instance, a more durable material may be placed at the edges or walls of a recess to prevent distortion of the recesses and thus improve longevity of the recesses. Likewise, in preferred embodiments wherein the lower footbed face complises one or more projecting elements (i.e. male parts) extending outwardly from the footbed surface, a part or all of said projecting elements may comprise a different material to the general lower footbed body. For instance, a more durable material may be used to improve longevity of the projecting elements. Alternatively, a more cushioned material may be provided for increase comfort.

Typically, the lower footbed face comprises a material independently selected from the materials as defined above for the footbed portion in general. For instance, the lower footbed face may comprise a material selected from textile materials and non-textile materials, preferably non-textile materials, more preferably plastics (plastics may be suitably defined as for any embodiment above). In a preferred embodiment, the lower footbed face comprises a layer of open cell foam, such as an open-cell polyurethane. The layer of foam can be varied in thickness depending on the level of cushioning and the depth of the male! female engagement desired.

In embodiments wherein the lower footbed face comprises two or more pieces, each piece may be the same or a different material to that of another piece. Suitably, the different pieces may not be made of the same material.

In the above embodiments, the lower footbed face may comprise materials as described above. In embodiments, at least half and preferably more than half of the total area of the lower footbed face comprises said material(s). For instance, in embodiments, substantially all of the total area of the lower footbed face comprises said material (i.e. at least 90%, such as at least 95%, 98% or 99%). For instance, the lower footbed face may consist entirely of said material. For instance, the lower footbed face may be formed from a non-textile material (which may be as described according to any embodiment above for the footbed portion in general). Alternatively, the lower footbed face may be formed from a textile material (which may be as described according to any embodiment above for the footbed portion in general).

In additional to its respective recesses or projecting elements, the substantially planar lower footbed face of the footbed portion may optionally comprise additional contours or surface features. Such features may for example be desirable to conform to the general surface outline of the upper outsole face or may assist in strengthening or limiting the weight of the footbed. The lower footbed surface may for instance by textured, with the intention of increasing friction with the substantially planar outsole portion in use (which may likewise be mutually textured) to improve restriction of horizontal sliding.

A particular advantage of the present invention is that the footbed portion may be removed manually without damaging the footbed. Thus, it is possible to envisage the use of interchangeable footbed portions which may be easily modified or personalised to an individual's foot contours, e.g. assisted by computer assisted design.

The skilled person will appreciate that the features and embodiments of the respective outsole portions and footbed portions defined above or elsewhere herein may be varied independently in the shoes of the present invention.

Shoe upper Suitably, the shoe of the invention comprises an upper. The upper is a piece of material typically attached to the outsole and suitable for wrapping around the top surface of a foot to attach the bottom of the shoe to the bottom of the foot in use. The upper may comprise a strap or series of straps, such as in sandals or other open-toed shoe constructs (common in ladies shoes), or the upper may fully enclose the toes to form a closed-toe construct, such as in most sports and dress shoes and boots.

Suitable materials will be apparent to the skilled person and may typically include leather, plastics (such as those described in embodiments above) and I or other natural or synthetic fabrics.

The upper may be adhered to the outsole by an adhesive and I or the upper may be stitched to the outsole.

In embodiments of the invention, the outsole portion comprises a groove proximal to, or at! the outer peripheral outsole edge which is configured to receive the peripheral edge of the upper (see, e.g. Figure 8). Suitably, wherein the outsole comprises one or more recesses in the upper outsole face, the upper may be advantageously engaged within (e.g. stitched into) the groove by use of a needle stitch through the inner wall of one or more recesses providing a stitch that is invisible once the footbed is in place. This is not possible using conventional shoe constructs (see, e.g. Figure 7), wherein an excess portion of the upper fabric is usually required to be passed between the outsole and insole layers to be held in place under the insole and footbed. This feature thus has the added advantage of eliminating waste of upper material.

Accordingly, in another aspect of the invention is provided a shoe comprising: an outsole comprising a groove proximal to or at the outer peripheral edge of Further aspects and embodiments As described above, the invention provides an entirely new approach to shoe construction. In particular, the invention provides a new shoe design that is based upon the interaction between a new outsole and footbed arrangement.

The shoe of the present invention may have a construction substantially as depicted in Figure 8.

An aspect of the invention thus provides an outsole portion comprising upper and lower faces, the lower face configured to contact a ground surface when in use and the upper face configured to mechanically engage with a footbed portion. The outsole portion may suitably be an outsole portion as described according to any aspect or embodiment above. For instance, in a particularly preferred embodiment is provided an outsole comprising one or more recesses in the upper outsole face for receiving one or more engaging portions of a footbed portion, and a groove in the outer peripheral edge of the outsole portion for receiving and affixing the peripheral edge of an upper. In preferred embodiments, the outsole portion is substantially as described herein with reference to Figure 1. Preferably, the outsole portion of this aspect is attached to an upper. For instance, an outsole attached to an upper provides a key feature of the shoes of the present invention which may for example be provided independently of the footbed portion.

In a further aspect of the invention is provided a footbed portion comprising upper and lower opposing faces, the upper footbed face configured to contact the bottom surface of a foot when in use in a shoe and the lower footbed face configured to mechanically engage an outsole portion of shoe. The footbed portion may suitably be a footbed portion as described according to any aspect or embodiment above. In preferred embodiments, the footbed portion is substantially as described herein with reference to Figure 2. Thus, the new footbeds of the present invention may be provided separately to the shoes as described above, e.g. as bespoke or replacement parts.

In a further aspect of the invention is provided a kit of parts comprising a footbed portion as described in any aspect or embodiment above and an outsole portion as described in any aspect and embodiment above, optionally wherein the outsole portion is attached to an upper, such as described above.

Also provided by the present invention is a product comprising a shoe as described according any aspect or embodiment herein, a footbed portion as described in any aspect or embodiment herein an outsole portion as described in any aspect or embodiment herein or a kit as defined in the previous aspect.

Methods of manufacture As described above, the present invention encompasses an entirely new shoe construction, wherein the usual midsole and insole portions of the shoe are not required.

Thus, in an aspect of the embodiment is provided a method of making a shoe, the method comprising providing a footbed portion (such as set out in any aspect and embodiment above) and an outsole portion (such as set out in any aspect and embodiment above) and mechanically engaging the footbed and outsole portions.

The method may suitably comprise attaching an upper to the outsole, optionally wherein the step of attaching the upper to the outsole is performed prior to mechanically engaging the footbed and outsole portions.

In embodiments, the upper is attached to the outsole in an inverted arrangement, i.e. wherein the upper is folded back under the bottom "ground-contacting" surface of the outsole. The footbed may then be attached before the upper is flipped back to the conventional upper placement above the footbed. Shoe

The shoe according to the above method may be any shoe as defined herein in the above aspects and embodiments of the invention.

Outsole Suitable methods of the above method may thus provide an outsole portion complising upper and lower (i.e. opposing) faces, the lower outsole face configured to contact a ground surface when in use and the upper outsole face configured to mechanically engage a footbed portion. Preferably, the upper outsole face comprises one or more recesses in the outsole body, wherein said one or more recesses are configured to mechanically engage with one or more projecting elements extending outwardly from the footbed portion. Alternatively, the upper face of the outsole portion may comprise one or more projecting elements extending outwardly from the outsole surface (i.e. in a plane orthogonal to the upper outsole face), wherein said projecting elements are configured to mechanically engage one or more recesses in the footbed portion. The outsole portion according to the above aspect may thus be any outsole as defined herein in the above aspects and embodiments of the invention.

Thus the process may comprise engaging said projecting elements and recesses in the respective footbed and outsole portions.

In preferred embodiments, the outsole portion comprises a groove in the outer peripheral edge of the outsole portion for receiving the peripheral edge of an upper, preferably wherein the outsole is provided with one or more recesses. Thus, in preferred embodiments, the step of attaching the upper comprises inserting the peripheral edge of the upper into said groove in the outer peripheral edge of the outsole and affixing the upper to the outsole groove.

The upper may be affixed to the outsole by any suitable means, such as using an adhesive and I or by stitching. In a preferred embodiment, the outsole comprises one or more recesses in the upper surface, and the upper is stitched into the groove through the inner wall of the one or more recesses. This thus provides a stitch that is invisible once the footbed is in place.

Footbed The footbed portion in the above method may be as described in any aspect or embodiment above. Suitably, the footbed portion comprises upper and lower (i.e. opposing) faces, the upper said footbed face configured to contact the bottom surface of a foot when in use and the lower footbed face configured to mechanically engage an outsole portion. The footbed portion may suitably be a footbed portion as described according to any aspect or embodiment above. In preferred embodiments, the footbed portion is substantially as described herein with reference to Figure 2.

The skilled person may independently select a suitable complementary outsole portion and footbed portion from any of the aspects and embodiments described herein.

In a further aspect is provided the use of footbed portion as described in any aspect and embodiment herein, and I or an outsole portion as described in any aspect and embodiment herein in a method of making a shoe. Preferably, the method of manufacturing the shoe is as defined above.

It will be appreciated that the features of aspects and embodiments described above may also be present, alone or in combination with any of the features of other embodiments according to any other aspect of the invention.

LIST OF FIGURES

Figure 1 depicts a plan view of an outsole portion of the invention comprising a single large cavity for receiving one or more mutually engaging projecting elements of a footbed portion of the invention.

Figure 2A depicts in the foreground an end-view of a footbed according to the invention (turned upside down for ease of viewing) and in the background depicts a perspective view of an outsole of the present invention. Figure 2B provides a figurative vertical cross-sectional view across the width of the footbed according to Figure 2A (shown the "right way up"). Figure 2C depicts a vertical cross-section across the width of the footbed as shown in Figure 2A.

Figure 3 depicts a perspective view of a footwear item of the present invention prior to attachment of the shoe upper to the outsole. The figure depicts the outsole portion as the bottom part of the item and the footbed portion as the top part of the item in mechanical engagement wherein a part of the footbed portion has been manually lifted from away from the outsole to show the engaging projecting element and recess of the footbed portion and outsole portions respectively.

Figure 4 depicts a side view of a shoe of the present invention prior to attachment of the shoe upper to the outsole. The figure depicts the outsole portion (bottom) in mechanical engagement with a footbed portion (top).

Figure 5 depicts a plan view of the shoe of the invention depicted in figure 4. The figure depicts the upper footbed face of the footbed portion which is overlaying and in mechanical engagement with the outsole portion.

Figure 6 depicts at a) to f) various exemplary alternative figurative cross-sectional views of a variety of recess shapes according to the invention.

Figure 7 depicts a vertical cross section across the width of a conventional shoe.

Part of the shoe upper has been omitted to improve clarity.

Figure 8 depicts a vertical cross section across the width of a shoe according to the present invention. Part of the shoe upper has been omitted to improve clarity.

DETAILED DESCRIPTION

Specific embodiments of the present invention will now be described further, by way of example, with reference to the accompanying drawings.

Figure 1 depicts the upper (footbed engaging) face of an outsole portion 100 according to the invention. The upper face comprises an upper outsole body surface and a single (i.e. only one) central cavity 11 in the outsole body surface and having a peripheral upstanding cavity wall that substantially follows the contour of the outer peripheral edge of the outsole. The cavity base as seen as 11 in the drawing comprises a number of further structures and recesses which act to further reduce the weight of the outsole portion.

The outsole portion is a single piece made from a process of direct injection moulding using thermo polyurethane (although thermo plastic rubber may also be used). The outsole portion may alternatively be made by using a vulcanised method of using high temperature and pressure to soften and liquidate sheets or blocks of rubber.

This will then flow into a solid mould that has been machined and engraved to represent the shape size and features of the finished outsole design.

Figures 2A (foreground) and 2B depict a preferred footbed portion according to the invention. The footbed portion is upside down in Figure 2A to illustrate the projecting element more clearly. Cross-sectional diagram Figure 2B shows more clearly the structural features of the Figure 2A footbed. The footbed portion comprises an upper footbed face 22 comprising a foot-engaging layer of leather 24 (providing a soft and smooth feel) representing the upper footbed surface laminated to a layer of open-cell polyurethane foam 23 (providing additional cushioning and support). The foam layer forms the bottom face of the footbed layer along with a single pad-like projecting element 20,21 of porous open-cell polyurethane foam extending away from the bottom footbed surface for engagement with an outsole recess. The projecting element comprises first and second foam layers 20 and 21 and is bonded to foam layer 23 by an adhesive! but may alternatively be cut from the same piece as foam layer 23. The projecting element has a horizontal cross-sectional area that is narrower at its base than its tip and which increases gradually from its base 25 to its tip 26 thus forming a dove-tail shape. The outermost portion (tip) of the projecting element has a substantially flat surface for engaging a respectively flat cavity base in an outsole portion 100.

The open cell foam layers 20, 21 and 23 are prepared by first forming large blocks of polyurethane that contains many open air pockets, providing a lightweight and breathable material. The blocks are then cut down to thinner sheets of approximately 2 metres in size and then are laminated to a textile material or non-textile substance, e.g. leather or suede, for instance, leather in this example. The laminated foam layers may then be cut down such that the upper footbed layer conform generally to a given shoe size, and the projecting elements may be cut to conform with one or more recesses in the outsole portion. The shape of the footbed may also be generated by moulding, e.g. using a machined steel or aluminium block engraved and cut to an exact 3 dimensional CAD" designed specification. In such a case, the smaller sheet pieces of material laminated sections are then placed onto the cold mould and cut into the desired shape by press-moulding.

Figures 2A (background) and Figure 2C depict a preferred outsole of the invention.

Cross-sectional diagram Figure 2C shows more clearly the structural features of the Figure 2A outsole. The contours and grooves of the lower outsole surface and the various contours and cutaway portions in the recess floor 11 are not depicted in the cross-sectional view. The outsole portion 100 has an outer peripheral groove 27 around the circumference of the outsole for direct attachment of a shoe upper (e.g. by an internal stitch through the inner upstanding wall of the outsole cavity 11). The outsole 100 comprises an upper face 10 which can support a lower footbed face, and a lower face 28 configured to contact the ground in use. The lower face 28 comprises a number of grooves and contours (not visible in this depiction) which act as treads for improving engagement with a ground surface in use. The single outsole cavity 11 has an outer peripheral upstanding wall that generally tollows the contour of the outer outsole edge such that the cavity substantially encompasses the entire upper face of the outsole portion for supporting the whole foot in use. The cavity has a larger chamber width 290 than cavity mouth width 291 by virtue of a lip 292 at the cavity mouth under which one or more projecting elements may be engaged to provide an interlock to prevent vertical lifting of the footbed in use. The upper surface of the cavity floor provides a generally level (flat) surface for supporting a projecting element of a footbed, and in the Figure 2A photograph, further cavity floor cutaway portions have been made to reduce the weight of the outsole. However, these portions do not necessarily need to play a part in engaging a footbed. This outsole shape therefore allows for an extra-thick footbed portion to be inserted without adding bulk to the shoe, thus maintaining a streamlined shoe profile.

Figures 3 and 4 depict the footbed in mechanical engagement with the outsole 100.

A portion of the lower footbed face 23 rests on the upper outsole face 10, and, as shown in figure 3, the dovetail element 20,21 projecting from the lower footbed face is resilient and is pressed into the cavity 11 in the upper outsole face. The recess walls abut the projecting element sides, preventing sliding movements in both horizontal dimensions. The outer part of the dovetail 21,22 also passes under a lip in the cavity mouth 11 (see figure 8), which mechanically interlocks the footbed and outsole and thus prevents the footbed from lifting vertically away from the outsole.

Moreover, because the footbed material is of a high cushioning nature and extremely malleable it will compress under pressure in use, thus widening and pressing against the peripheral cavity walls of the outsole to provide an enhanced tight-fit.

Nonetheless, the layers may still be separated using reasonable manual force as shown in figure 3, thus providing a suitably replaceable footbed.

Under normal shoe making practices, the outer sole comprises of a more dense solid structure sitting directly under the flat two-dimensional insole. Advantageously, the single large projecting element of this embodiment provides an exceptionally thick footbed layer compared to conventional standards. Because the insole has now been removed in the present invention and the footbed depth increased (by approx. 10mm in this example) the footbed material is allowed to press more deeply into the cushioning foam, thus increasing overall comfort.

This added footbed thickness also provides an extremely personalised foot support extremely simply as the foam adopts and supports the natural contour of the underfoot, rather than resisting it as in the case of conventional shoes. In practice, once the foot is positioned into the shoe and body weight is exerted (in the normal walking process) the excessive underfoot depth of foot cushioning foam responds rapidly and begins to automatically mould and form to the underside anatomical profile of the wearer. This is a significant advantage, because until now anatomically moulded and created footbeds (inner socks) are only formed to fixed generic profiles and shapes and do not ultimately fit to every individual's underfoot contours.

Furthermore, because an insole is not required in the present invention and because around 20% of the outsole material is replaced by lightweight porous foam in this embodiment, the overall weight of the shoe is significantly reduced.

Figure 4 shows a side view of a footbed 22 mechanically engaged with the outsole 100. The outsole comprises an upper face 10 engaged with the footbed 22 and a lower face 40 configured to contact the ground in use. The lower face 40 comprises a number of grooves and contours which aid act as treads for improving engagement with a ground surface. This side view also shows a groove 41 running around the peripheral outer edge of the outsole for engagement of the upper.

Figure 5 shows a plan view of the combined footwear item of figure 4 comprising a footbed 22 mechanically engaged with the outsole 100. Only the upper surface of the upper footbed face is visible showing a general foot outline contour.

Figure 6 depicts at a) to f) various exemplary alternative figurative cross-sectional views of a variety of recess shapes according to the invention. Each recess has a mouth portion 1, an upstanding recess wall 2, a recess floor 3 and a recess or hollow 4. a) provides an example of a recess having a mouth and internal width that is equal. b) and c) depict recesses wherein the mouth is wider than the largest width of the recess. d), e) and f) depict examples wherein the mouth width is narrower than the widest internal width of the recess. f) for example has a lip at the recess mouth.

Thus, d), e) and f) are ideal for engaging a projecting element to prevent vertical lift of the footbed (i.e. by providing interference or snap-fit engagements.

Figure 8 shows a cross section view of a shoe according to the present invention encompassing the outsole 100 and footbed 22 engaged as in Figure 4. The shoe comprises a substantially planar outsole portion 100 mechanically engaged with the footbed 22 and an upper 80 engaged directly to the outer peripheral groove 41 of the outsole (e.g. by an internal stitch through the inner upstanding wall of the outsole cavity). The outsole 100 comprises an upper face 10 engaged with the footbed 22 and a lower face 40 configured to contact the ground in use. The lower face 40 may comprises a number of grooves and contours (not visible in this depiction) which may act as treads for improving engagement with a ground surface. This side view also shows a groove 41 running around the peripheral outer edge of the outsole for engagement of the upper 80. The outsole cavity 11 has a larger cavity chamber width than cavity mouth width by virtue of a lip 81 at the cavity mouth under which the wider part of a single dove-tail shaped projecting element 82 protrudes from the lower surface of the footbed portion 84. The side walls of the protruding element abut the upstanding recess side walls 83 at their widest point and the flat tip engages with the flat recess floor to provide support for the foot in use. The pad-like projecting element 82 is a single element that has a width and outline which follows the general contour of the outline of the footbed portion (and the recess side walls), thus supporting the whole foot in use and extending throughout the shoe outsole 100 to prevent the footbed 22 lifting away from the outsole. This also therefore provides an extra-thick footbed without adding bulk to the shoe, thus maintaining a streamlined shoe profile.

Stitch and turn process of manufacture In an exemplary embodiment of the invention is provided a process for manufacturing a shoe comprising an inverted stitch and turn methodology. In such a procedure, the shoe upper is first stitched together (as in normal procedure), then the upper is turned inside out (inverted). The extreme outside periphery of upper is then positioned exactly into a groove 41 on the outside edge of the outsole unit (the outsole is manufactured as described above in the detailed description).

A heavy duty stitching machine comprising of a curved needle then proceeds to stitch / attach the upper edge through the outside groove 41 and internal wall of the outsole cavity 11. The stitching process may be continued completely around the whole outsole and upper as necessary until the entire upper and sole are connected.

Once this procedure has been completed, the whole finished shoe upper and outsole combination undergo a turning process, thus reverting the shoe upper back to its conventional position above the upper surface 10 of the outsole unit for further finishing processes, i.e. ready for insertion of the interlocking footbed portion. For instance, the footbed may then be inserted into the outsole and upper construct, wherein the projecting element of the footbed mechanically engages the outsole cavity. The footbed may also be manufactured as described above in the detailed

description.

In summary, the present invention provides a novel approach to shoe construction which provides an extra-deep thereby extra high-comfort footbed whilst delivering suitable shoe stability. The new approach also removes the need for conventional insole/midsole portions and serves the purpose of providing a simple "click-in" non-slip footbed that resists movement in use without use of chemical adhesives or stitching.

The above embodiments are described by way of example only. Other embodiments falling within the scope of the claims will be apparent to the skilled reader.

Claims

CLAIMS1. A shoe comprising an outsole portion and a footbed portion: the outsole portion comprising upper and lower outsole faces, the lower outsole face configured to contact a ground surface in use and the upper outsole face configured to mechanically engage the footbed portion; and the footbed portion comprising upper and lower footbed faces, the upper footbed face configured to contact the bottom surface of a foot when in use and the lower footbed face configured to mechanically engage the upper face of the outsole portion; wherein the outsole portion is in mechanical engagement with the footbed portion.
2. A shoe according to claim 1, wherein at least one and, optionally only one, of the upper outsole face and lower footbed face comprise one or more projecting elements extending outwardly from their respective surfaces in mechanical engagement with one or more recesses in the respective outsole or footbed portion.
3. A shoe according to claim 2, wherein the lower footbed face comprises one or more projecting elements extending outwardly from its surface in mechanical engagement with one or more recesses in the respective outsole or footbed portion.
4. A shoe according to claim 2 or 3 wherein the upper outsole face comprises from one to ten recesses in mechanical engagement with one or more footbed projecting elements, optionally wherein the upper outsole face comprises a single recess in mechanical engagement with said one or more projecting elements, optionally wherein the upper outsole face comprises a single recess in mechanical engagement with a single projecting element.
5. A shoe according to any one of claims 2 to 4, wherein said one or more projecting elements form a tight-fit engagement with said one or more recesses, optionally wherein the tight-fit engagement is an interference-fit or a snap-fit engagement.
6. A shoe according to any one of claims 2 to 5, wherein the cross-sectional area of the projecting element increases from the base towards the tip, optionally wherein the cross-sectional area of the projecting element increases from the base towards the tip to form a dove-tail shape.
7. A shoe according to any one of claims 2 to 6, wherein one or more of the recesses are cavities.
8. A shoe according to any previous claim wherein said outsole portion comprises a material selected from plastic, leather, metal or wood, optionally leather or plastic, optionally a plastic selected from polyurethane and ethyl vinyl acetate, optionally polyurethane.
9. A shoe according to any previous claim wherein said outsole portion comprises a single piece.
10. A shoe according to any previous claim wherein said footbed portion comprises a non-woven fabric, optionally a non-woven fabric selected from the group of leather, suede or plastic, optionally an open-cell foam.
11. A shoe according to any previous claim comprising an upper attached directly to the outsole portion, optionally wherein the upper is affixed within a groove proximal to, or in, the outer peripheral edge of the outsole portion.
12. A footbed portion as set out in any previous claim.
13. Afootbed portion substantially as depicted in Figure 2.
14. An outsole portion as set out in any previous claim, optionally attached to an upper, optionally wherein the upper is affixed within a groove in the outer peripheral edge of the outsole portion.
15. An outsole portion substantially as depicted in Figure 1, optionally attached to an upper, optionally wherein the upper is affixed within the groove in the outer peripheral edge of the outsole portion.
16. A kit of parts comprising a footbed portion as described in any one of claims 12 and 13 and an outsole portion as described in any one of claims 14 and 15.
17. A product comprising a shoe as described in any one of claims 1 to 11, a footbed portion as described in claim 12 or 13, an outsole portion as described in claim 14 or 15, or a kit as defined in claim 16.
18. A method of making a shoe, the method comprising mechanically engaging a footbed portion with an outsole portion, optionally wherein the footbed portion is as defined according to claim 12 or 13 and / or wherein the outsole portion is defined according to claim 14 or 15.
19. A method according to claim 18 further comprising attaching an upper to the outsole, optionally wherein the step of attaching the upper to the outsole is performed prior to mechanically engaging the footbed and outsole portions.
20. A method according to claim 19 wherein the peripheral edge of the upper is inserted into and attached to a groove in the outer peripheral edge of the outsole.
21. A method according to claim any one of claims 18 to 20 wherein the shoe is as defined in any one of claims 1 to 11.
22. A shoe as defined in any one of claims 1 to 11 or method according to any one of claims 18 to 21 wherein said mechanical engagement between the footbed and outsole portion is a mechanical interlock.
23. A shoe comprising an outsole portion in mechanical interlock with a footbed portion.