Layered footbeds and related methods

Abstract

A layered footbed may include at least a first layer and a second layer disposed below the first layer. One of the layers is formed from a soft, resilient, and / or comfortable cushioning foam material, while the other of the layers is a conforming foam designed to conform to the user's foot during use. The conforming foam may be a packable foam having a high compression set, or a memory foam having a long response time. The footbed also may include a third layer providing structural integrity and disposed below the second layer, and / or a fabric lining or covering placed above the first layer. The footbed may be incorporated in an article of footwear, and may be configured to accommodate a user's specific foot anatomy, maintain performance over time, and / or provide comfort-related personalization to the user.

Description

[0001] LAYERED FOOTBEDSAND RELATED METHODS

[0002] CROSS-REFERENCES

[0003] This application claims the benefit of U.S. provisional patent application no.

[0004] 63 / 745,231 entitled “LAYERED FOOTBEDS AND RELATED METHODS”, filed on January 14, 2025, which is hereby incorporated by reference herein in its entirety. However, such material is only incorporated to the extent that no conflict exists between the incorporated material and the statements and drawings set forth herein. In the event of any such conflict, including any conflict in terminology, the present disclosure is controlling.

[0005] FIELD

[0006] This disclosure relates to layered footbeds and related methods. More specifically, the disclosure relates to layered footbeds that may be incorporated into articles of footwear, and that have a conforming layer and a cushioning layer.

[0007] BACKGROUND

[0008] The footbed of an article of footwear is configured to support the user’s foot and provide cushioning. The specific characteristics of the footbed may have a large impact on the overall comfort and performance of the article of footwear. Additionally, the footbed may be responsible for preventing or causing injuries. This is especially true for footwear that is worn during athletics, e.g., running, walking, training, etc., including cleated footwear. Normally it takes a long time for midsoles to conform to the shape of the foot and through this time, they often lose or experience degradation of their comfort and / or performance attributes.

[0009] SUMMARY

[0010] Disclosed footbeds include a cushioning layer and a conforming layer. The cushioning layer may be a cushioning foam having a compression set of less than 50% and a hardness ranging about 5 to about 50 Asker C. The conforming layer may be disposed above or below the cushioning layer, and comprises a conforming foam thatmay be a packable foam ora memory foam. The packable foam may have a compression set of at least 55 percent and a hardness ranging from about 20 Asker C to about 50 Asker C. The memory foam may have a recovery time of greater than 30 minutes and an Indentation Force Displacement (IFD) ranging from about 10 pounds to about 50 pounds at 75 percent compression over temperatures ranging from 0 degrees C to 45 degrees C, or ranging from about 10 pounds to about 50 pounds at 65 percent compression over temperatures ranging from 0 degrees C to 45 degrees C. Articles of manufacture (i.e., articles of footwear) comprising such layered footbeds also are within the scope of the present disclosure.

[0011] Methods of manufacturing such footbeds and / or articles of manufacture incorporating such footbeds are also disclosed. Methods may include combining a cushioning layer and a conforming layer, wherein the cushioning layer may be a cushioning foam having a compression set of less than 50% and a hardness ranging about 5 to about 50 Asker C, and wherein the conforming layer may be a conforming foam that may be a packable foam or a memory foam. The packable foam may have a compression set of at least 55 percent and a hardness ranging from about 20 Asker C to about 50 Asker C. The memory foam may have a recovery time of greater than 30 minutes and an Indentation Force Displacement (IFD) ranging from about 10 pounds to about 50 pounds at 75 percent compression over temperatures ranging from 0 degrees C to 45 degrees C, or ranging from about 10 pounds to about 50 pounds at 65 percent compression over temperatures ranging from 0 degrees C to 45 degrees C. When combining the cushioning layer and the conforming layer, the conforming layer may be disposed above or below the textured layer, such that a bottom surface of the conforming layer directly contacts a top surface of the cushioning layer, or such that a bottom surface of the cushioning layer directly contacts a top surface of the conforming layer. The conforming layer is configured to conform to a wearer’s foot when a loading pressure is applied to the conforming layer.

[0012] In accordance with various embodiments, there is provided a footbed for an article of footwear, the footbed including: a first layer having a first layer top surface, a first layer bottom surface opposite the first layer top surface, a first layer thickness between the first layer top surface and the first layer bottom surface, a first layer width, and a first layerlength; and a second layer disposed below the first layer bottom surface, the second layer having a second layer top surface, a second layer bottom surface opposite the second layer top surface, a second layer thickness between the second layer top surface and the second layer bottom surface, a second layer width, and a second layer length; wherein the first layer is a cushioning layer including a cushioning foam having a compression set of less than 50 percent, and a hardness ranging from about 5 to about 50 Asker C; and wherein the second layer is a conforming layer including a conforming foam, wherein the conforming foam is a packable foam having a compression set of at least 55 percent and a hardness ranging from about 20 Asker C to about 50 Asker C, or the conforming foam is a memory foam having a recovery time of greater than 30 minutes and an Indentation Force Displacement (IFD) ranging from about 10 pounds to about 50 pounds at 75 percent compression over temperatures ranging from 0 degrees C to 45 degrees C, or ranging from about 10 pounds to about 50 pounds at 65 percent compression over temperatures ranging from 0 degrees C to 45 degrees C.

[0013] In accordance with various embodiments, there is provided a method of manufacturing a footbed, the method including: affixing a first layer and a second layer directly or indirectly to each other; wherein the first layer has a first layer top surface, a first layer bottom surface opposite the first layer top surface, a first layer thickness between the first layer top surface and the first layer bottom surface, a first layer width, and a first layer length; wherein the second layer has a second layer top surface, a second layer bottom surface opposite the second layer top surface, a second layer thickness between the second layer top surface and the second layer bottom surface, a second layer width, and a second layer length; wherein the first layer is a cushioning layer including a cushioning foam having a compression set of less than 50 percent, and a hardness ranging from about 5 to about 50 Asker C; and wherein the second layer is a conforming layer including a conforming foam, wherein the conforming foam is a packable foam having a compression set of at least 55 percent and a hardness ranging from about 20 Asker C to about 50 Asker C, or the conforming foam is a memory foam having a recovery time of greater than 30 minutes and an Indentation Force Displacement (IFD) ranging from about 10 pounds to about 50 pounds at 75 percent compression over temperatures ranging from 0 degrees C to 45 degrees C, or ranging from about 10 poundsto about 50 pounds at 65 percent compression over temperatures ranging from 0 degrees C to 45 degrees C.

[0014] BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Fig. 1 is a first illustrative schematic cross-section of a footbed in accordance with aspects of the present disclosure.

[0016] Fig. 2 is a top view of a first illustrative footbed in accordance with aspects of the present disclosure.

[0017] Fig. 3 is a second illustrative schematic cross-section of a footbed in accordance with aspects of the present disclosure.

[0018] Fig. 4 is a top view of a second illustrative footbed in accordance with aspects of the present disclosure.

[0019] Fig. 5 is an elevation schematic representation of an article of footwear including a footbed in accordance with aspects of the present disclosure.

[0020] Fig. 6 is a schematic flowchart diagram of methods according to the present disclosure.

[0021] Fig. 7A is a cutaway side elevation schematic representation of an article of footwear including a footbed in accordance with aspects of the present disclosure.

[0022] Fig. 7B is a cutaway side elevation schematic representation of an article of footwear including a footbed in accordance with aspects of the present disclosure.

[0023] Fig. 7C is a cutaway side elevation schematic representation of an article of footwear including a footbed in accordance with aspects of the present disclosure.

[0024] Fig. 8 is a third illustrative schematic cross-section of a footbed in accordance with aspects of the present disclosure.

[0025] DETAILED DESCRIPTION

[0026] Various aspects and examples of a footbed, as well as related methods, are described below and illustrated in the associated drawings. Unless otherwise specified, a footbed in accordance with the present teachings, and / or its various components, may contain at least one of the structures, components, functionalities, and / or variations described, illustrated, and / or incorporated herein. Furthermore, unless specificallyexcluded, the process steps, structures, components, functionalities, and / or variations described, illustrated, and / or incorporated herein in connection with the present teachings may be included in other similar devices and methods, including being interchangeable between disclosed embodiments. The following description of various examples is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. Additionally, the advantages provided by the examples and embodiments described below are illustrative in nature and not all examples and embodiments provide the same advantages or the same degree of advantages.

[0027] This Detailed Description includes the following sections, which follow immediately below: (1) Definitions; (2) Overview; (3) Examples, Components, and Alternatives; (4) Advantages, Features, and Benefits; and (5) Conclusion. The Examples, Components, and Alternatives section is further divided into subsections, each of which is labeled accordingly.

[0028] Definitions

[0029] The following definitions apply herein, unless otherwise indicated.

[0030] “Comprising,” “including,” and “having” (and conjugations thereof) are used interchangeably to mean including but not necessarily limited to, and are open-ended terms not intended to exclude additional, unrecited elements or method steps.

[0031] Terms such as “first,” “second,” and “third” are used to distinguish or identify various members of a group, or the like, and are not intended to show serial or numerical limitation.

[0032] “AKA” means “also known as,” and may be used to indicate an alternative or corresponding term for a given element or elements.

[0033] “Coupled” means connected, either permanently or releasably, whether directly or indirectly through intervening components.

[0034] “Resilient” describes a material or structure configured to respond to normal operating loads (e.g., when compressed) by deforming elastically and returning to an original shape or position when unloaded.

[0035] “Rigid” describes a material or structure configured to be stiff, non-deformable, or substantially lacking in flexibility under normal operating conditions.“Elastic” describes a material or structure configured to spontaneously resume its former shape after being stretched or expanded by 200% along at least one axis.

[0036] In this disclosure, one or more publications, patents, and / or patent applications may be incorporated by reference. However, such material is only incorporated to the extent that no conflict exists between the incorporated material and the statements and drawings set forth herein. In the event of any such conflict, including any conflict in terminology, the present disclosure is controlling.

[0037] Overview

[0038] In general, a layered footbed in accordance with the present teachings may include a cushioning layer and a conforming layer disposed on top of or below the cushioning layer. Specifically, disclosed footbeds include a first layer and a second layer disposed below the first layer (e.g., below a bottom surface of the first layer). One of the first layer and the second layer is a conforming layer comprising a conforming foam, and the other of the first layer and the second layer is a cushioning layer comprising a cushioning foam. Disclosed footbeds are configured to be a component of an insole for the article of footwear, to be an insole for the article of footwear, and / or to be a component of a sole structure of the article of footwear.

[0039] When a loading pressure is applied to a top surface of the footbed (e.g., by a user’s foot, when the user wears an article of footwear that incorporates the disclosed footbed), the cushioning layer provides soft and resilient comfort to the user, while the conforming layer will conform to the shape of the user’s foot. An optional third layer under the cushioning layer and the conforming layer may provide structural integrity to the footbed and hold its shape. In this manner, disclosed layered footbeds may maintain performance and comfort while also personalizing the footbed to the user with limited use.

[0040] In some examples, the layered footbeds of the present disclosure are utilized to form a portion of, or an entirety of, a footbed of an article of footwear. The layered footbed is configured to be utilized in the article of footwear to cradle a user’s foot and provide cushioning and support for different areas of the user’s foot. Disclosed layered footbeds may provide comfort-related personalization for users, and may become more comfortable over time due to the construction of the disclosed footbeds.The disclosed layered footbeds are suitable for use in a wide variety of footwear, including athletic footwear (e.g., footwear intended for wear during athletic activities such as running, walking, hiking, training, cycling, climbing, dancing, etc.), footwear intended for wear during athletic games such as basketball, tennis, pickleball, American football, soccer, etc., including cleated footwear, and the like. The disclosed footbeds are suitable for use in footwear intended for wear after athletic activity, often referred to as “recovery” footwear, including “recovery” slides and mules. The disclosed footbeds are also suitable for use in casual and dress footwear such as boots, slip-on and lace-up footwear, sandals and the like.

[0041] Examples, Components, and Alternatives

[0042] The following sections describe selected aspects of illustrative footbeds as well as related systems and / or methods. The examples in these sections are intended for illustration and should not be interpreted as limiting the scope of the present disclosure. Each section may include one or more distinct embodiments or examples, and / or contextual or related information, function, and / or structure.

[0043] A. Illustrative Foot beds

[0044] As shown in Figs. 1-4 and 8 (which are not drawn to scale), this section describes illustrative footbeds 100, 102, and 104. Footbeds 100, 102, 104 are an example of the footbeds described above. In some examples, footbed 100, 102, 104 forms a portion or an entirety of a footbed of an article of footwear, as described further below with reference to Fig. 5.

[0045] As shown in Figs. 1-2, footbed 100 may include a first layer 104 and a second layer 106. Second layer 106 may be disposed below first layer 104 in the orientation of footbed 100 as the footbed would be placed in an article of footwear. First layer 104 has a first layer top surface 108 and a first layer bottom surface 110 opposite first layer top surface 108. First layer 104 has a first layer thickness 112 (Fig. 1 ) between first layer top surface 108 and first layer bottom surface 110, as well as a first layer width 114 and a first layer length 116 (Fig. 2). Similarly, second layer 106 (which is disposed below and / orcoupled to first layer bottom surface 110) has a second layer top surface 120, a second layer bottom surface 122 opposite second layer top surface 120, and a second layer thickness 124 (Fig. 1) between second layer top surface 120 and second layer bottom surface 122. Second layer 106 also has a second layer width 126 and a second layer length 128, which may be substantially the same as first layer width 114 and first layer length 128, respectively, in some examples. In other examples, second layer width 126 may be greater than or less than first layer width 114, and / or second layer length 128 may be greater than or less than first layer length 116. Additionally or alternatively, first layer 104 and second layer 106 may have substantially the same footprint, shape, surface area, and / or coextensive perimeters, or first layer 104 and second layer 106 may be different from each other in footprint, shape, surface area, and / or perimeter locations.

[0046] With respect to disclosed layered footbeds, one of the layers (e.g., first layer 104 or second layer 106) is a conforming layer 140 comprising a conforming foam 142, while the other layer (e.g., the other of first layer 104 and second layer 106) is a cushioning layer 130 comprising a cushioning foam 132. In the example of footbed 100, first layer 104 is a cushioning layer 130, while second layer 106 is a conforming layer 140. Conforming layer 140 may be formed of one or more conforming foams 142. In some examples, conforming foam 142 is a packable foam having a high compression set of at least 55 percent. For example, conforming foam 142 may have a compression set ranging from about 55 percent to about 95 percent, from about 65 percent to about 95 percent, from about 70% to about 95 percent, and / or from about 75 percent to about 95 percent. The compression set of a material is the permanent deformation remaining after the removal of a force that was applied to it. Compression set of a foam may be measured by determining its original thickness (T1), compressing the foam under force to a specific percentage of its original thickness (e.g., 50 percent), holding it under the force for a period of time (e.g., 22 or 24 hours) at room temperature or at an increased temperature (e.g., 70-100 degrees C), releasing the load, and measuring its final thickness (T2) after releasing the load and allowing the foam to return to room temperature (if it was heated). The compression set is reported as a percentage of the foam’s original thickness calculated using the equation Compression Set (%) = [(T1 - T2) / T1 ] x 100. The results of a compression set test are expressed as a percentage value, where lower percentagesindicate that the material better resists permanent deformation under a given environment, and higher percentages indicate that a material retains a higher degree of deformation after removal of the applied force. In other words, a lower compression set indicates that a foam has better recovery and a lower level of permanent deformation than a foam having a higher compression set. Standard test methods such as ASTM D3574, ISO 815-1, or ISO 3386 and standard equipment such as a standard equipment such as a Universal Testing Machine (UTM) may be used in determining the compression set of a foam in some examples.

[0047] For example, to determine the compression set of conforming layer 140 (or of a material selected for use in conforming layer 140), a specimen may be compressed to a predetermined deflection (e.g., 50% or 75% of its original height, or thickness) for a set time (e.g., 24 hours), and held at a set temperature (e.g., 45 degrees C). The compression set of the specimen is then determined as the percentage of deflection remaining in the specimen after it has been left uncompressed for 30 minutes. The compression set of the specimen is thus a comparison between the thickness, or height, of the specimen at this time and the original thickness or height of the specimen prior to being held in compression. In some examples, a higher compression set foam or other material may be selected for a conforming foam 142 used in conforming layer 140 such that conforming foam 142 “packs” (i.e., cells of the foam at least partially collapse and remain collapsed when a loading pressure is applied, such that the foam loses some of its resiliency, hence being referred to as a packable foam) after a relatively short period of time, and / or such that the conforming foam 142 retains a shape permanently after conforming to the shape of the user’s foot. In this manner, disclosed footbeds 100 may be configured to pack to create a customized fit for a user. Such packable foams may have a hardness between about 20-50 Asker C, and / or between about 30-40 Asker C.

[0048] A variety of different test methods for determining hardness of foams are known in the art. One example is Asker C hardness, which uses an Asker C durometer (also referred to as a JIS C type durometer). Spherical (ball-type) indenters are commonly used for testing the hardness of foams and other soft elastomers. To perform the test, the foam sample is placed on a flat horizontal surface, and the indenter of the durometer is positioned on the top surface of the sample. A force is applied to push the indenter intothe sample and held in place for a few seconds, and the maximum reading of the gauge is recorded. The value reported is an average of at least five readings taken from different locations on the sample. The Asker C scale ranges from 0 to 100, with higher numbers indicating harder materials.

[0049] In some examples, conforming foam 142 is a memory foam having a recovery time of greater than 30 minutes and an Indentation Force Displacement (IFD) ranging from about 10 pounds to about 50 pounds at 75 percent compression over temperatures ranging from 0 degrees C to 45 degrees C, or ranging from about 10 pounds to about 50 pounds at 65 percent compression over temperatures ranging from 0 degrees C to 45 degrees C. The recovery time for memory foams used for conforming foam 142 may measured using tests such as the ASTM D3574 Test M, and standard equipment such as a Universal Testing Machine (UTM), or using specialized equipment specifically designed to test viscoelastic foams, may be used. For example, the amount of time required for a foam such as a viscoelastic foam to return to its original shape and size may be determined by compressing a sample of the foam to a predetermined percentage of its original thickness (e.g., 75%) using a platen for a specified time, and then quickly releasing the platen and measuring the recovery time required for the sample to return to its original thickness. Indentation Force Displacement (IFD) determines the amount of force required to achieve a specific amount of deflection of the original thickness of a foam sample (e.g., a deflection of 25% or 65% of the original thickness). In the test method, a platen (typically a perforated platen) is used to compress the foam, and the amount of force required for the platen to deform the sample by a specific amount is determined. This test may be performed according to a standard test method such as ASTM D3574 Method B1, and standard equipment such as a Universal Testing Machine (UTM) may be used. Additionally or alternatively, memory forms used for conforming foam 142 may have a hardness ranging from about 20 Asker C to about 50 Asker C, and / or from about 30 Asker C to about 40 Asker C.

[0050] Conforming foam 142 may have an open cell or closed cell structure. Suitable examples of materials for conforming foam 142 may include an ethylene-vinyl acetate (EVA) polymer foam, a polyether block amide (PEBA) foam, a thermoplastic polyesterelastomer (TPEE) foam, an ethylene propylene diene monomer (EPDM) foam, a polylactic acid (PLA) foam, a polyurethane (Pll) foam, or any combination thereof. The conforming foam 142 and / or the conforming layer 140 may comprise or consist of an EVA foam, a Pll foam, latex rubber foam, or any combination thereof. Conforming foam 142 may include a natural or synthetic rubber foam, such as a latex foam. In some examples, the conforming foam 142 is a viscoelastic foam. In other examples, the conforming foam 142 does not present viscoelastic properties in the strain rates expected within footwear. In some examples, conforming layer 140 is configured to pack out over 1 to 30 days of wear, or 1 to 30 cumulative hours of wear, or one to ten cumulative hours of wear of footbed 100, to conform to an underfoot shape of a wearer’s foot.

[0051] Cushioning layer 130 may comprise or consist of one or more cushioning foams 132. Cushioning foam 132 may have an open cell or closed cell structure. In some examples, cushioning foam 132 has a compression set of less than 55 percent, less than 40 percent, less than 30 percent, less than 20 percent, and / or less than 10 percent, though typically will be less than 20 percent. Additionally or alternatively, cushioning foam 132 may have a hardness ranging from about 10 to about 50 Asker C, from about 15 to about 50 Asker C, from about 20 to about 50 Asker C, from 25 to about 45 Asker C, from about 30 to about 40 Asker C, about 5 to about 45 Asker C, from about 10 to about 40 Asker C, and / or from about 15 to about 35 Asker C. Cushioning layer 130 is configured to deform when a loading pressure is applied to footbed 100, in order to provide underfoot cushioning during months or years of wear of footbed 100 in an article of footwear. Suitable examples of materials for cushioning foam 132 may include an EVA foam, a PEBAfoam, a TPEE foam, an EPDM foam, a PLA foam, a Pll foam, or any combination thereof. In some examples, the cushioning foam 132 and / or the cushioning layer 130 may comprise or consist of an EVA foam, a PEBA foam, a TPEE foam, a Pll foam, or any combination thereof. In some examples, the cushioning foam 132 is a viscoelastic foam. In other examples, the cushioning foam 132 does not present viscoelastic properties in the strain rates expected within footwear.

[0052] First layer 104 and second layer 106 are affixed together to form footbed 100. For example, second layer top surface 120 is affixed directly or indirectly to first layer bottomsurface 110, such as via adhesive or bonding, sewing, stitching, and / or or other techniques known to those of ordinary skill in the art.

[0053] First layer 104 and second layer 106 may have any suitable thicknesses 112, 124. For example, first layer thickness 112 may range from about 2 millimeters to about 4 millimeters, from about 2 millimeters to about 6 millimeters, and / or from about 4 millimeters to about 6 millimeters. Additionally or alternatively, second layer thickness 124 may range from about 2 millimeters to about 6 millimeters, from about 2 millimeters to about 4 millimeters, and / or from about 4 millimeters to about 6 millimeters. In other examples, first layer thickness 112 may be greater than or less than these ranges, and / or second layer thickness 124 may be greater than or less than these ranges. In some examples, first layer thickness 112 is about the same as second layer thickness 124. In one example, the first layer thickness ranges from about 4 millimeters to about 6 millimeters, and the second layer thickness ranges from about 2 millimeters to about 4 millimeters. In another example, the first layer thickness ranges from about 2 millimeters to about 4 millimeters, and the second layer thickness ranges from about 4 millimeters to about 6 millimeters. In some examples, first layer thickness 112 is less than second layer thickness 124, while in other examples, first layer thickness 112 is greater than second layer thickness 124.

[0054] Footbed 100 may include one or more additional layers. For example, a third layer 134 may be disposed below second layer 106 (e.g., below second layer bottom surface 122). Third layer 134 has a third layer top surface 136, a third layer bottom surface 138 opposite third layer top surface 136, and a third layer thickness 144 between third layer top surface 136 and third layer bottom surface 138. When third layer 134 is included in footbed 100, third layer top surface 136 is affixed directly or indirectly to second layer bottom surface 122. Third layer 136 also has a third layer width 146 and a third layer length 148. Third layer 134 is formed of a third layer material 150, which may be a solid third layer material 150 and / or a foam third layer material 150. For example, third layer material 150 may be, or include, a solid third layer material 150 having a hardness of at least 70 Shore A. Additionally or alternatively, third layer material 150 may be, or include, a foam third layer material 150 that has a hardness of at least 60 Asker C and / or a compression set ranging from about 0 percent to about 10 percent. In someexamples, third layer thickness 144 ranges from about 0.5 millimeters (mm) to about 4mm, from about 0.5 mm to about 2mm, from about 2mm to about 4mm, and / or from about 1mm to about 3mm. Third layer thickness 144 may be about the same as first layer thickness 112 and / or second layer thickness 124, or third layer thickness 144 may be greater than first layer thickness 112 and / or second layer thickness 124, and / or third layer thickness may be less than first layer thickness 112 and / or second layer thickness 124.

[0055] When footbed 100 includes third layer 134, said third layer 134 may have substantially the same footprint, shape, surface area, and / or coextensive perimeters as those of first layer 104 and / or second layer 106, or third layer 134 may be different from first layer 104 and / or second layer 106 in terms of footprint, shape, surface area, and / or perimeter locations. For example, first layer length 116 and third layer length 148 may be about the same, second layer length 128 and third layer length 148 may be about the same, and / or first layer length 116, second layer length 128, and third layer length 148 all may be about the same as each other. In some examples, first layer length 116 is less than third layer length 148, second layer length 128 is less than third layer length 148, first layer length 116 is less than both second layer length 128 and third layer length 148, and / or second layer length 128 is less than both first layer length 116 third layer length 148. In some examples, first layer length 116 is greater than third layer length 148, second layer length 128 is greater than third layer length 148, first layer length 116 is greater than both second layer length 128 and third layer length 144, and / or second layer length 128 is greater than both first layer length 116 and third layer length 148. In some examples, third layer length 148 is less than first layer length 116, third layer length 148 is less than second layer length 128, and / or third layer length 148 is less than both first layer length 116 and second layer length 128. In some examples, third layer length 148 is greater than first layer length 116, third layer length 148 is greater than second layer length 128, and / or third layer length 148 is greater than both first layer length 116 and second layer length 128.

[0056] Similarly, in some examples, first layer width 114, second layer width 126, and third layer width 146 are each individually about the same. In some examples, first layer width 114 is less than third layer width 146, second layer width 126 is less than third layer width 146, and / or second layer width 126 is less than both first layer width 114 and thirdlayer width 146. In some examples, first layer width 114 is greater than third layer width 146, second layer width 126 is greater than third layer width 146, and / or second layer width 126 is greater than first layer width 114 and is less than third layer width 146. In some examples, third layer width 146 is less than first layer width 114, third layer width 146 is less than second layer width 126, and / or third layer width 146 is less than both first layer width 114 and second layer width 126. In some examples, third layer width 146 is greater than first layer width 114, third layer width 146 is greater than second layer width 126, and / or third layer width 146 is greater than first layer width 114 and is less than second layer width 126.

[0057] Third layer 134 may be configured to retain its shape during wear of footbed 100, and to provide stability to at least a portion of footbed 100. In some examples, third layer 134 may be a solid material or a relatively rigid foam in order to provide support for the first and second layers 104, 106 (e.g., third layer 134 may be formed of a harder material than first layer 104 and / or second layer 106). For example, third layer 134 may comprise a polyurethane such as a thermoplastic polyurethane (TPU), a polyolefin such as a polyethylene, or a polypropylene, and / or any other suitable polymer having a suitable rigidity to maintain its shape.

[0058] In some examples, footbed 100 additionally or alternatively includes a fabric layer 152 disposed directly above first layer top surface 108. Fabric layer 152 may be configured to directly contact a foot when an article of footwear including footbed 100 is worn. Fabric layer 152 is an elastic fabric in some examples, but is not limited to elastic fabrics. Fabric layer 152 may serve as a cover fabric covering the other layers 104, 106, and / or 134 of footbed 100, may be a lining for footbed 100. Suitable materials for fabric layer 152 also may include a mesh material, a thin fabric material, a fabric comprising synthetic and / or natural yams that may be knitted, woven, and / or non-woven, and / or a multi-layered fabric or a spacer fabric that has three-dimensional structure to increase the cushioning and / or breathability of the surface that is in contact with the user’s foot or skin when the article of footwear incorporating disclosed footbeds 100 is worn. In some examples, fabric layer 152 may be configured to provide a uniform appearance of footbed 100 and to protect first layer top surface 108.Figs. 3-4 illustrate examples of disclosed layered footbeds in the form of footbed 102. While footbed 100 has cushioning layer 130 for first layer 104 and conforming layer 140 for second layer 104, footbed 102 illustrates examples where first layer 104 is the conforming layer 140, and where second layer 106 is the cushioning layer 130. Footbeds 102 otherwise may incorporate any or all of the features of footbed 100 discussed above in connection with Figs. 1-2.

[0059] Fig. 8 illustrates examples of disclosed layered footbeds in the form of footbed 104. Footbed 104 is similar to footbed 100, except that conforming layer 140 is formed by a first conforming layer 140a and a second conforming layer 140b. First conforming layer 140a may comprise a first conforming foam 142a, and second conforming layer 140b may comprise a second conforming foam 142b, with each of first and second conforming foams 142a, 142b being examples of conforming foam 142 described above. First conforming layer 140a may comprise or be a high compression set foam as described above for first conforming foam 142a, while second conforming layer 140b may comprise or be a memory foam as described above for second conforming foam 142b. In other words, in some disclosed footbeds, conforming layer 140 may include both a packable foam with a high compression set and a memory foam. The combination of these conforming layers 140a, 104b may be configured to help conforming layer 140 conform to a wider variety of users’ foot shapes. In some examples, first conforming layer 140a has a thickness 124a of between about 2 millimeters and about 6 millimeters, between about 2 millimeters and about 4 millimeters, and / or between about 4 millimeters and about 6 millimeters. In some examples, conforming layer 140b has a thickness 124b of between about 2 millimeters and about 6 millimeters, between about 2 millimeters and about 4 millimeters, and / or between about 4 millimeters and about 6 millimeters. The overall thickness 124 of conforming layer 140 may be the sum of thicknesses 124a and 124b in these examples. Other examples of footbed 104 may have cushioning layer 130 positioned below conforming layer 140 rather than above conforming layer 140 as shown in Fig. 8. Footbeds 104 otherwise may incorporate any or all of the features of footbed 100 discussed above in connection with Figs. 1-2.

[0060] Disclosed footbeds 100, 102, 104 may be configured to be a component of an insole for an article of footwear, to be an insole for the article of footwear, and / or to be acomponent of a sole structure of the article of footwear. In one example, disclosed footbed 100, 102, 104 is configured to be a component of an insole for an article of footwear. In another example, disclosed footbed 100, 102, 104 is configured to be an insole for an article of footwear, such as a drop-in midsole intended to replace a standard insole. In yet another example, disclosed footbed 100, 102, 104 is configured to be a component of a sole structure, or is a sole structure of an article of footwear, such as a component embedded within an article of footwear during manufacturing and / or permanently affixed to other components of the article of footwear, such as to an upper or to a midsole or outsole of the article of footwear. For example, Fig. 5 schematically represents an article of footwear 200 with footbed 100, footbed 102, and / or footbed 104 included therein, such as with said footbed 100, 102, 104 being a component of an insole 202, with said footbed 100, 102, 104 being insole 202, with said footbed 100, 102, 104 being a component of a midsole 203, with said footbed 100, 102, 104 being midsole 203, and / or with footbed 100, 102, 104 being a component of a sole structure 204 (also referred to herein as a sole 204) of article of footwear 200. The footbed 100, 102, 104 may be a drop-in midsole for sole structure 204 of article of footwear 200. Sole structure 204 may optionally include an outsole (not illustrated in Fig. 5). In some examples, footbed 100, 102, 104 may be affixed to the outsole and / or sole structure 204, while in some examples, footbed 100, 102, 104 may be placed inside a cavity 206 of article of footwear 200. In other words, footbed 100, 102, 104 may serve as insole 202 or midsole 203 for article of footwear 200, or may be directly coupled to midsole 203 of article of footwear 200.

[0061] Figs. 7A-7C schematically illustrate cutaway views of other examples of an article of footwear 208 that incorporates disclosed footbed 100, 102, 104 in different ways. Article of footwear 208 includes an upper 210 defining foot cavity 206 for receiving the user’s foot when article of footwear 208 is worn. In the example of Fig. 7A, footbed 100, 102, 104 is an insole 202 for article of footwear 208, and is positioned within foot cavity 206. Such articles of footwear 208 may include a strobel 212 attached to upper 210, with footbed 100, 102, 104 being positioned above strobel 212. Midsole 203 and an outsole 214 of sole structure 204 are illustrated under strobel 212, opposite the footbed 100, 102, 104 in this example. In the example of Fig. 7B, footbed 100, 102, 104 is a part of solestructure 204. For example, an optional insole 202 is illustrated above strobel 212, while footbed 100, 102, 104 is part of the underfoot sole structure 204, such as by being sandwiched between strobel 212 and midsole 203. Midsole 203 may be coupled to footbed 100, 102, 104. Similarly, outsole 214 may be attached to midsole 203 and footbed 100, 102, 104. In the example of Fig. 7C, footbed 100, 102, 104 is part of a drop-in midsole sole structure 204. In this example, an optional insole 202 may be positioned within foot cavity 206 above strobel 212. Under strobel 212, an outsole cavity 216 may be formed in outsole 214, with footbed 100, 102, 104 being positioned within outsole cavity 216 as a drop-in midsole.

[0062] As used in article of footwear 200, 208, a loading pressure may be applied to footbed 100, 102, 104 (e.g., to first layer top surface 108 or to fabric layer 152) by a user’s foot, either directly or indirectly. When the loading pressure is applied to footbed 100, 102, 104, the cushioning layer (e.g., cushioning layer 130) may resiliently compress and cushion the user’s foot, while the conforming layer (e.g., conforming layer 140) conforms to the shape of the user’s foot. Footbeds 100, 102, 104 may be utilized in any suitable article of footwear 200, 208 including boots, athletic shoes, sandals, and / or the like.

[0063] Articles of footwear 200, 208 including disclosed footbeds 100, 102, 104 may be configured to provide comfort-related personalization due to conforming layer 140 conforming to the shape of the user’s foot to provide customized support to the user’s foot. In some examples, users may find such articles of footwear 200, 208 to become more comfortable over time as footbed 100, 102, 104 conforms more to the user’s individual foot shape. Furthermore, disclosed footbeds 100, 102, 104 may be configured to maintain performance and comfort while quickly feeling customized to the shape of the user’s foot. While conventional midsoles may eventually partially conform to the shape of a foot over a long period of time, they often lose or experience degradation of their comfort and / or performance attributes by the time this occurs. In contrast, presently disclosed footbeds 100, 102, 104 are designed to conform to the user’s foot quickly (e.g., within one to thirty cumulative hours of wear, or within one to ten cumulative hours of wear), such that the resiliency, comfort, and performance offered by cushioning layer 130 remain intact while conforming layer 140 is conformed to the user’s foot. This effect maybe enhanced by use of third layer 134 to provide structural integrity to first layer 104 and second layer 106.

[0064] With reference to Fig. 6, methods 300 of manufacturing a footbed, such as footbed 100, 102, 104, and / or an article of footwear, such as article of footwear 200 or 208, include affixing a first layer (e.g., first layer 104) and a second layer (e.g., second layer 106) directly or indirectly to each other, at 302. In such methods 300, the first layer has a first layer top surface, a first layer bottom surface opposite the first layer top surface, a first layer thickness between the first layer top surface and the first layer bottom surface, a first layer width, and a first layer length, and the second layer has a second layer top surface, a second layer bottom surface opposite the second layer top surface, a second layer thickness between the second layer top surface and the second layer bottom surface, a second layer width, and a second layer length. When the first layer and the second layer are affixed together at 302, the second layer is disposed below the first layer bottom surface. Affixing the first layer and the second layer together at 302 may include, for example, adhering the first layer and the second layer together, and / or sewing or stitching the first layer and the second layer together.

[0065] In methods 300, either the first layer or the second layer is a conforming layer (e.g., conforming layer 140), and the other of the first layer and the second layer is a cushioning layer (e.g., cushioning layer 130). The conforming layer comprises a conforming foam, which may be a packable foam or a memory foam. Suitable packable foams may have a compression set of at least 55 percent and a hardness ranging from about 20 Asker C to about 50 Asker C. Suitable memory foams may have a recovery time of greater than 30 minutes and an Indentation Force Displacement (IFD) ranging from about 10 pounds to about 50 pounds at 75 percent compression over temperatures ranging from 0 degrees C to 45 degrees C, or ranging from about 10 pounds to about 50 pounds at 65 percent compression over temperatures ranging from 0 degrees C to 45 degrees C. The cushioning layer comprises a cushioning foam, which may have a compression set of less than 50 percent, and a hardness ranging from about 5 to about 50 Asker C.

[0066] Some methods 300 further include affixing a third layer (e.g., third layer 134) to the first and second layers, at 308, and / or covering or lining the other layers with a fabric layer (e.g., fabric layer 152), at 310. Together, the first layer, second layer, third layer, and / orfabric layer make up the disclosed footbed. Methods 300 may include manufacturing an article of footwear, such as by affixing a footbed according to the present disclosure to a sole structure of an article of footwear, at 304, or by placing a footbed according to the present disclosure inside a cavity of the article of footwear, at 306.

[0067] Some methods 300 further include forming the first layer at 312, and / or forming the second layer at 314, before affixing the first and second layers together at 302. The first and second layers may be formed at 312, 314 by any suitable method, such as by die cutting, molding, pouring, 3D printing or other additive manufacturing technique, machining, etc.

[0068] B. Selected Embodiments and Claim Concepts

[0069] This section describes additional aspects and features of footbeds, presented without limitation as a series of clauses, some or all of which may be alphanumerically designated for clarity and efficiency. Each of these clauses can be combined with one or more other clauses, and / or with disclosure from elsewhere in this application, in any suitable manner. Some of the clauses below may expressly refer to and further limit other clauses, providing without limitation examples of some of the suitable combinations.

[0070] A1. A footbed for an article of footwear, the footbed comprising:

[0071] a first layer having a first layer top surface, a first layer bottom surface opposite the first layer top surface, a first layer thickness between the first layer top surface and the first layer bottom surface, a first layer width, and a first layer length;

[0072] a second layer disposed below the first layer bottom surface, the second layer having a second layer top surface, a second layer bottom surface opposite the second layer top surface, a second layer thickness between the second layer top surface and the second layer bottom surface, a second layer width, and a second layer length;

[0073] wherein one of the first layer and the second layer is a conforming layer comprising a conforming foam, and wherein the other of the first layer and the second layer is a cushioning layer comprising a cushioning foam.A1.1. The footbed of clause A1, wherein the conforming foam comprises a packable foam having a compression set of at least 55 percent and a hardness ranging from about 20 Asker C to about 50 Asker C.

[0074] A1.2. The footbed of clause A1 or A1.1 , wherein the conforming foam comprises a memory foam having a recovery time of greater than 30 minutes and an Indentation Force Displacement (IFD) ranging from about 10 pounds to about 50 pounds at 75 percent compression over temperatures ranging from 0 degrees C to 45 degrees C, or ranging from about 10 pounds to about 50 pounds at 65 percent compression over temperatures ranging from 0 degrees C to 45 degrees C.

[0075] A2. The footbed of any of clauses A1 -A1.2, wherein the conforming foam has a compression set ranging from about 55 percent to about 95 percent, from about 65 percent to about 95 percent, and / or from about 75 percent to about 95 percent.

[0076] A3. The footbed of any of clauses A1-A2, wherein the conforming foam has a hardness ranging from about 30 Asker C to about 40 Asker C.

[0077] A4. The footbed of any of clauses A1 -A3, wherein the conforming foam has an open cell structure.

[0078] A5. The footbed of any of clauses A1-A4, wherein the conforming foam has a closed cell foam structure.

[0079] A6. The footbed of any of clauses A1-A5, wherein the conforming foam comprises an ethylene-vinyl acetate polymer foam.

[0080] A7. The footbed of any of clauses A1-A6, wherein the conforming foam comprises a polyether block amide (PEBA) foam.A8. The footbed of any of clauses A1-A7, wherein the conforming foam is a viscoelastic foam.

[0081] A9. The footbed of any of clauses A1-A8, wherein the conforming foam comprises a polyurethane foam.

[0082] A10. The footbed of any of clauses A1-A9, wherein the conforming foam comprises a latex foam.

[0083] A11. The footbed of any of clauses A1 -A10, wherein the cushioning foam has a compression set of less than 40 percent, less than 30 percent, and / or less than 20 percent.

[0084] A12. The footbed of any of clauses A1 -A11 , wherein the cushioning foam has a hardness ranging from about 10 to about 50 Asker C, from about 15 to about 50 Asker C, from about 20 to about 50 Asker C, from 25 to about 45 Asker C, and / or from about 30 to about 40 Asker C.

[0085] A13. The footbed of any of clauses A1-A12, wherein the first layer is the conforming layer, and the second layer is the cushioning layer.

[0086] A14. The footbed of any of clauses A1-A13, wherein the first layer is the cushioning layer, and the second layer is the conforming layer.

[0087] A15. The footbed of any of clauses A1 -A14, wherein the second layer top surface is affixed directly or indirectly to the first layer bottom surface.

[0088] A16. The footbed of any of clauses A1-A15, wherein the first layer thickness ranges from about 2 millimeters to about 6 millimeters, or the second layer thickness ranges from about 2 millimeters to about 6 millimeters, or the first layer thickness rangesfrom about 4 millimeters to about 6 millimeters and the second layer thickness ranges from about 2 millimeters to about 4 millimeters.

[0089] A17. The footbed of any of clauses A1 -A16, wherein the first layer length and the second layer length are about the same, or the second layer length is less than the first layer length, or the second layer length is greater than the first layer length.

[0090] A18. The footbed of any of clauses A1 -A17, wherein the first layer width and the second layer width are about the same, or the second layer width is less than the first layer width, or the second layer width is greater than the first layer width.

[0091] A19. The footbed of any of clauses A1-A18, wherein the cushioning layer is configured to deform when a loading pressure is applied to the footbed to provide underfoot cushioning during months or years of wear of the footbed in an article of footwear, and wherein the conforming layer is configured to pack out over 1 to 30 days of wear of the footbed to conform to an underfoot shape of a wearer’s foot.

[0092] A20. The footbed of any of clauses A1-A19, wherein the footbed further comprises a third layer, wherein the third layer is disposed below the second layer bottom surface, wherein the third layer has a third layer top surface, a third layer bottom surface opposite the third layer top surface, a third layer thickness between the third layer top surface and the third layer bottom surface, a third layer width, and a third layer length, and wherein the third layer comprises a third layer material including at least one of a solid third layer material and a foam third layer material.

[0093] A20.1. The footbed of clause A20, wherein the third layer material comprises the solid third layer material and wherein the solid third layer material has a hardness of at least 70 Shore A.

[0094] A20.2. The footbed of clause A20 or A20.1, wherein the third layer material comprise the foam third layer material, and wherein the foam third layer material has ahardness of at least 60 Asker C and compression set ranging from about 0 percent to about 10 percent.

[0095] A21. The footbed of any of clausesA20-A20.2, wherein the third layer thickness ranges from about 0.5mm to about 4mm.

[0096] A22. The footbed of any of clauses A20-A21 , wherein the third layer top surface is affixed directly or indirectly to the second layer bottom surface.

[0097] A23. The footbed of any of clauses A20-A22, wherein

[0098] the first layer length and the third layer length are about the same, or the second layer length and the third layer length are about the same, or the first layer length, the second layer length, and the third layer length are each individually about the same; or the first layer length is less than the third layer length, or the second layer length is less than the third layer length, the first layer length is less than the second layer length and is less than the third layer length, or the second layer length is less than the first layer length and is less than the third layer length; or

[0099] the first layer length is greater than the third layer length, or the second layer length is greater than the third layer length, the first layer length is greater than the second layer length and is greater than the third layer length, or the second layer length is greater than the first layer length and is greater than the third layer length; or

[0100] the third layer length is less than the first layer length, or the third layer length is less than the second layer length, or the third layer length is less than the first layer length and is less than the second layer length; or

[0101] the third layer length is greater than the first layer length, or the third layer length is greater than the second layer length, or the third layer length is greater than the first layer length and is greater than the second layer length.

[0102] A24. The footbed of any of clauses A20-A23, wherein

[0103] the first layer width, the second layer width, and the third layer width are each individually about the same; orthe first layer width is less than the third layer width, or the second layer width is less than the third layer width, or the second layer width is less than the first layer width and is less than the third layer width; or

[0104] the first layer width is greater than the third layer width, or the second layer width is greater than the third layer width, or the second layer width is greater than the first layer width and is less than the third layer width; or

[0105] the third layer width is less than the first layer width, or the third layer width is less than the second layer width, or the third layer width is less than the first layer width and is less than the second layer width;

[0106] or the third layer width is greater than the first layer width, or the third layer width is greater than the second layer width, or the third layer width is greater than the first layer width and is less than the second layer width.

[0107] A25. The footbed of any of clauses A20-A24, wherein the third layer is configured to retain its shape during wear of the footbed, and to provide stability to at least a portion of the footbed.

[0108] A26. The footbed of any of clauses A1-A25, wherein the footbed further comprises a fabric layer disposed directly above the first layer top surface, and wherein the fabric layer is configured to directly contact a foot when the article of footwear comprising the footbed is worn.

[0109] A27. The footbed of clause 26, wherein the fabric layer comprises an elastic fabric.

[0110] A28. The footbed of any of clauses A1-A27, wherein the cushioning foam has a hardness ranging from about 5 to about 45, from about 10 to about 40, and / or from about 15 to about 35 Asker C.A29. The footbed of any of clauses A1 -A28, wherein the footbed is configured to be a component of an insole for the article of footwear or to be an insole for the article of footwear.

[0111] A30. The footbed of any of clauses A1 -A29, wherein the footbed is configured to be a component of a sole structure of the article of footwear.

[0112] A31. The footbed of any of clauses A1-A30, wherein the conforming layer comprises a first conforming layer including a first conforming foam, wherein the conforming layer further comprises a second conforming layer including a second conforming foam, optionally wherein the first conforming foam is a packable foam having a compression set of at least 55 percent, and wherein the second conforming foam is a memory foam having a recovery time of greater than 30 minutes and an Indentation Force Displacement (IFD) ranging from about 10 pounds to about 50 pounds at 75 percent compression over temperatures ranging from 0 degrees C to 45 degrees C, or ranging from about 10 pounds to about 50 pounds at 65 percent compression over temperatures ranging from 0 degrees C to 45 degrees C.

[0113] B1. An article of footwear comprising the footbed of any of clauses A1 -A31.

[0114] C1. A method of manufacturing a footbed, the method comprising:

[0115] affixing a first layer and a second layer directly or indirectly to each other, wherein the first layer has a first layer top surface, a first layer bottom surface opposite the first layer top surface, a first layer thickness between the first layer top surface and the first layer bottom surface, a first layer width, and a first layer length;

[0116] wherein the second layer is disposed below the first layer bottom surface, and the second layer has a second layer top surface, a second layer bottom surface opposite the second layer top surface, a second layer thickness between the second layer top surface and the second layer bottom surface, a second layer width, and a second layer length; andwherein one of the first layer and the second layer is a conforming layer, the conforming layer comprising a conforming foam, optionally wherein the conforming foam is a packable foam having a compression set of at least 55 percent and a hardness ranging from about 20 Asker C to about 50 Asker C, or wherein the conforming foam is a memory foam having a recovery time of greater than 30 minutes and an Indentation Force Displacement (IFD) ranging from about 10 pounds to about 50 pounds at 75 percent compression over temperatures ranging from 0 degrees C to 45 degrees C, or ranging from about 10 pounds to about 50 pounds at 65 percent compression over temperatures ranging from 0 degrees C to 45 degrees C; and

[0117] wherein the other of the first layer and the second layer is a cushioning layer comprising a cushioning foam, the cushioning foam optionally having a compression set of less than 50 percent, and a hardness ranging from about 5 to about 50 Asker C.

[0118] C2. A footbed made by the method of clause C1.

[0119] D1. A method of manufacturing an article of footwear, the method comprising: affixing a footbed to a sole structure of the article of footwear, or placing the footbed inside a cavity of the article of footwear, wherein the footbed is the footbed according to any of clauses A1 -A31.

[0120] D2. An article of footwear manufactured by the method of clause D1.

[0121] Advantages, Features, and Benefits

[0122] The different embodiments and examples of the layered footbeds described herein provide several advantages over known solutions for footbeds of articles of footwear. For example, illustrative embodiments and examples described herein allow for a footbed configured having a cushioning layer to provide comfortability and a desired sensation to a user’s foot (e.g., via a soft resiliency), and a conforming layer. The conforming layer may include a packable foam with a high compression set that is designed to pack out relatively quickly to conform to the shape of the user’s foot, or may include a memory foam. An optional third, lower, layer having structural integrity may be included that isconfigured to hold its shape during use and provide support to the other layers of the footbed.

[0123] Additionally, and among other benefits, illustrative embodiments and examples described herein allow a layered footbed to have a conforming layer with a cushioning layer disposed above or below it.

[0124] Additionally, and among other benefits, illustrative embodiments and examples described herein allow layered footbeds for footwear to exhibit comfort-related personalization that becomes more comfortable over time.

[0125] Additionally, and among other benefits, illustrative embodiments and examples described herein allow for layered footbeds for footwear to maintain performance and comfort while also personalizing the footbed to the user with limited use.

[0126] No known system or device can perform these functions. However, not all embodiments and examples described herein provide the same advantages or the same degree of advantage.

[0127] Conclusion

[0128] The disclosure set forth above may encompass multiple distinct examples with independent utility. Although each of these examples has been disclosed in its preferred form(s), the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense, because numerous variations are possible. The subject matter of the example(s) includes all novel and nonobvious combinations and subcombinations of the various elements, features, functions, and / or properties disclosed herein.

[0129] Certain combinations and subcombinations regarded as novel and nonobvious are particularly pointed out throughout this disclosure. Other combinations and subcombinations of features, functions, elements, and / or properties may be claimed, with or without variation in scope, in applications claiming priority from this or a related application.

[0130] Explicit reference is hereby made to all examples, embodiments, inventions, labels, terms, descriptions, and illustrative measurements shown in the drawings and / or in any included appendices, whether or not described further herein. To the extent thatsection headings are used within this disclosure, such headings are for organizational purposes only.

Claims

CLAIMS1. A footbed for an article of footwear, the footbed comprising:a first layer having a first layer top surface, a first layer bottom surface opposite the first layer top surface, a first layer thickness between the first layer top surface and the first layer bottom surface, a first layer width, and a first layer length; anda second layer disposed below the first layer bottom surface, the second layer having a second layer top surface, a second layer bottom surface opposite the second layer top surface, a second layer thickness between the second layer top surface and the second layer bottom surface, a second layer width, and a second layer length;wherein the first layer is a cushioning layer comprising a cushioning foam having a compression set of less than 50 percent, and a hardness ranging from about 5 to about 50 Asker C; andwherein the second layer is a conforming layer comprising a conforming foam, wherein the conforming foam is a packable foam having a compression set of at least 55 percent and a hardness ranging from about 20 Asker C to about 50 Asker C, or the conforming foam is a memory foam having a recovery time of greater than 30 minutes and an Indentation Force Displacement (IFD) ranging from about 10 pounds to about 50 pounds at 75 percent compression over temperatures ranging from 0 degrees C to 45 degrees C, or ranging from about 10 pounds to about 50 pounds at 65 percent compression over temperatures ranging from 0 degrees C to 45 degrees C.

2. The footbed of claim 1 , wherein the conforming foam is the packable foam.

3. The footbed of claim 1 , wherein the conforming foam is the memory foam.

4. The footbed of claim 1 , wherein the cushioning foam has a compression set of less than 20 percent and has a hardness ranging from about 30 to about 40 Asker C; andwherein the conforming foam is the packable foam and has a compression set of from about 70 percent to about 95 percent; or the conforming foam has a hardness ranging from about 10 to about 40 Asker C, or from about 15 to about 35 Asker C; or theconforming foam has both a compression set of from about 70 percent to about 95 percent and a hardness ranging from about 10 to about 40 Asker C, or from about 15 to about 35 Asker C.

5. The footbed of claim 1, wherein the second layer top surface is affixed directly to the first layer bottom surface.

6. The footbed of claim 1 , wherein the first layer thickness ranges from about 2 millimeters to about 6 millimeters, or the second layer thickness ranges from about 2 millimeters to about 6 millimeters, or the first layer thickness ranges from about 4 millimeters to about 6 millimeters and the second layer thickness ranges from about 2 millimeters to about 4 millimeters.

7. The footbed of claim 1 , wherein the cushioning layer is configured to deform when a loading pressure is applied to the footbed to provide underfoot cushioning during months or years of wear of the footbed in the article of footwear, and wherein the conforming layer is configured to pack out over 1 to 30 days of wear of the footbed to conform to an underfoot shape of a wearer’s foot.

8. The footbed of claim 1 , wherein the bottom surface of the second layer is configured to directly contact a midsole, last, or insole of the article of footwear when the footbed is positioned within a cavity of the article of footwear.

9. The footbed of claim 1 , wherein the footbed further comprises a third layer, wherein the third layer is disposed below the second layer bottom surface, wherein the third layer has a third layer top surface, a third layer bottom surface opposite the third layer top surface, a third layer thickness between the third layer top surface and the third layer bottom surface, a third layer width, and a third layer length, and wherein the third layer comprises a third layer material including at least one of a solid third layer material and a foam third layer material, wherein the solid third layer material has a hardness ofat least 70 Shore A, and wherein the foam third layer material has a hardness of at least 60 Asker C and compression set ranging from about 0 percent to about 10 percent.

10. The footbed of claim 9, wherein the third layer thickness ranges from about 0.5mm to about 4mm.

11. The footbed of claim 9, wherein the third layer top surface is affixed directly or indirectly to the second layer bottom surface.

12. The footbed of claim 9, wherein the third layer bottom surface is configured to directly contact a midsole, last, or insole of the article of footwear when the footbed is positioned within a cavity of the article of footwear.

13. The footbed claim 1 , wherein the first layer is configured to directly contact a foot during wear of the article of footwear comprising the footbed.

14. The footbed of claim 1 , wherein the footbed further comprises a fabric layer disposed directly above the first layer top surface, and wherein the fabric layer is configured to directly contact a foot during wear of the article of footwear comprising the footbed.

15. The footbed of claim 14, wherein the fabric layer comprises an elastic fabric.

16. The footbed of claim 1 , wherein the footbed is configured to be a component of an insole for the article of footwear, or is configured to be an insole for the article of footwear.

17. The footbed of claim 1 , wherein the footbed is configured to be a component of a sole structure of the article of footwear.

18. The footbed of claim 1, wherein the conforming layer comprises a first conforming layer and a second conforming layer, wherein the conforming foam comprises a first conforming foam and a second conforming foam, wherein the first conforming layer comprises the first conforming foam, wherein the second conforming layer comprises the second conforming foam, wherein the first conforming foam is the packable foam, and wherein the second conforming foam is the memory foam.

19. An article of footwear comprising the footbed of claim 1.

20. A method of manufacturing a footbed, the method comprising:affixing a first layer and a second layer directly or indirectly to each other; wherein the first layer has a first layer top surface, a first layer bottom surface opposite the first layer top surface, a first layer thickness between the first layer top surface and the first layer bottom surface, a first layer width, and a first layer length; wherein the second layer has a second layer top surface, a second layer bottom surface opposite the second layer top surface, a second layer thickness between the second layer top surface and the second layer bottom surface, a second layer width, and a second layer length;wherein the first layer is a cushioning layer comprising a cushioning foam having a compression set of less than 50 percent, and a hardness ranging from about 5 to about 50 Asker C; andwherein the second layer is a conforming layer comprising a conforming foam, wherein the conforming foam is a packable foam having a compression set of at least 55 percent and a hardness ranging from about 20 Asker C to about 50 Asker C, or the conforming foam is a memory foam having a recovery time of greater than 30 minutes and an Indentation Force Displacement (IFD) ranging from about 10 pounds to about 50 pounds at 75 percent compression over temperatures ranging from 0 degrees C to 45 degrees C, or ranging from about 10 pounds to about 50 pounds at 65 percent compression over temperatures ranging from 0 degrees C to 45 degrees C.

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