Shoe with insole as part sole filler and method of making same

A boot having a rigid tread sole and an insole formed of soft, cushioning, light weight, thermal insulating material comprising:

• (a) a tread sole having a toe region at one end thereof and a heel region at an opposing end thereof and an upper secured to said tread sole;
• (b) said tread sole including a cavity therein extending continuously from said toe region and beneath the ball of a wearer's foot to and beneath said heel region, and wherein said cavity in the heel region is of greater depth than the depth of the cavity extending from said toe region and beneath the ball of a wearer's foot;
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• (c) a removable insole of premolded material with a first portion in the shape of said cavity extending continuously from said toe region and beneath the ball of a wearer's foot to and beneath said heel region including the central portion of said heel region to provide cushioning relative to said sole and to provide support under a wearer's heel depressed against said central portion of said heel region, said first portion of said insole disposed over said tread sole in said cavity, and wherein the height of the insole in the heel region is of greater height than the height of the insole extending from said toe region and beneath the ball of the wearer's foot.

A boot having a rigid tread sole and an insole formed of soft, cushioning, light weight thermal insulating materials comprising:

• (a) a tread sole and having a toe region at one end thereof and a heel region having a heel at an opposing end thereof and an upper completely surrounding the wearer's foot and secured to said tread sole;
• (b) said tread sole including a cavity therein extending continuously from said toe region and beneath the ball of a wearer's foot to and beneath said heel region and wherein said cavity in the heel region is of greater depth than the depth of the cavity extending from said toe region and beneath the ball of a wearer's foot;
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• (c) a removable insole of premolded material with a first portion in the shape of said cavity extending continuously from said toe region and beneath the ball of a wearer's foot to and beneath said heel region including the central portion of said heel region to provide cushioning relative to said sole and to provide support under the ball of the wearer's foot and said central portion of said heel region when the wearer's foot is depressed thereagainst, said first portion of said insole disposed over said tread sole in said cavity, wherein said insole provides thermal insulation to the wearer's foot, and secured in said cavity and wherein the height of the insole in the heel region is of greater height than the height of the insole extending from said toe region and beneath the ball of the wearer's foot.

A method of manufacture of footwear comprising the steps of:

• (a) providing a last with an upper thereon said last having a toe region at one end thereof and a heel region at an opposing end thereof;
• (b) providing a mold insert on the bottom of said last extending continuously from said toe region and beneath the ball of a wearer's foot to and beneath said heel region;
• (c) providing a mold having a mold cavity for an outer sole;
• (d) disposing said last and upper against said mold with said mold insert disposed within said mold cavity;
• (e) forming an outer sole in said mold cavity having a cavity therein in the shape of said mold insert;
• (f) providing an insole of premolded material in said cavity with at least a portion thereof in the shape of said cavity extending continuously from said toe region of and beneath the ball of a wearer's foot to and beneath said heel region including the central portion of said heel region to provide cushioning relative to said sole and to provide support under a wearer's foot depressed against said insole from said toe region to said central portion of said heel region, said outer sole including a plurality of one of tongues and grooves and said insole having a plurality of the other of tongues and grooves, said tongues and grooves mating with each other;
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• (g) securing said insole to said sole in said cavity.