Injection-molded half‑insert (shoe mid‑sole fork)
A rigid, injection‑molded half‑insert (called a half fork) intended to sit in the mid‑sole/waist region of a shoe to stiffen and support the arch. It pairs a molded plastic main body with an internal waist core formed as one piece, plus surface coverings (fabric, paper or plastic); locating holes and beveled edges help positioning and adhesion during sole assembly. Intended for footwear manufacturers fitting insoles and mid‑sole assemblies in dress and casual shoes.
(57) What the patent covered
The main independent claim covers a shoe molded insole half‑fork formed as a rigid plastic injection‑molded main body that envelops a waist core integrated by the same molding process, where the upper surface of the main body includes two locating holes at the ends of the waist‑core region. Specific features required are the injection‑molded rigid plastic main body, an integrated waist core, and the two locating holes on the upper surface at the waist‑core ends.
The distinctive part: Making the fork and its internal waist core as a single rigid injection‑molded plastic piece with locating holes for positioning instead of a paper plate with a separate metal shank.
Novelty 3/5. At filing, internal arch supports and shank plates in shoes were common (paper or metal shanks); this is a clever improvement replacing multi‑part shanks with an integrated molded plastic piece and added locating holes to aid assembly and adhesion.
Making it
Injection molded rigid plastic part, secondary application of surface material (laminated fabric/paper or heat/adhesive bonding), cut or trimmed edges and manual or automated placement into sole lasts during shoe assembly.
Materials: Rigid thermoplastic (likely ABS or polypropylene), Thin fabric, paper or plastic surface layer, Possibly a different polymer or filler in the waist core (speculative)
Manufacturability 4/5. Single molded part keeps tooling simple but needs an injection mold; surface layer lamination and part trimming add secondary steps and handling; overall several simple parts and hand or machine assembly.
Is anyone buying?
Comparable products are on sale; this exact design wasn't found. Typical retail price: $38. Multiple half-sole orthotics in the FREEDOM Accommodator family are listed; the XPE Half Sole Orthotic is in stock and eligible for FSA; product pages show several size options and related half-sole products.
- FREEDOM XPE Half Sole Orthotic · AliMed$38.50
This demand check was run with a web search in the week of Sep 7, 2026. Listings change often, so treat it as a starting point for your own research.
Who buys it: footwear manufacturers, shoe assembly shops
Before you make it
We didn't find any related continuation or divisional patents still in force, although that doesn't rule out design patents, trademarks or unrelated patents covering the same product.
Practical issues include finding the right polymer stiffness and bonding method for lamination and sole glues; crowded market for shank/arch inserts and the patent is lapsed so no enforceable exclusivity.
Owners occasionally revive lapsed patents (about 1.5% are), and this page is a research lead rather than legal advice, so get a freedom-to-operate opinion before you manufacture anything.