U.S. patent application number 10/858105 was filed with the patent office on 2005-12-01 for footwear comfort componentry.
This patent application is currently assigned to Polymer Dynamics Technology, Inc.. Invention is credited to Peoples, Duane Eric.
Application Number | 20050262736 10/858105 |
Document ID | / |
Family ID | 35423610 |
Filed Date | 2005-12-01 |
United States Patent
Application |
20050262736 |
Kind Code |
A1 |
Peoples, Duane Eric |
December 1, 2005 |
Footwear comfort componentry
Abstract
The present invention relates to footwear componentry for
alleviating the discomfort caused by wearing high-heeled
footwear.
Inventors: |
Peoples, Duane Eric;
(Allentown, PA) |
Correspondence
Address: |
Polymer Dynamics Technology, Inc.
2200 South 12th Street
P. O. Box 4400
Allentown
PA
18105-4400
US
|
Assignee: |
Polymer Dynamics Technology,
Inc.
Allentown
PA
|
Family ID: |
35423610 |
Appl. No.: |
10/858105 |
Filed: |
June 1, 2004 |
Current U.S.
Class: |
36/44 |
Current CPC
Class: |
A43B 7/38 20130101; A43B
7/144 20130101; A43B 17/14 20130101; A43B 13/38 20130101; A43B
7/1445 20130101 |
Class at
Publication: |
036/044 |
International
Class: |
A43B 013/38 |
Claims
I claim:
1. A footbed comprising a protuberance in the subcalcaneous region
of said footbed, wherein further, the anterior portion of said
protuberance is larger, relative to the posterior portion of said
protuberance.
2. A footbed according to claim 1, wherein further, said footbed is
prepared from polyurethane materials.
3. A footbed according to claim 2, wherein the top surface of said
footbed is bonded to a polyurethane film, said film, capable of
receiving colorants, fabrics or hides, or mixtures thereof.
4. A footbed according to claim 2, wherein said footbed comprises a
top surface of soft polyurethane foam, further provided that said
protuberance in the subcalcaneous region of said footbed is a
visco-elastic polyurethane elastomer.
5. An insole comprising: a. a posterior rigid foam 3/4 component
having a depression in the subcalcaneous region; further provided
that the longitudinal and medial arches of said insole follow the
contours of the last; and b. a flexible metatarsal region.
6. An insole according to claim 5, wherein further said posterior
rigid foam 3/4 component comprises a stepped taper along the
forward edge of said posterior rigid foam 3/4 component.
7. An insole according to claim 5, wherein said posterior rigid
foam 3/4 component comprises a contour along its forward edge,
further provided that the forward medial point of said forward edge
extends behind the first metatarsal and the forward lateral point
of said forward edge extends behind the fifth metatarsal.
8. An insole according to claim 5, wherein further, said insole is
prepared from polyurethane materials.
9. An insole according to claim 5, further provided that said
contours reflect a lower profile along the lateral side of said
insole and a higher profile along the medial side of said
insole.
10. An insole according to claim 5, further provided that said
posterior rigid foam 3/4 component has one or more negative
recesses along the top surface of said posterior rigid foam 3/4
component and one or more positive protuberances along the bottom
surface of said posterior rigid foam 3/4 component.
11. An insole according to claim 5, wherein further, said flexible
metatarsal region comprises a tapered leading edge.
12. A bi-layer footwear component comprising: a. a first layer,
wherein said first layer is comprised of a footbed comprising a
protuberance in the subcalcaneous region of said footbed, wherein
further, the anterior portion of said protuberance is larger
relative to the posterior portion of said protuberance; and b. a
second layer, wherein said second layer is comprised of an insole
comprising: 1) a posterior rigid foam 3/4 component having a
depression in the subcalcaneous region; further provided that the
longitudinal and medial arches of said insole follow the contours
of the last; and 2) a flexible metatarsal region.
13. A bi-layer footwear component according to claim 12, wherein
said footbed comprises a top layer of soft polyurethane foam,
further provided that said protuberance in the subcalcaneous region
of said footbed is a visco-elastic polyurethane elastomer.
14. A bi-layer footwear component according to claim 12, wherein
said contours reflect a lower profile along the lateral side of
said insole and a higher profile along the medial side of said
insole.
15. A bi-layer footwear component according to claim 12, wherein
said posterior rigid foam 3/4 component has one or more negative
recesses along the top surface of said posterior rigid foam 3/4
component and one or more positive protuberances along the bottom
surface of said posterior rigid foam 3/4 component.
16. Shankless high-heel footwear comprising: a. a footbed, said
footbed comprising a protuberance in the subcalcaneous region of
said footbed, wherein further, the anterior portion of said
protuberance is larger relative to the posterior portion of said
protuberance; and b. a posterior rigid foam 3/4 component having a
depression in the subcalcaneous region; further provided that the
longitudinal and medial arches of said insole follow the contours
of the last; and c. a flexible metatarsal region
17. A bi-layer footwear component comprising: a. a first layer
comprising a footbed having a protuberance in a subcalcaneous
region of the footbed; and b. a second layer including an insole
comprising a posterior rigid heel portion having a depression in a
subcalcaneous region of the rigid heel portion adapted to receive
the protuberance of the footbed, a rigid arch region sized and
shaped for extending under and supporting an arch of a wearer's
foot free of any other supporting structure at the arch, and a
flexible metatarsal region, the rigid heel portion and rigid arch
portion being formed of the same material.
18. A bi-layer footwear component according to claim 17 wherein the
rigid arch region has a generally channel-shaped cross section.
19. A b-layer footwear component according to claim 17, wherein the
material forming the rigid heel region and the rigid arch region is
a polymeric material.
20. A bi-layer footwear component according to claim 19 wherein the
material forming the rigid heel region and the rigid arch region is
polyurethane.
21. A bi-layer footwear component according to claim 19 wherein the
material forming the rigid heel region and the rigid arch region is
a foamed polymeric material.
22. A bi-layer footwear component according to claim 17 wherein the
rigid heel region and the rigid arch region are formed as one
piece.
23. A shankless high heel footwear comprising: a. an outsole; b. a
heel; c. an insole comprising a posterior rigid heel portion having
a depression in a subcalcaneous region of the rigid heel portion
and a rigid arch region sized and shaped for extending under and
supporting an arch of a wearer's foot free of any other supporting
structure at the arch, and a flexible metatarsal region, the rigid
heel portion and rigid arch portion being formed of the same
material; d. a footbed having a protuberance in a subcalcaneous
region of the footbed adapted to be received in the depression of
the posterior rigid heel portion of the insole; and e. an
upper.
24. A shankless high heel footwear according to claim 23 wherein
the rigid arch region has a general channel-shaped cross
section.
25. A shankless high heel footwear according to claim 23 wherein
the material forming the rigid heel region and the rigid arch
region is a polymeric material.
26. A shankless high heel footwear according to claim 25 wherein
the material forming the rigid heel region and the rigid arch
region is polyurethane.
27. A shankless high heel footwear according to claim 25 wherein
the material forming the rigid heel region and the rigid arch
region is a foamed polymeric material.
28. A shankless high heel footwear according to claim 23 wherein
the rigid heel region and rigid arch region are formed as one
piece.
Description
BACKGROUND OF THE INVENTION
[0001] High heel footwear makes a fashion statement. However, there
is an inherent discomfort in wearing said footwear. As many as 20%
of the wearers of such footwear immediately experience foot pain
related to the shoes, and the majority of wearers experience such
pain after as little as four hours of wear. This discomfort results
primarily from the wearer's foot sliding forward in the shoe with
the consequence that the wearer's toes are jammed in the toe
portion of the shoe. Specifically, by raising the heel higher than
that of the natural foot angle, the wearer's natural walking
pattern is altered, resulting in higher impulsive loads on the
musculoskeletal system. In an investigation utilizing small
low-mass piezoelectric accelerometers attached to the skin surface
of both tibial tuberosities, the heel and metatarsal strike
acceleration values began to exceed the barefoot values in the heel
height ranges of 1.75 to 2.25 inches. Notwithstanding the inherent
discomfort associated with high heel footwear, many women choose to
wear such footwear in order to enhance the apparent length and
slenderness of their legs. Further, men can experience the same
discomfort while wearing elevated heel footwear, such as work boots
and Western-style boots.
[0002] The art has attempted to develop componentry to manage the
problem of discomfort while maintaining the desired stylishness
that higher heels convey. For example, U.S. Pat. No. 4,876,805
discloses a flexible, energy absorbing insole for high heel
footwear comprising an open cell, microcellular, flexible
polyurethane foam having an energy absorbing polymer in the heel
region of said insole. U.S. Pat. No. 4,835,884 discloses a shank
containing high heel shoe structure having a heel pad and a basket
for receiving said pad.
[0003] Further, U.S. Pat. No. 6,519,874 teaches a footwear assembly
having an insole with cushioning that aligns with a footbed having
a cavity in the rear portion. However, previous componentry failed
to take into consideration the influence of gait mechanics as it
relates to heel strike, mid-foot loading, metatarsal strike and toe
off. It is well accepted that, as the heel is inclined, the foot's
natural mechanism for shock absorbing and structural support are
compromised, thus creating great discomfort.
[0004] Now, the Applicant has solved the problems that the previous
componentry failed to solve. Applicant's componentry, when used in
the assembly of high heel shoes, effectively lowers the internal
heel height without compromising the external heel height, thereby,
bringing the foot's mechanics closer to a naturally gaited foot.
The integration of Applicant's footwear components into a variety
of heel heights, ranging from as low as 3/4 inch to as high as 3
inches, provides a reduction in actual heel height ranging from 5%
to 55%. It is an accepted phenomenon that, as the heel is elevated;
the forces are transferred from heel strike to a phenomenon known
as metatarsal strike, as foot pressures are re-proportioned across
the plantar surface of the foot. These forces that enter the body
during the metatarsal strike are reduced by 10% to 50% when the
Applicant's componentry is incorporated into footwear. Hence, the
discomfort associated with wearing higher heel heights is reduced,
while maintaining the desired stylishness. When Applicant's
componentry is used in footwear, said footwear is both comfortable
and aesthetically pleasing at the point of purchase display and on
the foot of the wearer. Further, said componentry eliminates the
need for a metal shank or other inserted stiffener, while providing
the desired flexibility and stability to the wearer.
SUMMARY OF THE INVENTION
[0005] The present invention relates to a footbed comprising a
protuberance in the subcalcaneous region of said footbed wherein
further, the anterior portion of said protuberance is larger
relative to the posterior portion of said protuberance.
[0006] The present invention further relates to an insole
comprising:
[0007] a. a posterior rigid foam % component, having a depression
in the subcalcaneous region; further provided that the longitudinal
and medial arches of said insole follow the contours of the last;
and
[0008] b. a flexible metatarsal region.
[0009] The present invention also relates to a bi-layer footwear
component comprising:
[0010] a. a first layer, wherein said first layer is comprised of a
footbed comprising a protuberance in the subcalcaneous region of
said footbed, wherein further, the anterior portion of said
protuberance is larger relative to the posterior portion of said
protuberance; and
[0011] b. a second layer, wherein said second layer is comprised of
an insole comprising:
[0012] 1) a posterior rigid foam 3/4 component having a depression
in the subcalcaneous region; further provided that the longitudinal
and medial arches of said insole follow the contours of the last;
and
[0013] 2) a flexible metatarsal region.
[0014] The following terms have the following meanings herein:
[0015] The term "subcalcaneous region" means the region below the
heel.
[0016] The term "anterior portion" as used herein means the larger
portion of said subcalcaneous protuberance.
[0017] The term "posterior portion" as used herein means the
smaller portion of said subcalcaneous protuberance.
[0018] The term "larger," as used herein is a relative term
indicating that the anterior portion of said subcalcaneous
protuberance and the posterior portion of said subcalcaneous
protuberance can never be equal in size. Upon visual examination of
said subcalcaneous protuberance, one ordinarily skilled in the art
will observe that the anterior portion is larger relative to the
posterior portion of said subcalcaneous protuberance. Further, the
size relationship between the anterior portion of said
subcalcaneous protuberance and the posterior portion of said
subcalcaneous protuberance may be quantified by determining
protrusion volumes. To quantify the difference in the volume of the
anterior and posterior regions of the subcalcaneous protuberance,
the following procedure was followed: A casting of the protuberance
was made using a rigid elastomer of known, calculated density. The
weight of the casting was measured and recorded. The length of the
midline longitudinal axis (posterior to anterior) of the casting
was measured and recorded. A portion, less than half based on the
length of the longitudinal axis, was removed from the posterior
portion of the protuberance perpendicular to the longitudinal axis.
The posterior of the remaining portion of the protuberance was
sanded perpendicular to the longitudinal axis until its length,
posterior to anterior, was half of the original longitudinal axis
length. The weight of the anterior half of the protuberance casting
was measured and recorded. The weight of the posterior half of the
protuberance casting was calculated from the initial weight of the
casting and the weight of the anterior half of the casting
(W.sub.p=W.sub.i-W.sub.a). The volume of the anterior and posterior
portions of the casting were calculated using the known density of
the casting material and the weights of the anterior and posterior
portions of the casting, respectively (V.sub.a=W.sub.a/D,
V.sub.p=W.sub.p/D, D=density of casting material). The percent
difference between the volume of the posterior and anterior
portions of the protuberance was calculated as a percentage of the
volume of the posterior portion of the protuberance
(((V.sub.p-V.sub.a)/V.sub.a).times.100).
[0019] In an embodiment of the invention, the % difference between
the volume of the anterior portion of the subcalcaneous
protuberance and the volume of the posterior portion of the
subcalcaneous protuberance is 5%.
[0020] In another embodiment of the invention, the % difference
between the volume of the anterior portion of the subcalcaneous
protuberance and the volume of the posterior portion of the
subcalcaneous protuberance is 8.9%
[0021] In yet another embodiment of the invention, the % difference
between the volume of the anterior portion of the subcalcaneous
protuberance and the volume of the posterior portion of the
subcalcaneous protuberance is 12%.
[0022] The term "metatarsal region" means the forefoot region. The
terms "metatarsal" and "forefoot" can be used interchangeably
herein.
[0023] The term "medial arch" means the arch from the medial point
to the midpoint of the foot. The term "longitudinal arch" means the
anterior to posterior length of the natural arch.
[0024] The term "plantar surface" means the bottom of the foot.
[0025] The term "Shore Scale" as used herein means a materials'
hardness scale commonly used to measure the surface hardness or
resistance to indention of plastics or rubbers. The hardness is
measured using equipment called durometers. Durometers vary in the
range of hardnesses they can measure by the difference in their
spring force and indenter geometry.
[0026] The term "pphp" as used here in means parts per hundred
polyol.
[0027] The term "footbed," as used herein means the footwear
component of the present invention having the subcalcaneous
protuberance that the wearer's foot rests on, whose top view is
visible to the wearer.
[0028] The term "insole," as used herein, means the footwear
component of the present invention having the subcalcaneous
depression, said depression also known as a bucket, which is not
visible to the wearer.
[0029] The term "bi-layer footwear component," as used herein,
means the component formed by the combining of the footbed to the
insole, wherein said footbed is placed on top of said insole.
[0030] The term "last," as used herein, means the form over which a
shoe is made, which determines the size, shape, contours and style
features of the shoe.
DESCRIPTION OF THE DRAWINGS OF THE INVENTION
[0031] FIG. 1 illustrates a top view of the footbed of the present
invention comprising the subcalcaneous protuberance.
[0032] FIG. 1a illustrates a bottom view of the footbed of the
present invention comprising the subcalcaneous protuberance.
[0033] FIG. 1b illustrates a side view of the footbed of the
present invention comprising the subcalcaneous protuberance.
[0034] FIG. 2 illustrates a bottom view of the insole of the
present invention comprising the subcalcaneous depression.
[0035] FIG. 2a illustrates a top view of the insole of the present
invention comprising the subcalcaneous depression.
[0036] FIG. 2b illustrates a side view of the insole of the present
invention comprising the subcalcaneous depression.
[0037] FIG. 2c illustrates a rear view of the insole of the present
invention comprising the subcalcaneous depression.
[0038] FIG. 2d illustrates a cross-sectional view taken across
lines 2d-2d of FIG. 2a of the insole of the present invention.
[0039] FIGS. 3a and 3b illustrate how the footbed with the
subcalcaneous protuberance can be fastened to the insole with the
subcalcaneous depression to prepare a bi-layer footwear
component.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The present invention relates to a footbed comprising a
protuberance in the subcalcaneous region of said footbed wherein
further, the anterior portion of said protuberance is larger than
the posterior portion of said protuberance.
[0041] The present invention further relates to an insole
comprising:
[0042] a. a posterior rigid foam 3/4 component having a depression
in the subcalcaneous region; further provided that the longitudinal
and medial arches of said insole follow the contours of the last;
and
[0043] b. a flexible metatarsal region.
[0044] The present invention also relates to a bi-layer footwear
component comprising:
[0045] a. a first layer, wherein said first layer is comprised of a
footbed comprising a protuberance in the subcalcaneous region of
said footbed, wherein further, the anterior portion of said
protuberance is larger relative to the posterior portion of said
protuberance; and
[0046] b. a second layer, wherein said second layer is comprised of
an insole comprising:
[0047] 1) a posterior rigid foam 3/4 component having a depression
in the subcalcaneous region; further provided that the longitudinal
and medial arches of said insole follow the contours of the last;
and
[0048] 2) a flexible metatarsal region.
[0049] The footwear componentry of the present invention, as
illustrated herein, can be prepared from materials including, but
not limited to, polyurethanes; polycarbonates;
polyethyleneterphthlate(PET); polyesters; polyamides; polyalkenes;
neoprenes; acrylonitrile/butadiene/sytyrene (ABS);
styrene/butadiene; polyvinylchloride; synthetic and natural latex
rubbers; ethylene vinyl acetate; polyacrylates,
polymethylmethacrylates; silicone elastomers; and polystyrene
[0050] In an embodiment of the present invention, polyurethane
chemistry is used in the manufacture of the present invention. The
basics of polyurethane chemistry are known to those skilled in the
art. The basic reaction for making polyurethanes involves mixing an
isocyanate with a polyol in the presence of ingredients including,
but not limited to, catalysts, antifoamers, absorbents, chain
extenders and pigments.
[0051] Isocyanates useful in the practice of the present invention
include, but are not limited to Polycarbodiimide-modified
diphenylmethane diisocyanate (e.g. ISONATE 143L); Carbodiimide
Modified MDI (e.g. LURPRANATE MM103); Benzene, 1,1'-Methylene
bis-(4-isocyanato-homopolymer (e.g. MONDUR CD); 4,4'-MDI
Homopolymer (e.g. RUBINATE 1680); and prepolymer modified
polyisocyanate (e.g. RUBINATE 9100, RUBINATE 1920).
[0052] Polyols useful in the practice of the present invention
include, but are not limited to, polypropylene glycol diols (e.g.
ARCOL PPG-1025, PLURACOL P1010, CARPOL PGP1000, Poly-G 20-112);
EO-capped polyoxypropylene triols (e.g. MULTRANOL 3901, PLURACOL
380, PLURACOL 220, CARPOL GP6515, Poly-G 85-28, CARPOL GP1535);
polyoxypropylene triols (e.g. PLURACOL TP440, MULTRANOL 4012,
Poly-G 30-400T, ARCOL E-900, PLURACOL 1198, and Poly-G 92-27);
EO-capped polyoxypropylene diols (e.g. MULTRANDOL 9111, PLURACOL
1062, CARPOL PGP4025).
[0053] Catalysts useful in the practice of the present invention
include, but are not limited to, Triethylenediamine-based catalysts
(e.g. DABCO 33LV, DABCO 1027, DABCO 1028, NIAX A-33, JEFFCAT
TD-33A, TOYOCAT TEDA-L33, and TEGOAMIN 33);
Bis(2-dimethylaminoethyl)ether-based catalysts (e.g. DABCO BL-17,
NIAX A-107, JEFFCAT ZF-54, TOYOCAT ETF),
1,8-Diazabicyclo-5,4,0-undecene-7 catalysts (POLYCAT SA-1, PC CAT
DBU TA1) and organotin catalysts (e.g. FOMREZ UL-1 and DABCO
120).
[0054] Antifoamers useful in the practice of the present invention
include, but are not limited to, dimethyl polysiloxanes (e.g.
TA-100 and DOW CORNING ANTIFOAM 1500).
[0055] Absorbents useful in the practice of the present invention
include, but are not limited to, powdered alkali metal
alumino-silcates (e.g. MOLSIV ABSORBENT TYPE 4A, SILIPORITE NK 10
AP, Sigma-Aldrich M2135, and SYLOSIV A4).
[0056] Chain extenders useful in the practice of the present
invention include, but are not limited to, ethylene glycol; 1,4
Butanediol and N,N'-dialkylaminodiphenylmethane (e.g. UNILINK
4200).
[0057] Colorants useful in the practice of the present invention
include, but are not limited to, pigment dispersions, and reactive
dyes.
[0058] In an embodiment of the present invention, as illustrated by
FIGS. 1, 1a, and 1b, the footbed is composed of a soft (50-60 Shore
00 scale as measured by ASTM D2240) visco-elastic polyurethane
elastomer subcalcaneous region and a soft (45-55 Shore 00 scale as
measured per ASTM D2240) PU foam. Said soft polyurethane
visco-elastic subcalcaneous region is produced by mixing a
carbodiimide modified polyisocyanate (ISONATE 143L) with a polyol
resin blend. Said polyol resin blend is prepared by blending the
following ingredients:
[0059] 1. 55 pphp (parts per 100 polyol) 1000 molecular weight
polypropylene glycol diol (ARCOL PPG-1025).
[0060] 2. 25 pphp 6000 molecular weight polyoxypropylene triol,
with ethylene oxide capping (MULTRANOL 3901).
[0061] 3. 20 pphp 400 molecular weight polyoxypropylene triol
(PLURACOL TP440).
[0062] 4. 0.50 pphp tertiary amine catalyst, 33% triethylene
diamine in dipropylene glycol (DABCO 33LV).
[0063] 5. 0.05 pphp dialkyltin mercaptide catalyst (FOMREZ
UL-1).
[0064] 6. 0.10 pphp dimethyl polysiloxane antifoaming agent
(TA-100).
[0065] 7. 2.0 pphp alkali metal alumino-silicate 4 absorbent 10
.mu.m powder (MOLSIV ABSORBENT TYPE 4A).
[0066] 8. A colorant: pigment dispersion, reactive dye, or
combination thereof.
[0067] Said polyisocyanate is blended with the polyol resin blend,
prepared as described hereinabove, at a ratio of 24 to 37 parts
isocyanate to 100 parts polyol resin blend. Mixing-induced
nucleation is removed by vacuum prior to complete
polymerization.
[0068] Said soft PU foam is produced by mixing a carbodiimide
modified polyisocyanate (ISONATE 143L) with a PU foam polyol resin
blend. Said polyol resin blend is prepared by blending the
following ingredients:
[0069] 1. 70 pphp 6000 molecular weight polyoxypropylene triol,
with ethylene oxide capping (MULTRANOL 3901).
[0070] 2. 30 pphp 6600 molecular weight polyoxypropylene triol,
with ethylene oxide capping, and a styrene/acrylonitrile copolymer
(ARCOL E-900
[0071] 3. 1.2 pphp Water
[0072] 4. 0.40 pphp tertiary amine catalyst, 33% triethylene
diamine in dipropylene glycol (DABCO 33LV).
[0073] 5. 0.01 pphp dialkyltin mercaptide catalyst (FOMREZ
UL-1).
[0074] 6. 0.16 pphp diethanolamine
[0075] 7. A colorant: pigment dispersion, reactive dye, or
combination thereof.
[0076] Said polyisocyanate is blended with the PU foam polyol resin
blend at a ratio of 20 to 25 parts isocyanate to 100 parts polyol
resin blend.
[0077] The procedure for producing the footbed, as illustrated in
FIGS. 1, 1a and 1b, is as follows:
[0078] 1. Pre-mix both the elastomeric and the foam resin
blends.
[0079] 2. Heat the mold to 125-135 F. and treat the bottom cavity
with the appropriate mold release.
[0080] 3. Insert a piece of U073 plastic-backed PU film into a
fabric frame with the PU film side down.
[0081] 4. Mix the PU elastomer resin blend and the corresponding
isocyanate at the specified ratio for 10 seconds.
[0082] 5. Degas the mixture for 20-30 seconds at 25 in Hg.
[0083] 6. Pour specified amount of degassed mixture into heel
cavities.
[0084] 7. Allow elastomer to cure to tack.
[0085] 8. Mix the PU foam resin blend and the corresponding
isocyanate at the specified ratio for 10 seconds.
[0086] 9. Pour the specified amount of foam mixture into the
footbed cavities, spreading the material length-wise, heel to toe,
in the center of the cavity.
[0087] 10. Place the framed PU film on the bottom cavity, PU film
side down.
[0088] 11. Place mold lid on top of PU film/bottom cavity and
clamp.
[0089] 12. De-mold in 5-10 min.
[0090] In an embodiment of the present invention, as illustrated by
FIGS. 2, 2a, 2b, 2c and 2d, the insole is composed of a flexible
microcellular PU foam metatarsal component of varying density
(0.28-0.60 g/cc) and hardness (10-60 Shore A scale as measured by
ASTM D2240) that is bonded to a hard (75 Shore D scale as measured
by ASTM D2240), dense (1.00 g/cc), rigid microcellular PU foam
three-quarter component in the posterior region of said insole.
[0091] In an embodiment of the present invention, the lower density
(0.28 g/cc), soft (10 Shore A), flexible metatarsal component is
produced by mixing a carbodiimide modified polyisocyanate (ISONATE
143L) with a polyol resin blend at a ratio of 20 to 25 parts
isocyanate to 100 parts polyol resin blend. Said polyol resin blend
is prepared by blending the following ingredients:
[0092] 1. 70 pphp 6000 molecular weight polyoxypropylene triol,
with ethylene oxide capping (MULTRANOL 3901).
[0093] 2. 30 pphp 6600 molecular weight polyoxypropylene triol,
with ethylene oxide capping, and a styrene/acrylonitrile copolymer
(ARCOL E-900
[0094] 3. 1.2 pphp Water
[0095] 4. 0.40 pphp tertiary amine catalyst, 33% triethylene
diamine in dipropylene glycol (DABCO 33LV).
[0096] 5. 0.01 pphp dialkyltin mercaptide catalyst (FOMREZ
UL-1).
[0097] 6. 0.16 pphp diethanolamine
[0098] 7. A colorant: pigment dispersion, reactive dye, or
combination thereof.
[0099] The procedure for producing the flexible forefoot component,
as illustrated in FIGS. 2, 2a, and 2b, is as follows:
[0100] 1. Premix the polyol resin blend for the forefoot foam.
[0101] 2. Heat the mold to 125-135 F. and treat the bottom cavity
and the lid with the appropriate mold release.
[0102] 3. Mix the forefoot foam polyol resin blend and the
corresponding isocyanate at the specified ratio for 10 seconds.
[0103] 4. Pour the specified amount of foam mixture into the
Forefoot cavities.
[0104] 5. Place mold lid on top of the bottom cavity and clamp.
[0105] 6. De-mold in 5-10 min.
[0106] 7. Trim or die cut the Forefoot component for use with the
rigid three-quarter component.
[0107] In another embodiment of the present invention, a higher
density (0.60 g/cc), firm (60 Shore A), flexible metatarsal
component is prepared by molding a mixture of a prepolymer modified
polyisocyanate (Rubinate 9100) with a polyol resin blend at a ratio
of 60 to 74 parts isocyanate to 100 parts polyol resin blend. Said
polyol resin blend is prepared by blending the following
ingredients:
[0108] 1. 75 pphp 4000 molecular weight polyoxpropylene diol, with
ethylene oxide capping (MULTRANOL 9111).
[0109] 2. 25 pphp 6000 molecular weight polyoxypropylene triol,
with ethylene oxide capping (MULTRANOL 3901).
[0110] 3. 8.9 pphp chain extender (ETHYLENE GLYCOL).
[0111] 4. 4.9 pphp aromatic diamine chain extended (UNILINK
4200).
[0112] 5. 0.47 pphp tertiary amine gelation catalyst, triethylene
diamine in dipropylene glycol (DABCO 33LV).
[0113] 6. 0.11 pphp tertiary amine delayed-action blowing catalyst,
bis (dimethylaminoethyl) ether in dipropylene glycol (DABCO
BL-17).
[0114] 7. 0.71 pphp Water.
[0115] 8. A colorant: pigment dispersion, reactive dye or
combination.
[0116] The procedure for producing the flexible forefoot component,
as illustrated in FIGS. 2, 2a, and 2b, is as follows:
[0117] 1. Premix the polyol resin blend for the forefoot foam.
[0118] 2. Heat the mold to 125-135 F. and treat the bottom cavity
and the lid with the appropriate mold release.
[0119] 3. Mix the forefoot foam resin blend and the corresponding
isocyanate at the specified ratio for 10 seconds.
[0120] 4. Pour the specified amount of foam mixture into the
forefoot cavities.
[0121] 5. Place mold lid on top of the bottom cavity and clamp.
[0122] 6. De-mold in 5-10 min.
[0123] 7. Trim or die cut the forefoot component for use with the
rigid three-quarter component.
[0124] In an embodiment of the present invention, the posterior
rigid, three-quarter component of the insole, as illustrated by
FIGS. 2, 2a, and 2b, is produced by molding a mixture of modified
polyisocyanate (RUBINATE 1920) and a polyol resin blend at a ratio
of 102 to 114 parts isocyanate to 100 parts polyol resin blend.
Said polyol resin blend is prepared by blending the following
ingredients:
[0125] 1. 100 pphp 1500 molecular weight polyoxyproprylene triol,
with ethylene oxide capping (CARPOL GPI535).
[0126] 2. 21 pphp chain extender (ETHYLENE GLYCOL).
[0127] 3. 5.9 pphp aromatic diamine chain extender (Unilink
4200).
[0128] 4. 0.92 pphp delayed-action, amine gelation catalyst
(DABCO).
[0129] 5. 0.26 pphp dimethyl polysiloxane antifoaming agent
(TA-100)
[0130] 6. A colorant: pigment dispersion, reactive dye or
combination thereof.
[0131] 7. The percentage of water in the polyol resin blend is
measured and adjusted to 0.15-0.20%.
[0132] The procedure for producing the rigid, three-quarter,
posterior, insole component with said polyol resin blend, as
illustrated in FIGS. 2, 2a, and 2b, is as follows:
[0133] 1. Premix the polyol resin blend for the rigid foam.
[0134] 2. Heat the mold to 125-135 F. and treat the bottom cavity
and the lid with the appropriate mold release.
[0135] 3. Mix the polyol resin blend and the corresponding
isocyanate at the specified ratio for 10 seconds.
[0136] 4. Pour the specified amount of rigid foam mixture into the
mold cavities.
[0137] 5. Place mold lid on top of the bottom cavity and clamp.
[0138] 6. Open mold in 5-10 minutes.
[0139] 7. De-mold the part 1-5 minutes after mold opening.
[0140] In another embodiment of the present invention, the
posterior rigid, three-quarter component of the insole, as
illustrated by FIGS. 2, 2a, and 2b, is produced by molding a
mixture of modified polyisocyanate (RUBINATE 1920) and a polyol
resin blend at a ratio of 103 to 110 parts isocyanate to 100 parts
polyol resin blend. Said polyol resin blend is prepared by blending
the following ingredients:
[0141] 1. 100 pphp 400 molecular weight polyoxyproprylene triol
(MULTRANOL 4012).
[0142] 2. 0.40 pphp delayed-action, amine gelation catalyst
(POLYCAT SA-1).
[0143] 3. 0.04 pphp dialkyltin mercaptide catalyst (FOMREZ
UL-1).
[0144] 4. 0.26 pphp dimethyl polysiloxane antifoaming agent
(TA-100)
[0145] 5. A colorant: pigment dispersion, reactive dye or
combination thereof.
[0146] 6. The percentage of water in the polyol resin blend is
measured and adjusted to 0.15-0.20%.
[0147] The procedure for producing the rigid, three-quarter,
posterior, insole component with said polyol resin blend, as
illustrated in FIGS. 2, 2a, and 2b, is as follows:
[0148] 1. Premix the polyol resin blend for the rigid foam.
[0149] 2. Heat the mold to 165-175 F. and treat the bottom cavity
and the lid with the appropriate mold release.
[0150] 3. Mix the PU rigid foam polyol resin blend and the
corresponding isocyanate at the specified ratio for 10 seconds.
[0151] 4. Pour the specified amount of rigid foam mixture into the
mold cavities.
[0152] 5. Place mold lid on top of the bottom cavity and clamp.
[0153] 6. Open mold in 5-10 minutes.
[0154] 7. De-mold the part 1-5 minutes after mold opening.
[0155] In an embodiment of the present invention, as illustrated by
FIGS. 2, 2a, and 2b, the flexible forefoot component and the rigid
posterior component may be attached by using an appropriate
adhesive.
[0156] In another embodiment of the present invention, as
illustrated by FIGS. 2, 2a, and 2b, the flexible forefoot component
and the rigid posterior component may be attached by molding the
rigid posterior component directly to the pre-molded and trimmed
flexible forefoot component using the following procedure:
[0157] 1. Premix the polyol resin blend for the rigid foam.
[0158] 2. Heat the mold to 125-135 F. or 165-175 F. depending on
the rigid foam polyol resin blend being used, and treat the bottom
cavity and the lid with the appropriate mold release.
[0159] 3. Insert the flexible forefoot piece into the mold in the
proper orientation. (The core cell structure of the forefoot
component, exposed by trimming or die cutting, allows the flexible
and rigid components to bond.)
[0160] 4. Mix the rigid foam resin blend and the corresponding
isocyanate at the specified ratio for 10 seconds.
[0161] 5. Pour the specified amount of rigid foam mixture into the
heel and arch areas of the mold cavities.
[0162] 6. Place mold lid on top of the bottom cavity and clamp.
[0163] 7. Open mold in 5-10 minutes.
[0164] 8. De-mold the part 1-5 minutes after mold opening.
[0165] FIGS. 1, 1a and 1b illustrate an embodiment of the footbed
(3) of the present invention comprising the protuberance in the
subcalcaneous region (10). FIG. 1 is a top view of said footbed
(3), illustrating the soft polyurethane foam portion (9) of said
footbed (3), which spans the entire length of the top view of said
footbed (3). FIG. 1a is a bottom view of said footbed (3),
illustrating the protuberance in the subcalcaneous region (10) and
the soft polyurethane foam portion (9), of said footbed (3). Said
protuberance in the subcalcaneous region (10) is affixed to the
soft polyurethane foam portion (9) of said footbed (3). The
anterior portion (11) of said protuberance (10) is larger relative
to the posterior portion (12) of said protuberance in the
subcalcaneous region (10). FIG. 1b is a side view of said footbed
(3) illustrating the soft polyurethane foam portion (9) of said
footbed (3) and the protuberance in the subcalcaneous region (10).
Said protuberance has an anterior portion (11) that is larger
relative to the posterior portion (12).
[0166] FIGS. 2, 2a, 2b, 2c and 2d illustrate an embodiment of the
insole (13) of the present invention comprising the subcalcaneous
depression (4). FIG. 2 is a bottom view of said insole (13),
illustrating the subcalcaneous depression (4) in the posterior
rigid foam 3/4 component (5) of said insole (13) and the flexible
metatarsal component (6) and an optional metatarsal cushion (14).
Said posterior rigid foam % component (5) is combined to the
flexible metatarsal component (6) to create the insole (13). FIG.
2a is a top view of said insole (13), illustrating the posterior
rigid foam % component (5) of said insole and the flexible
metatarsal component (6) and an optional metatarsal cushion (14).
FIG. 2b is a side view of said insole (13), illustrating the
longitudinal arch (7) of said insole (13). FIG. 2c is a rear view
of said insole (13), illustrating the subcalcaneous depression (4).
FIG. 2d is a cross-sectional view taken across lines 2d-2d of FIG.
2a to illustrate the medial arch (8) of said insole (13).
[0167] One skilled in the art of footwear manufacturing understands
the need for comfort as well as style. Footwear with eye appealing
contours is a goal of footwear manufacturers. Applicant's
componentry, which is comprised of the insole and the footbed, is
adaptable to the contours of a wide variety of stylish footwear.
Said componentry provides comfort without adding excess bulk to the
footwear's silhouette. For example, in an embodiment of the
invention, the footbed is a cushioned device that extends from the
rearward heel point to the most forward point of the flexible
metatarsal region. Said footbed has a central positioned
protuberance in the subcalcaneous region of said footbed. Said
protuberance is a visco-elastic polyurethane elastomer. Said
protuberance has a greater proportion of material forward of its
mid-point. Said visco-elastic polyurethane elastomer protuberance
in the subcalcaneous region is attached to a soft polyurethane
foam. Said soft polyurethane foam is visible as the top surface of
the entire footbed. Said footbed is fully tapered around its
perimeter edges and exhibits a side-to-side taper from the center
line to the perimeter edges to promote maximum cushioning and a
refined tailored silhouette to the finished constructed footwear.
The top surface of the footbed is bonded directly to a polyurethane
film that may have a multitude of layers. The purpose of said film
is to provide a clean bonding surface capable of receiving
colorants, fabrics, hides or combinations thereof. Said footwear
may also feature a molded arch and heel counter and any variety of
surface ornamentations. The material characteristics of the foot
bed are such that a lining material, a textile synthetic or natural
hide, can be attached by of methods, including but not limited to
cementing and stitching. Both the top and bottom surfaces of the
foot bed may include functional or decorative elements or both.
[0168] In an embodiment of the invention, the insole is comprised
of a posterior rigid foam 3/4 component and a flexible metatarsal
region. Said posterior rigid foam % component is free formed or
cast to fit the exact profile dimensions of the manufacturer's
footwear designing contoured last. The contours of the posterior
rigid foam % component reflect a lower profile along the lateral
side of said rigid foam % component and a higher profile along the
medial side of said rigid foam % component. The top of said
posterior rigid foam % component is tapered to blend into the
contoured surfaces of the manufacturer's foot-forming last. The
forward edge of the rigid posterior foam % component exhibits a
side-to-side tapered dimension from the center line and perimeter
edges, which is symmetrical to the leading edge of the flexible
front piece, which also exhibits a side-to-side tapered dimension
from the center line to the perimeter edges.
[0169] Said posterior rigid foam 3/4 component is resistant to
flexing, while providing stability to the wearer. Further, these
properties are achieved without the use of any metal shank or other
inserted stiffener. The posterior rigid foam % component part is
designed to compliment the aesthetics of the fully assembled shoe,
while providing the requisite stability without the need for a
shank.
[0170] Said posterior rigid foam 3/4 component is stepped tapered
along its forward edge. Further, said posterior rigid foam 3/4
component is contoured along its forward edge. The forward medial
point of said forward edge extends behind the first metatarsal and
the forward lateral point of said forward edge extends behind the
fifth metatarsal.
[0171] The contours of the posterior rigid foam % component add
comfort to the assembled footwear because said contours follow the
normal, human gaiting patterns. Further, said posterior rigid foam
% component has a depression in the subcalcaneous region which
promotes proper fit within the heel seat of the assembled footwear,
as well as providing the wearer with the desired stability. Said
posterior rigid foam % component has a molded and integrated arch
to provide support along the longitudinal and transverse arches of
the human foot. Said arch has a generally channel-shaped cross
section. Said posterior rigid foam % component, which includes the
depression in the subcalcaneous region, has one or more negative
recesses along its top surface and, one or more positive
protuberances along its bottom surface for the purpose of attaching
said posterior rigid foam % component to the heel units. Attachment
to the heel units is accomplished by means including, but not
limited to screws, nails, tacks or rivets. Because the posterior
rigid foam % component does not require the addition of a metal
shank or other inserted stiffener, the connection of said posterior
rigid foam 3/4 component to the outside heel is a direct
connection.
[0172] Said posterior rigid foam 3/4 component is combined with
said flexible metatarsal region to form Applicant's insole. The
flexible metatarsal region is sufficiently elastic so as to follow
the contours of the shoe forming contoured last and to easily flex
without the use of additional flex grooves. The flexible metatarsal
region can be shaped to match any variety of toe characteristics by
methods including, but not limited to, trimming, cutting, sanding
or skiving. The leading edge of said flexible metatarsal region is
tapered and contoured to promote a connection to the posterior
rigid foam % component that is comfortable to the wearer. The
material characteristics of this flexible metatarsal region are
such that a textile substrate can be attached. In a further
embodiment, a multiple density flexible metatarsal region can be
constructed wherein the material characteristics of said flexible
metatarsal region are such that a second density polymer can be
added to further attenuate shock generated by metatarsal
strike.
[0173] In an embodiment of the present invention, the posterior
rigid foam 3/4 component has a pronounced and stepped taper to
allow for a seamless connection to said flexible metatarsal region.
This stepped tapered point of connection is also contoured in a
sloping fashion, medial to lateral or side-to-side, to promote a
comfortable transition from the posterior rigid foam % component to
the flexible metatarsal region. Said flexible metatarsal region can
be combined with the posterior rigid foam % component by mechanical
or chemical means to construct the Applicant's insole.
[0174] Either the footbed, as illustrated by FIGS. 1, 1a, and 1b,
or the insole, as illustrated by FIGS. 2, 2a, 2b, 2c and 2d, can be
used alone as a component in the manufacture of footwear.
[0175] Further, the footbed, as illustrated by FIGS. 1, 1a, and 1b,
and the insole as illustrated by FIGS. 2, 2a, 2b, 2c and 2d can be
used together to form a bi-layer footwear component for use in the
manufacture of footwear. When said footbed and insole are used
together, the top view of the footbed with the protuberance in the
subcalcaneous region, as illustrated by FIGS. 1, 1a, and 1b will be
visible to the wearer. In an embodiment of the invention, the
protuberance in the subcalcaneous region (10) of the footbed (3),
will fit into the subcalcaneous depression (4) of the insole (13),
as illustrated in FIGS. 3a and 3b to form a bi-layer footwear
component, suitable for use in high-heel footwear. Said footbed and
insole can be incorporated into footwear by methods known to those
skilled in the art of shoe manufacturing.
[0176] The application of Norman Dean, entitled FOOTWEAR HAVING A
HEEL AND HEEL BREAST, filed simultaneously herewith is incorporated
by reference.
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