U.S. patent application number 13/005893 was filed with the patent office on 2011-11-17 for responsive insoles.
This patent application is currently assigned to Polyworks, Inc.. Invention is credited to Richard B. Fox, James E. Gaudet.
Application Number | 20110277348 13/005893 |
Document ID | / |
Family ID | 44304639 |
Filed Date | 2011-11-17 |
United States Patent
Application |
20110277348 |
Kind Code |
A1 |
Fox; Richard B. ; et
al. |
November 17, 2011 |
RESPONSIVE INSOLES
Abstract
Disclosed here are insoles with one or more regions responsive
to maintain a user's foot in a corrected position in the
insole.
Inventors: |
Fox; Richard B.;
(Smithfield, RI) ; Gaudet; James E.; (Blackstone,
MA) |
Assignee: |
Polyworks, Inc.
North Smithfield
RI
|
Family ID: |
44304639 |
Appl. No.: |
13/005893 |
Filed: |
January 13, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61294716 |
Jan 13, 2010 |
|
|
|
Current U.S.
Class: |
36/43 |
Current CPC
Class: |
A43B 7/148 20130101;
A43B 7/144 20130101; A43B 17/00 20130101; A43B 13/188 20130101;
A43B 7/142 20130101; A43B 7/1445 20130101 |
Class at
Publication: |
36/43 |
International
Class: |
A43B 13/40 20060101
A43B013/40; A43B 13/38 20060101 A43B013/38 |
Claims
1. An insole, comprising: a contoured surface selected to maintain
a user's foot in a corrected position; a footbed comprising a
footbed material; a first responsive region defined in the footbed,
the first responsive region comprising a first energy dispersive
material, different from the footbed material; wherein the first
energy dispersive material is substantially flexible in a first
configuration such that the user's foot can move from the corrected
position to an uncorrected position, and substantially rigid in a
second configuration, such that upon impact by the user's foot, the
first energy dispersive material becomes substantially rigid and
forces the user's foot to move from the uncorrected position to the
corrected position.
2. The insole of claim 1, further comprising a second responsive
region defined in the footbed, the second responsive region
comprising a second energy dispersive material different than the
footbed material and the first energy dispersive material.
3. The insole of claim 1, wherein the first responsive region is
selected from the group consisting of an arch support, a heel cup,
a heel pad, a metatarsal support, and combinations of the
foregoing.
4. The insole of claim 2, wherein the second responsive region is
selected from the group consisting of an arch support, a heel cup,
a heel pad, a metatarsal support, and combinations of the
foregoing.
5. The insole of claim 1, wherein the first responsive region
further comprises a graduated density.
6. The insole of claim 2, wherein the second responsive region
further comprises a graduated density.
7. The insole of claim 1, wherein the first responsive region
further comprises a graduated thickness.
8. The insole of claim 2, wherein the second responsive region
further comprises a graduated thickness.
9. The insole of claim 1, wherein the first energy dispersive
material comprises a shear thickening foam.
10. The insole of claim 2, wherein the second energy dispersive
material comprises a shear thickening foam.
11. The insole of claim 9, wherein the shear thickening foam
comprises a urethane foam.
12. The insole of claim 10, wherein the shear thickening foam
comprises a urethane foam.
13. An insole, comprising: a contoured surface selected to maintain
a user's foot in a corrected position; a footbed comprising a
footbed material; a first responsive region defined in the footbed,
the first responsive region comprising a first energy dispersive
material, different from the footbed material; a second responsive
region defined in the footbed, the second responsive region
comprising a second energy dispersive material different than the
footbed material and the first energy dispersive material; wherein
the second material comprises a first energy dispersive material
that is substantially flexible in a first configuration such that
the user's foot can move from the corrected position to an
uncorrected position, and substantially rigid in a second
configuration, such that upon impact by the user's foot, the first
responsive region becomes substantially rigid and forces the user's
foot to move from the uncorrected position to the corrected
position; and wherein the first and second responsive regions are
selected from the group consisting of an arch support, a heel cup,
a heel pad, a metatarsal support, and combinations of the
foregoing.
Description
RELATED CASES
[0001] Priority is claimed herein to U.S. Provisional Patent
Application No. 61/294716, which was filed on Jan. 13, 2010, and
which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to insoles with one or more
responsive regions that are constructed to maintain a user's foot
in a corrected position in the insole.
RELATED ART
[0003] Severe foot pain is a debilitating experience, which often
results in an individual compensating for the foot pain by shifting
the balance of weight from the foot in pain, to the other foot,
which may be in less pain, or no pain. Compensation in such a
manner can result in other symptoms and/or medical problems such
as, for example, pronation, plantar fascitis, heel spurs, and the
like.
[0004] To ease foot pain, many individuals use removable insoles in
their shoes, which may be made of polymeric materials that provide
cushioning. The cushioning properties of the insole provide some
pain relief, and allow foot movement within the shoe.
[0005] To ease more severe foot pain, resulting from problems with
poor posture, misalignment, and the like, custom orthotics may be
used. In contrast to removable insoles, custom orthotics are made
of rigid materials, and are useful for correcting problems with
misalignment of feet, etc., because they force an individual's foot
to move into a corrected position, and prevent movement of the foot
to the original position which caused the problem and foot pain.
While effective, orthotics are expensive, heavy, and often
uncomfortable.
SUMMARY
[0006] The present disclosure is directed, in one embodiment, to an
insole. The insole comprises a contoured surface selected to
maintain a user's foot in a corrected position; a footbed
comprising a footbed material; and a first responsive region
defined in the footbed, the first responsive region comprising a
first energy dispersive material, different from the footbed
material; wherein the first energy dispersive material is
substantially flexible in a first configuration such that the
user's foot can move from the corrected position to an uncorrected
position, and substantially rigid in a second configuration, such
that upon impact by the user's foot, the first energy dispersive
material becomes substantially rigid and forces the user's foot to
move from the uncorrected position to the corrected position.
[0007] In another embodiment, the insole comprises a contoured
surface selected to maintain a user's foot in a corrected position;
a footbed comprising a footbed material; a first responsive region
defined in the footbed, the first responsive region comprising a
first energy dispersive material, different from the footbed
material; a second responsive region defined in the footbed, the
second responsive region comprising a second energy dispersive
material different than the footbed material and the first energy
dispersive material; wherein the second material comprises a first
energy dispersive material that is substantially flexible in a
first configuration such that the user's foot can move from the
corrected position to an uncorrected position, and substantially
rigid in a second configuration, such that upon impact by the
user's foot, the first responsive region becomes substantially
rigid and forces the user's foot to move from the uncorrected
position to the corrected position; and wherein the first and
second responsive regions are selected from the group consisting of
an arch support, a heel cup, a heel pad, a metatarsal support, and
combinations of the foregoing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Advantages, novel features, and uses of the disclosure will
become more apparent from the following detailed description of
non-limiting embodiments of the disclosure when considered in
conjunction with the accompanying drawings, which are schematic and
which are not intended to be drawn to scale. In the figures, each
identical or substantially similar component that is illustrated in
various figures is typically represented by a single numeral or
notation. For purposes of clarity, not every component is labeled
in every figure, nor is every component of each embodiment of the
disclosure shown where illustration is not necessary to allow those
of ordinary skill in the art to understand the disclosure. In the
drawings:
[0009] FIG. 1 is a top plan view of one exemplary insole according
to the present disclosure;
[0010] FIG. 1A is a cross-sectional view of the insole of FIG. 1
through line 1A-1A;
[0011] FIG. 1B is a cross-sectional view of the insole of FIG. 1
through line 1B-1B;
[0012] FIG. 2 is a top plan view of another exemplary insole
according to the present disclosure, comprising a heel pad;
[0013] FIG. 2A is a cross-sectional view of the insole of FIG. 1
through line 2A-2A;
[0014] FIG. 2B is a cross-sectional view of the insole of FIG. 1
through line 2B-2B;
[0015] FIG. 3 is a top plan view of another exemplary insole
according to the present disclosure, comprising a heel pad and a
metatarsal pad;
[0016] FIG. 3A is a cross-sectional view of the insole of FIG. 1
through line 3A-3A;
[0017] FIG. 3B is a cross-sectional view of the insole of FIG. 1
through line 3B-3B; and
[0018] FIG. 3C is a cross-sectional view of the insole of FIG. 1
through line 3C-3C.
DETAILED DESCRIPTION
[0019] The present disclosure is directed to relatively lightweight
footwear products, such as insoles, comprising various degrees of
hardness and impact-resistance. The insoles may comprise one or
more responsive regions that are designed to allow the insole to
conform to the shape of a foot, providing comfort when at rest, and
when subjected to a stress, such as when a user is moving (i.e.,
walking, running, dancing, etc.), to stiffen and to keep the foot
in the corrected position. A contoured insole made at least in part
of a responsive material such as a shear thickening foam, may be
soft to the touch, but can stiffen on impact to keep, for example,
the heel and arch support of the insole properly aligned in
relation to the foot. That is, the insole is soft enough to conform
to the shape of a foot, providing comfort when at rest, but
responsive to keep in the foot properly aligned on the insole and
in footwear.
[0020] The size, shape and configuration of the insoles can be
designed to provide suitable vibration dampening, impact
absorption, friction reduction, as well as cushioning, which can be
varied as desired or necessary to achieve the desired customized
insole characteristics.
[0021] Reference will now be made in detail to exemplary
embodiments of the disclosure, examples of which are illustrated in
the accompanying drawings. Wherever possible, the same reference
numbers will be used throughout the drawings to refer to the same
or like parts. The figures, when taken together, illustrate various
embodiments of insoles, each comprising one or more responsive
regions selected to provide varying degrees of vibration dampening,
impact resistance or absorption, rebound, friction reduction,
stabilization and/or cushioning, and the like, as determined by the
needs of a particular user, such as heel pads, metatarsal pads, and
the like, based on an evaluation of the needs of a particular
individual or of a group of individuals with a common problem.
[0022] FIGS. 1-1B, when taken together, show one exemplary
embodiment of an insole 5 according to the present disclosure,
comprising a foot portion 10 (hereinafter "footbed 10") and two
responsive regions defined in the footbed 10. It should be
understood that although the illustrated embodiments comprise two
or more responsive regions, as stated above, the present disclosure
also encompasses one responsive region. In the present embodiment,
the insole 5 comprises a responsive heel cup 20 (hereinafter "heel
cup 20") and a responsive arch support 30 (hereinafter "arch
support 30).
[0023] Insole 5 may be contoured to conform to the shape of a
user's foot, or the desired corrected position for a user's foot.
For example, heel cup 20 may be contoured to accommodate the user's
heel (not illustrated), and arch support 30 may be contoured to
accommodate the instep of the user's foot (not illustrated), both
of which assist in properly locating or positioning the user's foot
on the insole. The shape, size and configuration of the insole
contours may be predetermined and standardized based on average
foot shapes and sizes, as is common in the industry or,
alternatively, the size, shape and configuration of the insole may
be customized for a particular individual's foot. The insoles
disclosed herein may be manufactured using a variety of techniques
and equipment, including those disclosed in commonly owned and
co-pending U.S. patent application Ser. No. 11/644,266, filed on
Dec. 23, 2006, the disclosure of which is incorporated herein by
reference in its entirety.
[0024] FIGS. 2-2B, when taken together, show another exemplary
embodiment of an insole 5' according to the present disclosure,
comprising a responsive heel pad 40 (hereinafter "heel pad
40").
[0025] FIGS. 3-3B, when taken together, show another exemplary
embodiment of an insole 5'' according to the present disclosure,
comprising a heel pad 40 and a metatarsal pad 50 (hereinafter
"metatarsal pad 40").
[0026] In any of the foregoing embodiments, the insoles can
comprise any materials comprising sufficient structural integrity
to be formed into predetermined shapes; sufficient softness and/or
pliability to provide comfort against a body; and that are capable
of withstanding the environment in which it is intended to be used,
without substantial degradation.
[0027] Suitable materials for the footbed portion 10 include, but
are not limited to, polymeric materials, including foamed plastics,
gel materials, such as silicone, elastomers, such as thermoplastic
polyurethane ("TPU"), composite materials, and the like. Examples
of suitable polymeric materials include, but are not limited to, a
thermosetting polymeric material, an elastomeric polymeric
material, thermoplastic material, including a thermoplastic
elastomeric material, and combinations comprising at least one of
the foregoing. Some possible materials comprise polyurethane,
silicone, and/or the like, and combinations comprising at least one
of the foregoing materials.
[0028] In any of the foregoing embodiments, the one or more
responsive regions (e.g., 20,30,40,50) can comprise any material
comprising sufficient structural integrity to be formed into
predetermined shapes; sufficient softness and/or pliability to
provide comfort against a body, when at rest, and sufficient
rigidity to cushion against shock when in use; and that is capable
of withstanding the environment in which it is intended to be used,
without substantial degradation.
[0029] Suitable materials for responsive regions include, but are
not limited to, shear thickening or dilatant materials, and the
like. As used herein, the term "shear thickening materials" is
meant to cover all categories of shear thickening materials and
combinations of shear thickening materials known to those skilled
in the art. Examples of shear thickening or dilatant materials,
include, but are not limited to, shear thickening fluids; shear
thickening gels; encapsulated fluids or gels; shear thickening
foams; shear thickening solids; shear thickening filaments;
impregnated fibers (e.g., a fiber or yarn that has absorbed, and/or
is coated with, a shear thickening material); impregnated fiber
reinforced materials (e.g., a fabric that has absorbed, and/or is
coated with, a shear thickening material, wherein the impregnated
fiber reinforced material includes previously impregnated fibers
woven together to form a fabric); shear thickening composites
(e.g., a solid foamed synthetic polymer with an elastic, and/or an
elastomeric matrix and a polymer-based dilatant different from the
solid foamed synthetic polymer, in which the polymer-based dilatant
is distributed through the matrix and incorporated therein during
manufacture); and a solid, closed cell foam matrix with a
polymer-based dilatant, different from the matrix, distributed
through the matrix; shear thickening layers (e.g., a layer of
material formed from one of, or a combination of, the
above-categories of shear thickening materials).
[0030] Shear thickening or dilatant materials have properties that
distinguish them from other materials. For example, when shear
thickening materials are subjected to an increasing rate of shear
deformation, they undergo an increase in viscosity and/or rigidity.
For example, a shear thickening material may behave like a low
viscosity fluid when not subjected to shear deformation or
subjected to a low rate of shear deformation, but may behave like a
highly viscous fluid when subjected to a high rate of shear
deformation. Another shear thickening material may behave like a
fluid when not subjected to shear deformation or subjected to a low
rate of shear deformation, but may behave like a quasi-solid or
solid when subjected to a high rate of shear deformation. Yet
another a shear thickening material may behave like a quasi-solid
or flexible solid when not subjected to shear deformation or
subjected to a low rate of shear deformation, but may behave like a
rigid solid when subjected to a high rate of shear deformation.
[0031] Shear thickening foam may be desirable to use for the
regions. Such foams may be formed by trapping gas bubbles, produced
using physical or chemical means, in a shear thickening fluid or
gel, after which the material may be solidified. The interactions
and mechanisms behind the shear thickening behavior of a shear
thickening foam may be similar to those of other shear thickening
materials. When the shear thickening foam is subjected to the
energy of a sudden impact, its rigidity can increase. Before and
after the impact, under normal conditions, the shear thickening
foam can be relatively flexible. One suitable shear thickening foam
is a polyurethane frothed foam that is commercially available from
Rogers Corporation under the name PORON.RTM. XRD, which may be
formed to have a variety of densities and properties. Other shear
thickening foams may be used for the responsive regions are
available from other manufacturers.
[0032] In any of the foregoing embodiments, the responsive regions
may be molded together with the footbed in the same manufacturing
operation, or formed separately. If desired, the responsive regions
may be encapsulated or covered with another material, and inserted
into the footbed using a variety of techniques, such as, gluing,
heat sealing, and the like. Also if desired, various additives
and/or active agents may be included in the materials, as described
in the '266 application.
[0033] To produce insoles customized for a particular individual or
group of individuals, the size, shape and configuration of the
responsive regions can be varied, as can the material and the
material properties from which they are formed (e.g., density,
durometer, rebound, elastic modulus, etc.). For example, the
responsive regions of an insole can comprise the same or different
materials, and they can comprise materials with graduated
thickness, graduated density, or both. The configuration of the
insole 5 can be customized to be responsive to the gait of an
individual by using combinations of materials with different
characteristics, such as gels, foams, particularly energy
dispersive foams, and other materials, and combinations of the
foregoing.
[0034] In one exemplary embodiment, in regions of the footbed in
which relatively low rebound may be desirable, an energy dispersive
foam with such low rebound characteristics may be used to form the
responsive regions. Regions formed from such a low rebound material
can feel soft when touched, but become hard when impacted. For
example, it may be desirable to have low rebound in the perimeter
of the heel cup 20 and/or the arch support 30. When walking, upon
impact of the user's foot to the ground, the heel cup and arch
support regions 20,30 will harden, thereby maintaining the proper
location of the heel and arch within the insole. One suitable
material that may be used for such regions is a microcellular
urethane foam available under the product name Poron XRD, from
Rogers Corporation. Poron XRD is available with varying levels of
cushioning, impact resistance and rebound characteristics.
Comparable materials are available from other manufacturers.
[0035] In another exemplary embodiment, it may be desirable to for
certain regions to have relatively high rebound. For example, it
may be desirable to have relatively high rebound in the heel pad 40
and/or metatarsal pad 50, such that when walking or running, the
amount of "bounce" is relatively low. Again, Poron XRD may be a
suitable material for such an application.
[0036] The insoles of the present disclosure can be advantageous
because they are relatively lightweight, simple and inexpensive to
manufacture in comparison to other custom orthotics.
[0037] Throughout the application, it should be noted that the
terms "first," "second," and the like herein do not denote any
order or importance, but rather are used to distinguish one element
from another, and the terms "a" and "an" herein do not denote a
limitation of quantity, but rather denote the presence of at least
one of the referenced items. Similarly, it is noted that the terms
"bottom" and "top" are used herein, unless otherwise noted, merely
for convenience of description, and are not limited to any one
position or spatial orientation. In addition, the modifier "about"
used in connection with a quantity is inclusive of the stated value
and has the meaning dictated by the context (e.g., includes the
degree of error associated with measurement of the particular
quantity).
[0038] Compounds are described using standard nomenclature. For
example, any position not substituted by an indicated group is
understood to have its valency filled by a bond as indicated, or a
hydrogen atom A dash ("--") that is not between two letters or
symbols is used to indicate a point of attachment for a
substituent. For example, --CHO is attached through carbon of the
carbonyl group. Unless defined otherwise herein, all percentages
herein mean weight percent ("wt. %"). Furthermore, all ranges
disclosed herein are inclusive and combinable (e.g., ranges of "up
to about 25 weight percent (wt. %), with about 5 wt. % to about 20
wt. % desired, and about 10 wt. % to about 15 wt. % more desired,"
are inclusive of the endpoints and all intermediate values of the
ranges, e.g., "about 5 wt. % to about 25 wt. %, about 5 wt. % to
about 15 wt. %", etc.). The notation "+/-10% means that the
indicated measurement may be from an amount that is minus 10% to an
amount that is plus 10% of the stated value.
[0039] Finally, unless defined otherwise, technical and scientific
terms used herein have the same meaning as is commonly understood
by one of skill in the art to which this disclosure belongs.
[0040] While the disclosure has been described with reference to an
exemplary embodiment, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the disclosure. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
disclosure without departing from the essential scope thereof.
Therefore, it is intended that the disclosure not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this disclosure, but that the disclosure will include
all embodiments falling within the scope of the appended
claims.
* * * * *