U.S. patent application number 13/255034 was filed with the patent office on 2012-02-02 for shoe sole inserts for pressure distribution.
This patent application is currently assigned to AETREX WORLDWIDE, INC.. Invention is credited to Laurence I. Schwartz, Joseph Skaja.
Application Number | 20120023776 13/255034 |
Document ID | / |
Family ID | 42199572 |
Filed Date | 2012-02-02 |
United States Patent
Application |
20120023776 |
Kind Code |
A1 |
Skaja; Joseph ; et
al. |
February 2, 2012 |
SHOE SOLE INSERTS FOR PRESSURE DISTRIBUTION
Abstract
Embodiments of the present invention are directed to a shoe
insert that can provide overall improved foot comfort to a user and
can specifically provide beneficial localized pressure relief
improving foot health and mitigating painful and/or damaging
conditions. The shoe insert can comprise a pressure moderator sheet
and one or more pressure pads removably and replaceably attached to
the moderator sheet. The insert may further comprise a cushioning
material or layer.
Inventors: |
Skaja; Joseph; (Dumont,
NJ) ; Schwartz; Laurence I.; (Closter, NJ) |
Assignee: |
AETREX WORLDWIDE, INC.
TEANECK
NJ
|
Family ID: |
42199572 |
Appl. No.: |
13/255034 |
Filed: |
March 9, 2010 |
PCT Filed: |
March 9, 2010 |
PCT NO: |
PCT/US10/26615 |
371 Date: |
September 26, 2011 |
Current U.S.
Class: |
36/44 ; 12/142R;
36/43 |
Current CPC
Class: |
A43B 7/1465 20130101;
A43B 7/1445 20130101; A43B 7/143 20130101; A43B 7/1435 20130101;
A43B 7/1425 20130101; A43B 17/026 20130101; A43B 7/144
20130101 |
Class at
Publication: |
36/44 ; 36/43;
12/142.R |
International
Class: |
A43B 13/38 20060101
A43B013/38; A43D 11/00 20060101 A43D011/00; A43B 13/40 20060101
A43B013/40 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 9, 2009 |
US |
61/158494 |
Claims
1. A removable insert for placement in a shoe between the shoe sole
and the foot of a user, the insert comprising: a formed pressure
moderator sheet; and a series of discrete pressure pads removably
and replaceably attached to the pressure moderator sheet, wherein
the pressure moderator sheet is positioned to separate the pressure
pads from the foot of the user such that pressure between the foot
and the pressure pads are locally distributed across the moderator
sheet.
2. The removable insert of claim 1, further comprising a cushioning
layer positioned to separate at least a portion of the moderator
sheet from the foot of the user.
3. The removable insert of claim 2, wherein the cushioning layer is
absent in the area of the moderator sheet overlying the discrete
pressure pads.
4. The removable insert of claim 2, wherein the cushioning layer
comprises a polyurethane foam.
5. The removable insert of claim 1, wherein the pressure moderator
sheet comprises a top surface and a bottom surface and is formed to
have surface ridges and indentations formed in each of the top and
bottom surfaces.
6. The removable insert of claim 5, wherein the discrete pressure
pads are positioned in at least one indentation formed in the
bottom surface of the moderator sheet.
7. The removable insert of claim 6, wherein each of the discrete
pressure pads has a thickness substantially equal to a height of
the at least one indentation formed in the bottom surface of the
moderator sheet.
8. The removable insert of claim 6, wherein each of the discrete
pressure pads has a thickness different than a height of the at
least one indentation formed in the bottom surface of the moderator
sheet.
9. The removable insert of claim 5, comprising a cushioning
material positioned in indentations formed in the top surface of
the moderator sheet.
10. The removable insert of claim 9, wherein the cushioning
material comprises a polyurethane foam.
11. The removable insert of claim 5, wherein the surface ridges and
indentations formed in the bottom surface of the moderator sheet
corresponds to the surface indentations and ridges, respectively,
formed in the top surface of the moderator sheet.
12. The removable insert of claim 5, wherein the indentations at
least partially interlineate and surround the ridges.
13. The removable insert of claim 1, wherein the series of discrete
pressure pads comprises a plurality of pressure pad units, each
unit comprising a center pad component and a peripheral pad
component at least partially encircling the center pad
component.
14. The removable insert of claim 13, wherein at least one of the
peripheral pads is rectangular in shape and at least one of the
center pads is oval in shape.
15. The removable insert of claim 13, wherein at least one of the
peripheral pads and at least one of the center pads are circular in
shape.
16. The removable insert of claim 1, wherein at least a portion of
the discrete pressure pads are positioned in an area of the insert
configured to correspond to the ball of the foot of a user.
17. The removable insert of claim 1, wherein at least a portion of
the discrete pressure pads are positioned in an area of the insert
configured to correspond to the heel of the foot of a user.
18. The removable insert of claim 1, wherein at least a portion of
the discrete pressure pads are positioned in an area of the insert
configured to correspond to the big toe of the foot of a user.
19. The removable insert of claim 1, wherein the pressure moderator
sheet is a thermoplastic polyurethane sheet.
20. The removable insert of claim 19, wherein the thermoplastic
polyurethane sheet has a thickness of less than 3 mm.
21. The removable insert of claim 19, wherein the thermoplastic
polyurethane sheet has a thickness of less than 2 mm.
22. The removable insert of claim 19, wherein the pressure
moderator sheet is a continuous sheet of thermoplastic
polyurethane.
23. The removable insert of claim 1, wherein the pressure pads
comprise a polyurethane material.
24. The removable insert of claim 1, wherein the pressure pads are
directly attached to the pressure moderator sheet without the use
of a separate adhesive material.
25. The removable insert of claim 1, wherein the pressure pads are
directly attached to the pressure moderator sheet via surface
interactions between the pressure pads and the pressure moderator
sheet.
26. The removable insert of claim 25, wherein the pressure pads are
directly attached to the pressure moderator sheet via surface
tension between the pressure pads and the pressure moderator
sheet.
27. The removable insert of claim 1, wherein the pressure pads are
gel pods.
28. The removable insert of claim 27, wherein the gel pods comprise
a urethane gel at least partially coated with a thin film.
29. The removable insert of claim 28, wherein the thin film
comprises thermoplastic polyurethane.
30. The removable insert of claim 1, wherein the at least one of
the pressure moderator sheet or pressure pads is texturized so as
to reduce noise between the insert and the shoe during use.
31. The removable insert of claim 1, wherein a thickness of the
pressure moderator sheet is substantially less than a thickness of
each of the pressure pads.
32. A removable insert for placement in a shoe between the shoe
sole and the foot of a user, the insert comprising: a pressure
moderator sheet; and a plurality of discrete pressure pads
removably and replaceably attached to the pressure moderator sheet
via surface interactions therebetween, wherein the pressure
moderator sheet is positioned to separate the pressure pads from
the foot of the user such that pressure between the foot and the
pressure pads are locally distributed across the moderator
sheet.
33. A method of forming a removable insert for placement in a shoe
between the shoe sole and the foot of a user, the method
comprising: providing a pressure moderator sheet; and attaching a
series of discrete pressure pads to the pressure moderator sheet,
the pressure pads being removably and replaceably attached to the
pressure moderator sheet, wherein the pressure moderator sheet is
positioned to separate the pressure pads from the foot of the user
such that pressure between the foot and the pressure pads are
locally distributed across the moderator sheet.
34. The method of claim 33, wherein providing comprises forming the
pressure moderator sheet.
35. The method of claim 34, wherein forming comprises forming
surface ridges and indentations in the pressure moderator
sheet.
36. The method of claim 35, wherein attaching comprises positioning
the discrete pressure pads in at least one indentation formed in
the moderator sheet.
37. The method of claim 33, further comprising attaching a
cushioning material to at least a portion of the pressure moderator
sheet to separate at least a portion of the moderator sheet from
the foot of the user.
38. The method of claim 33, wherein attaching comprises directly
attaching the pressure pads to the pressure moderator sheet via
surface interactions between the pressure pads and the pressure
moderator sheet.
39. The method of claim 38, wherein attaching comprises directly
attaching the pressure pads to the pressure moderator sheet via
surface tension between the pressure pads and the pressure
moderator sheet.
40. The method of claim 33, wherein attaching comprises directly
attaching the pressure pads to the pressure moderator sheet without
the use of a separate adhesive material.
41. The method of claim 33, further comprising detecting high
pressure areas on the sole of a foot, and wherein attaching
comprises selectively adding or removing the pressure pads from the
pressure moderator sheet based on the detected high pressure areas.
Description
FIELD OF THE INVENTION
[0001] The present invention is directed to inserts for shoes. More
particularly, the invention relates to shoe in-sole inserts that
provide for pressure distribution across defined areas of the
foot.
BACKGROUND
[0002] Shoe inserts are widely available devices that are useful to
increase the comfort of shoes or prolong the useful lifetime of
shoes. Inserts can also be specifically designed orthotic devices
used to relieve painful conditions, such as corns, calluses,
metatarsal conditions, or other painful conditions of the foot.
Over-the-counter shoe inserts are relatively inexpensive but can
provide limited relief of many conditions. Specially designed
orthotics can provide more relief, but are expensive, inconvenient
to replace, and are typically relatively non-adjustable.
[0003] Accordingly, there remains a need in the art for shoe
inserts that are relatively inexpensive, widely available, provide
relief for a wide range of painful and/or damaging foot conditions,
and are easily adjustable to provide therapeutic benefit to a wide
range of users with a wide range of conditions affecting the foot.
The present invention meets this need.
SUMMARY OF THE INVENTION
[0004] Embodiments of the present invention are directed to a shoe
insert that can provide therapeutic benefit to a user by modulating
pressure applied to the foot of a user. The shoe insert of the
invention makes use of a combination of removable pressure pads and
a pressure moderator to beneficially alter pressure transfer
between the sole of a shoe and the foot of a user.
[0005] In one embodiment, the present invention provides a
removable insert for placement in a shoe between the shoe sole and
the foot of a user. The insert comprises a formed pressure
moderator sheet and a series of discrete pressure pads removably
and replaceably attached to the moderator sheet. The moderator
sheet is positioned to separate the pressure pads from the foot of
the user and is particularly useful to locally distribute the
pressure between the foot and the pressure pads across the
moderator sheet.
[0006] In further embodiments, the insert may further comprise a
cushioning layer. Such layer may have a variety of sizes covering
all or a part of the overall area of the insert. In particular, the
cushioning layer may be positioned to separate at least a portion
of the moderator sheet from the foot of the user. In specific
embodiments, the cushioning layer may be absent in the area of the
moderator sheet overlying the discrete pressure pads. The
cushioning layer may be formed of a variety of materials, such as
polyurethane foam.
[0007] In certain embodiments, the pressure moderator sheet can be
described as comprising a top surface and a bottom surface.
Moreover, the moderator sheet may be described as being formed to
have surface ridges and indentations defined in each of the top and
bottom surfaces. According to one aspect, the indentations at least
partially interlineate and surround the ridges. In specific
embodiments, the ridges of the top surface may correspond to
indentations of the bottom surface, and the indentations of the top
surface may correspond to ridges of the bottom surface. The formed
ridges and indentations may provide specific functions. For
example, the discrete pressure pads can be positioned in one or
more of the indentations formed in the bottom surface of the
pressure moderator sheet. In other embodiments, the cushioning
material may be positioned in the indentations formed in the top
surface of the moderator sheet. The pressure pads may have various
thicknesses in relation to the moderator sheet. For example, each
of the discrete pressure pads may have a thickness substantially
equal to a height of the at least one indentation formed in the
bottom surface of the moderator sheet. Alternatively, each of the
discrete pressure pads may have a thickness different than a height
of the at least one indentation formed in the bottom surface of the
moderator sheet. In one embodiment, the pressure pads and/or
moderator sheet is texturized so as to reduce noise between the
insert and the shoe during use. Moreover, a thickness of the
pressure moderator sheet may be substantially less than a thickness
of each of the pressure pads.
[0008] The pressure pads can be described in terms of number and
positioning of the pads. For example, the shoe insert may comprise
a series of discrete pressure pad that are purposefully positioned
in relation to one another to provide beneficial properties and
allow for customization of the insert through removal of only part
of the series of pads to design the desired pressure moderation. In
particular, the series of discrete pressure pads may comprise a
plurality of pressure pad units, each unit comprising a center pad
component and a peripheral pad component at least partially
encircling the center pad component. For instance, at least one of
the peripheral pads may be rectangular in shape and at least one of
the center pads may be oval in shape, or at least one of the
peripheral pads and at least one of the center pads may be circular
in shape. Moreover, other unit combinations would also be
encompassed by the invention.
[0009] The pressure pads are preferably positioned on the shoe
insert to correspond to anatomical portions of the foot where
pressure points are likely to occur or where foot diseases or
conditions related to pressure may occur. In some embodiments, at
least a portion of the discrete pressure pads are positioned in an
area of the insert corresponding to the ball of the foot of a user.
In other embodiments, at least a portion of the discrete pressure
pads can be positioned in an area of the insert corresponding to
the heel of the foot of a user. In still other embodiments, at
least a portion of the discrete pressure pads may be positioned in
an area of the insert corresponding to the big toe of the foot of a
user.
[0010] The beneficial pressure modulation abilities of the
inventive shoe insert can particularly be related to the pressure
moderator sheet and the properties thereof that allow for
distribution of pressure between the foot and an underlying
pressure inducer, such as a pressure pad. In specific embodiments,
the pressure moderator sheet can comprise a thermoplastic
polyurethane sheet, which can have a thickness of less than about 3
mm. Preferably, the pressure moderator sheet is a continuous sheet
of thermoplastic polyurethane. The pressure pads may likewise
comprise a polyurethane material.
[0011] The shoe insert can be easily customized by a user through
removal of specific pressure pads to adjust the degree of pressure
applied to specific portions of the foot and to adjust the softness
of the insert in specified areas. The ease of use and customization
of the shore insert can be particularly related to the ability to
remove and replace the individual pressure pads. Moreover, in
specific embodiments, the pressure pads can be directly attached to
the pressure moderator sheet without the use of a separate adhesive
material. For example, the pressure pads can be attached to the
pressure moderator sheet via surface interactions (e.g., surface
tension) between the pressure pads and the pressure moderator
sheet. The pressure pads may particularly be in the form of gel
pods (e.g., a urethane gel at least partially coated with a thin
film, such as a thermoplastic polyurethane film).
[0012] In one embodiment, the invention provides a removable shoe
insert comprising: a continuous sheet of thermoplastic polyurethane
having a top surface and a bottom surface and being formed to have
surface ridges and indentations; a layer of cushioning material
integrally adhered to and positioned in the indentations of the top
surface of the thermoplastic polyurethane sheet; and a series of
discrete pressure pads removably and replaceably attached to and
positioned in at least a portion of the indentations in the bottom
surface of the thermoplastic polyurethane sheet.
[0013] According to another aspect, a removable insert for
placement in a shoe between the shoe sole and the foot of a user is
provided. The shoe insert includes a pressure moderator sheet and a
plurality of discrete pressure pads removably and replaceably
attached to the pressure moderator sheet via surface interactions
therebetween. The pressure moderator sheet is positioned to
separate the pressure pads from the foot of the user such that
pressure between the foot and the pressure pads are locally
distributed across the moderator sheet.
[0014] According to another embodiment, a method of forming a
removable insert for placement in a shoe between the shoe sole and
the foot of a user is provided. The method includes providing a
pressure moderator sheet and attaching a series of discrete
pressure pads to the pressure moderator sheet, the pressure pads
being removably and replaceably attached to the pressure moderator
sheet. The pressure moderator sheet is positioned to separate the
pressure pads from the foot of the user such that pressure between
the foot and the pressure pads are locally distributed across the
moderator sheet.
[0015] Aspects of the method include forming the pressure moderator
sheet, which may include forming surface ridges and indentations in
the pressure moderator sheet. The attaching step may include
positioning the discrete pressure pads in at least one indentation
formed in the moderator sheet. In addition, the method may further
include attaching a cushioning material to at least a portion of
the pressure moderator sheet to separate at least a portion of the
moderator sheet from the foot of the user. The pressure pads may be
directly attached to the pressure moderator sheet via surface
interactions (e.g., surface tension) between the pressure pads and
the pressure moderator sheet. Thus, in one embodiment, the pressure
pads may be directly attached to the pressure moderator sheet
without the use of a separate adhesive material. The method may
further include detecting high pressure areas on the sole of a
foot, such as using iStep.RTM. technology, wherein the attaching
step includes adding or removing the pressure pads from the
pressure moderator sheet based on the detected high pressure
areas.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] In order to assist the understanding of embodiments of the
invention, reference will now be made to the appended drawings,
which are not necessarily drawn to scale. The drawings are
exemplary only, and should not be construed as limiting the
invention in any way.
[0017] FIG. 1 is a bottom view of a shoe insert according to one
embodiment of the invention.
[0018] FIG. 2 is a bottom view of a shoe insert according to
another embodiment of the invention.
[0019] FIG. 2b is a cross-section of the shoe insert of FIG. 2
along the line A-A.
[0020] FIG. 3 is a top view of a shoe insert according to the
embodiment shown in FIG. 2.
[0021] FIG. 4 is a top view of the shoe insert according to another
embodiment of the invention.
[0022] FIG. 4b is a cross-section of the shoe insert of FIG. 4
along the line B-B.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The invention now will be described more fully hereinafter
through reference to various embodiments. These embodiments are
provided so that this disclosure will be thorough and complete, and
will fully convey the scope of the invention to those skilled in
the art. Indeed, the invention may be embodied in many different
forms and should not be construed as limited to the embodiments set
forth herein; rather, these embodiments are provided so that this
disclosure will satisfy applicable legal requirements. As used in
the specification, and in the appended claims, the singular forms
"a", "an", "the", include plural referents unless the context
clearly dictates otherwise.
[0024] Embodiments of the present invention provide shoe inserts
having a variety of useful properties. The inventive shoe inserts
provide increased comfort generally but can also provide particular
therapeutic benefits to specific areas of the foot. This may be
accomplished through the specific combination of multiple shoe
insert components that function together to modulate localized
areas of foot pressure. Moreover, this combination of components
can provide a shoe insert that is easily customizable by the user
to fit not only the specific needs of multiple individual users but
also the changing needs of each user.
[0025] Accordingly, in one aspect, the present invention is
directed to a removable insert that can particularly be designed
for placement in a shoe between the shoe sole and the foot of a
user. The inventive insert can thus be used in addition to an
existing shoe insole or even in addition to another shoe insert. In
some embodiments, though, the shoe insert of the present invention
can be used to replace an existing shoe insole or an existing shoe
insert. In specific embodiments, the shoe insert of the invention
may work particularly well when it is the only insert present to
modulate pressure between the foot of the user and the permanent
shoe sole (e.g., the midsole or a non-removable insole).
[0026] In certain embodiments, an insert according to the invention
may comprise one or more pressure pads. As used herein, the term
"pressure pad" is intended to mean a thin piece of cushioning
material that is sufficiently soft (i.e., has a sufficient degree
of recoverable compression) to provide a cushioning effect to a
localized area of the foot and that has sufficient bulk such that
the absence of the pad in a localized area of the foot would be
readily sensed. These characteristics may be achieved through a
specific combination of materials and dimensions. For example, a
material that is very soft and is easily compressed may need to be
thicker than a material that is less soft and is not as easily
compressed.
[0027] Any material providing the above characteristics,
particularly recoverable compression, could be used as a pressure
pad according to the present invention. For example, a pressure pad
could comprise gels, foams, honeycombed materials, batting, or the
like. Gels may be particularly useful according to the invention in
light of their favorable pressure distribution properties.
[0028] Gels, such as polyurethane gels, are particularly useful as
pressure pads according to one embodiment of the invention due in
part to the balanced pressure distribution provided by the gel.
Specifically, gels tend to exhibit tri-dimensional deformation
properties such that the gel reacts to the applied pressure by
deforming along three axes: the X and Y axes in the plane of the
gel surface, as well as the Z axis that lies perpendicular to the
plane of the gel surface. This leads to an even distribution of the
exerted pressure, which lessens the pressure felt by the user at
the pressure points.
[0029] In particular embodiments, it may be useful for the pressure
pads to comprise a thermoset or thermoplastic urethane, silicone,
or other polymer gel.
[0030] In some embodiments, the pressure pads that form part of the
inventive shoe insert may comprise a combination of materials. For
example, the pressure pads may comprise a first material that is at
least partially covered or enclosed by a second material. In other
embodiments, the pressure pads may comprise multiple layers.
Preferably, at least part of the pressure pad comprises a gel
material. In a specific embodiment, a pressure pad according to the
invention may comprise a gel material and a covering material that
completely surrounds and encloses the gel material. In some
embodiments, the covering material can be a thermoplastic
polyurethane (TPU) material. For example, the pressure pads may be
gel pods that comprise a urethane gel coated with a thin film, such
as a TPU film, silicone film, or other thermoplastic film.
According to one embodiment, the gel material could be partially
surrounded by a covering material such that different portions of
the pressure pads interact differently with the moderator sheet.
For example, only the surface(s) of the pressure pads not
contacting the moderator sheet may be covered (e.g., a TPU covered
surface not contacting the moderator sheet) such that the raw gel
material of the pad contacts the moderator sheet. In this instance,
the covered portions of the pressure pads will resist adhering to
other surrounding materials due to surface interactions
therebetween such as by minimizing surface tension or friction.
[0031] The thickness of the pressure pads used in the inventive
shoe inserts can vary and may particularly be a thickness that is
substantially equivalent to the overall thickness of the shoe
insert. In specific embodiments, the pressure pads can have a
thickness of up to about 10 mm, up to about 8 mm, up to about 6 mm,
up to about 5 mm, or up to about 4 mm. In other embodiments, the
pressure pads can have a thickness of about 1 mm to about 10 mm,
about 1 mm to about 8 mm, about 1 mm to about 6 mm, about 1 mm to
about 5 mm, about 2 mm to about 5 mm, or about 2 mm to about 4
mm.
[0032] A shoe insert according to one embodiment of the invention
can comprise a plurality of pressure pads. The plurality of pads
can comprise two, three, four, five, six, seven, eight, nine, ten,
thirteen, fourteen, fifteen, sixteen, or even more pads. In
specific embodiments, it can be particularly useful for a shoe
insert according to the invention to comprise a series of pressure
pads. As used herein, the term "series" indicates a plurality of
pads that are provided on the insert in a defined number, alignment
relative to each other, shape, alignment relative to an anatomical
portion of the foot, or dimension. In some embodiments, a series of
pressure pads may be defined by two or more of these factors in
combination.
[0033] The gel pads being in a series can mean the pads are aligned
relative to each other such that two or more pads are in a specific
spatial arrangement. For example, a first pad and a second pad may
be aligned relative to one another such that the first pad is
encircled by the second pad. Of course, further embodiments are
also encompassed by the invention, i.e., a third pad encircling the
second pad, etc.
[0034] In light of the above, it is clear that the pressure pads
used can take on a variety of shapes, such as square, oval, circle,
rectangle, oblong, or the like. Moreover, two or more pads may be
shaped specifically to enable the pads to be positioned in a
defined spatial arrangement. For example, a pad could be
rectangular around the perimeter thereof but could have a cut-out
portion (e.g., an oval-shaped cut-out). A second pad could be
shaped and sized to nest within the cut-out portion of the first
pad. Of course, the cut-out portion and the second pad nested
within the cut-out portion could be any shape or size. Likewise,
the first pad could be formed such that the perimeter thereof is in
a shape other than a rectangle. The shape of the pad may
particularly relate to the two-dimensional shape thereof (i.e.,
length and width). In specific embodiments the third pad dimension
(thickness or height) can be understood to be the thickness as
described herein with the pad having a relatively flattened shape
(i.e., having a relatively uniform thickness). In other
embodiments, the pads may be formed to have a thickness that varies
across the length or width of the pad (e.g., a dome-shaped or
cone-shaped pad).
[0035] It can be particularly beneficial for the pressure pads to
be located in a series such that they are aligned with an
anatomical portion of the foot. Multiple portions of the foot may
be subject to particularly increased pressure. Likewise, a variety
of diseases and conditions may cause certain areas of the foot to
be tender or otherwise increasingly susceptible to further injury
caused by the normal pressures to which the foot is subjected in
walking, running, or other activities. The pressure pads of the
inventive shoe insert may be located on the insert to correspond to
these defined areas of the foot. Specifically, the pressure pads
may be located to substantially align with one or more of the areas
of the foot known as the "ball of the foot" or the area of the foot
just before the toes that corresponds to the metatarsal heads. The
normal shape of the foot and the normal walking and running motions
causes this area of the foot to undergo much pressure. Moreover,
improperly fitting footwear and footwear with a narrow toe box can
inhibit the walking process (i.e., the normal transfer of forces
from the heel through the ball and through the toes). Metatarsalgia
can particularly be alleviated or avoided by placement of a series
of pressure pads so as to substantially align with the ball of the
foot.
[0036] Another high pressure area of the foot is the heel of the
foot. Running may particularly impart excessive pressure to the
heel. Accordingly, a series of pressure pads may be placed on the
inventive shoe insert to substantially align with the bottom of the
heel of the foot. Likewise, the big toe may be an anatomical
portion of the foot that is subject to excessive pressure. Harmful
pressure to the big toe can arise from an improperly fitting shoe,
the nature of a person's gait, or other causes. The big toe is a
common location for calluses, corns, and other conditions arising
from excessive pressure. Thus, a series of pressure pads may be
place on the inventive shoe insert to substantially align with the
big toe.
[0037] The dimensions of the pressure pads may vary depending upon
the shape of the pad, the location of the pad relative to other
pads, the location of the pad relative to an anatomical part of the
foot, and the overall size of the shoe insert.
[0038] In addition to the pressure pads, a shoe insert according to
one embodiment of the invention further comprises a formed pressure
moderator sheet. As more fully described herein, the pressure
moderator sheet can provide a unique and specialized function not
heretofore recognized as useful in the art. In particular, the
pressure moderator sheet can be positioned to separate the pressure
pads from the foot of the user. Accordingly, the pressure forces
between the foot and the pressure pads can be locally distributed
across the moderator sheet.
[0039] The formed pressure moderator sheet can comprise any
material useful to provide the functionality of the moderator as
described herein. In specific embodiments, the moderator
specifically can be a resilient material that deforms locally, such
as around the pressure pads or in areas where a pressure pad is
originally positioned but has been removed, as described herein. In
some embodiments, the pressure moderator sheet can comprise a sheet
of thermoplastic polyurethane (TPU). Any thermoplastic that is
durable could be used, with transparent materials affording the
most graphic design potential.
[0040] Preferably, the pressure moderator sheet exhibits sufficient
stiffness to resist complete deformation or "bottoming out" in
areas where a pressure pad is removed. For example, if the pressure
pads have an average thickness of 2 mm, a pressure moderator sheet
covering the pressure pads would be considered to bottom out upon
application of a force in a discrete area where a pressure pad is
absent if the pressure moderator sheet deformed downward by at
least 2 mm. This resistance to bottoming out can span a distance of
up to about 30 mm, the distance being measured as the open space
between two adjacent pressure pads. In specific embodiments, the
distance can be measured as an open space between two adjacent
pressure pads where there are no additional or intervening layers
other than the pressure moderator sheet. In other embodiments, the
resistance to bottoming out can span a distance of up to about 25
mm, up to about 22 mm, up to about 20 mm, up to about 18 mm, up to
about 16 mm, up to about 15 mm, up to about 12 mm, or up to about
10 mm. In still further embodiments, the resistance to bottoming
out can span a distance of about 0.5 mm to about 30 mm, about 1 mm
to about 25 mm, about 1 mm to about 20 mm, about 1 mm to about 15
mm, or about 1 mm to about 10 mm.
[0041] In specific embodiments, the pressure moderator can be a
continuous sheet. In other words, a single shoe insert according to
the invention would comprise a single pressure moderator sheet,
according to this embodiment of the invention. In certain
embodiments, the single pressure moderator sheet can also span
substantially the entire length and width of the shoe insert. In
other words, the pressure moderator sheet would form a layer,
according to this embodiment, that is present throughout the entire
range of possible shoe insole cross-sections. The use of a
continuous, single sheet in the pressure moderator sheet can be
particularly beneficial to ensure the pressure moderating
properties of the layer is not compromised at any discrete points
across the pressure moderator sheet. Sheets could be bonded
together to act as a continuous sheet or a partial sheet could be
used, although such alternatives may result in insertion problems
and be more expensive to manufacture.
[0042] According to one embodiment, the moderator sheet may be
multiple layers and formed using, for example, a "double shot"
molding process. In this regard, a first layer or skin of a
moderator sheet (e.g., TPU material) may be placed into a mold and
a first shot of polymeric material (e.g., thermoset or
thermoplastic polyurethane) may be placed on the skin and the mold
closed to cure the first shot and form a first layer of polymeric
material on the skin. The mold may then be opened and a second shot
of polymeric material (e.g., thermoset or thermoplastic urethane)
may be placed on the skin and the first layer of polymeric
material. The mold is then closed to cure the second shot and form
the second layer of polymeric material. The first and second layers
formed on the skin may have different material properties from one
another, such as different stiffness and/or elasticity. For
example, the first layer formed on the skin may be stiffer than the
second layer formed on the skin.
[0043] In certain embodiments, it can further be useful for the
pressure moderator sheet to be formed of a solid material. More
specifically, it can be useful to avoid the use of foamed
materials. While not wishing to be bound by theory, it is believed
that the use of foamed materials reduces the ability of the layer
to function as a true pressure moderator. Foamed materials tend to
resist full deformation of the layer. When a pressure is applied to
the top surface of a foam layer, while there may be deformation to
some discrete depth of the foam layer, the bottom surface of the
foam layer does not necessarily deform (or at least does not deform
in proportion to the deformation at the top of the layer). Thus, a
foam layer does not moderate an applied pressure across a void
space--rather, the foam itself absorbs the pressure. This does not
provide the type of pressure moderation achieved according to the
present invention. In addition to moderating pressure, the
moderator sheet also acts as a canvas for decoration, which can be
done on the inside of the sheet and shown through, so that the
graphics potential is increased and more durable. As more fully
described below, the use of a relatively thin, solid, continuous,
resilient sheet as the pressure moderator sheet provides a
beneficial moderation of applied pressure that functions in
combination with the pressure pads to provide a unique and useful
pressure relief that is both comfortable and therapeutically
beneficial.
[0044] The pressure moderator sheet used in the present invention
may be described as being a "formed" sheet. This terminology
denotes a specific structure that is not an inherent quality of any
known standard method of manufacturing a sheet material. Rather,
the pressure moderator sheet is expressly formed to have ridges and
valleys or indentations.
[0045] As more clearly described below in relation to the various
drawings, a pressure moderator sheet according to the invention can
be characterized as having a top surface and a bottom surface, and
the sheet further can be characterized has having surface ridges
and indentations. More particularly, the top surface can be defined
in terms of specific ridges, and the top surface can thus have
indentations, which are the areas between the ridges that are lower
than the ridges when viewed in the plane of the pressure moderator
sheet. Likewise, the bottom surface can be defined in terms of
specific ridges, and the bottom surface can thus have indentations,
which are the areas between the ridges that are higher than the
ridges when viewed in the plane of the pressure moderator sheet. In
specific embodiments, the ridges of the top surface of the pressure
moderator sheet substantially correspond to the indentations of the
bottom surface of the sheet, and the indentations of the top
surface of the pressure moderator likewise correspond to the ridges
of the bottom surface of the sheet.
[0046] The presence of the indentations and ridges in the formed
pressure moderator sheet can provide particular benefits to the
present invention. For example, in certain embodiments, the
indentations of the top surface of the pressure moderator sheet can
provide an area for placement of the pressure pads. Moreover, in
certain embodiments, the ridges formed in the pressure moderator
sheet can have a height (in reference to the bottom of the
indentations in the formed pressure moderator sheet) that can be
substantially identical to the height (or thickness) of the
pressure pads. In other embodiments, however, the height (or
thickness) of the pressure pads can be somewhat greater or less
than the height of the ridges in the pressure moderator sheet.
[0047] The formed ridges and indentations can also take specific
shapes. A ridge (and thus its corresponding on the reverse side of
the pressure moderator sheet) could have a substantial length
and/or width. For example, a ridge could have a length and/or width
of up to almost the entire width of the shoe insert. In other
embodiments, a ridge could have a length and/or width of up to
about 50 mm, up to about 45 mm, up to about 40 mm, up to about 30
mm, up to about 25 mm, up to about 20 mm, up to about 15 mm, or up
to about 10 mm. Of course, such dimensions could also be related to
the shape of the ridge (e.g., a diameter for a circle or oval
shape, etc.). Ridges could also have a substantial length while
having a very insubstantial width (or vice versa). For example, a
ridge could have a width of only about 1 or 2 mm and have a length
that is much greater (e.g., 3, 4, 5, 6, 7, 8, 9, 10 mm, or even up
to substantially the width of the shoe insert).
[0048] The term formed can also refer to other characteristics of
the shoe insert. For example, the shoe insert can be formed to have
the overall shape of a foot or a shoe. Moreover, the shoe insert
can be formed to have specific contouring, such as to take on the
three-dimensional shape of the bottom of a foot.
[0049] In some embodiments, the shoe insert of the invention can
include one or more pressure pads removably and replaceably
attached to the insert. More specifically, the pressure pads may be
removably and replaceably attached to the formed pressure moderator
sheet. In particular embodiments, one or more pressure pads may be
removably and replaceably attached to the pressure moderator sheet
and located in one or more indentations formed in the moderator
sheet. The pressure pads are removably and replaceably attached in
that the pressure pads are attached to the pressure moderator sheet
but are not permanently attached. Rather, the pressure pads may be
removed from the pressure moderator sheet by the express action of
a user (e.g., purposefully removing one or more of the pads). The
pressure pads are replaceably attached in that, after removal, the
pads may be re-attached to the pressure moderator sheet.
Preferably, the pads may be removed and replaced an unlimited
number of times.
[0050] The means for removably and replaceably attaching the
pressure pads to the pressure moderator sheet can be any means
recognizable as useful in the art. In some embodiments, it can be
useful for the pressure moderator sheet and the pressure pads to be
formed of materials whereby the pads are directly attached to the
sheet without the use of any separate adhesive material. For
example, the pressure moderator sheet and the pads may both
comprise a TPU material, and the attachment of the pressure pads to
the pressure moderator sheet may be through surface charge
interactions that naturally arise between the materials. In
particular, the surface tension between the pressure pads and the
moderator sheet allows sufficient attachment therebetween. Thus,
adhesives or other attachment techniques (e.g., Velcro) are not
required in order to secure the pressure pads directly to the
moderator sheet. Moreover, one surface of the pressure pads may be
formed of a material or covering that attaches to the moderator
sheet via surface interactions, while another surface may be formed
of a different material or covering that will resist adhering to
the moderator sheet or other materials. For instance, the bottom
surface of the pressure pads may be uncovered and configured to be
positioned in direct contact with the moderator sheet while the
surfaces not in contact with the moderator sheet may be covered
with a material that does not attach to the moderator sheet or
other materials in the shoe (e.g., a gel pod with a TPU film
covering).
[0051] The pressure pads may be applied to the pressure moderator
sheet such that the pressure pads are separated from the foot of a
user by the pressure moderator sheet. Thus, the pressure pads may
be attached to the bottom surface of the pressure moderator sheet.
Accordingly, the pressure pads may be attached to the bottom
surface of the overall shoe insert.
[0052] The shoe insert of one embodiment of the invention may
comprise one or more additional components. Such additional
components may be positioned on either the top surface of the
pressure moderator sheet, the bottom surface of the pressure
moderator sheet, or both the top and bottom surfaces of the
pressure moderator sheet.
[0053] In some embodiments, the additional component may be
positioned on the pressure moderator sheet (and thus the shoe
insert) to be present only in discrete areas of the insert. For
example, in some embodiments, the additional component may be
positioned only in one or more of the indentations formed in the
pressure moderator sheet. In particular embodiments, the additional
component may be positioned only in indentations formed in the
pressure moderator sheet on the side of the pressure moderator
sheet opposite the attachment of the pressure pads.
[0054] The additional component can be used to fill all of the
indentations formed on a single side of the pressure moderator
sheet. Thus, the additional component may form a substantially
continuous layer on a single side of the pressure moderator sheet.
The additional component may otherwise form one or more discrete,
non-continuous layers on one or both sides of the pressure
moderator sheet.
[0055] The additional component preferably comprises a material
providing a favorable degree of cushioning. Any material providing
such cushioning may be used, including but not limited to gels,
foams, batting, honeycombed materials, and the like. In specific
embodiments, the additional component may comprise a polyurethane
foam, an ethylene vinyl acetate, a polyethylene, or a blown
silicone. In one embodiment, the polyurethane foam is a thermoset
material with very low densities typical of footwear products.
[0056] A shoe insert according to the invention may be more
specifically described in relation to the various drawings, wherein
specific embodiments are illustrated for the sake of complete
description and are not intended to limit the scope of the
disclosure.
[0057] As seen in the bottom view of FIG. 1, a shoe insert 10
according to the invention can comprise a pressure moderator sheet
20 having a plurality of pressure pads 30, 40, 50, 60, and 70
attached thereto, particularly being positioned in relation to the
ball of the foot of a user when inserted into a shoe. The shoe
insert 10 of the embodiment of FIG. 1 further includes pressure
pads 80 and 90 positioned in relation to the big toe of the foot of
a user and pressure pad 100 positioned in relation to the heel of
the foot of a user. Of course, in other embodiments, the shoe
insert may comprise more or fewer pressure pads, and the pads may
be in different positions. In the presently illustrated embodiment,
the pressure pads are beneficially located to correspond to areas
of the foot that typically undergo the greatest and/or potentially
most damaging pressure on the foot.
[0058] Another embodiment of a shoe insert 10 is illustrated in the
bottom view of FIG. 2, which illustrates a formed pressure
moderator sheet 20. The moderator sheet 20 is particularly formed
to have a plurality of ridges 200 that take on a variety of shapes
and sizes. The moderator sheet 20 is further formed to have a
plurality of indentations 250 that at least partially interlineate
and surround the ridges 200. The illustrated shoe insert also
includes a series of pressure pads. In this embodiment, the
pressure pads are shaped to comprise a series of pad units, each
unit formed of a perimeter pad (30, 40, 50, 60, 70, 80, 90, 100)
surrounding a center pad (35, 45, 55, 65, 75, 85, 95, 105). Of
course, the pressure pad units could be formed of other
combinations of pad components, the different pad components
forming the units varying in number, size, and shape.
[0059] As illustrated in FIG. 2, the pressure pads can be
positioned in a indentation formed in the bottom surface of the
formed pressure moderator sheet. The pressure pad unit formed of
peripheral pad 60 and center pad 65 is illustrated in FIG. 2 with
dashed lines to indicate its absence from the figure. It is thus
shown that the removal of the pads reveals a corresponding portion
of the indentation 250 in which the pads are positioned.
[0060] FIG. 2b provides a cross-section of the shoe insert of FIG.
2 along line A-A. The cross-section shows the relatively thin
profile of the pressure modulator sheet 20 and the construction of
the shoe insert arising from the formed nature of the modulator
sheet. The pressure modulator sheet 20 is formed to have ridges 200
and indentations 250. Residing in one indentation is the pressure
pad unit for the heel area of the shoe insert, specifically
peripheral pressure pad 100 and center pressure pad 105. The outer
edges of the pressure modulator sheet 20 are further formed to have
a three dimensional contour.
[0061] FIG. 3 illustrates a top view of the shoe insert 10 from
FIG. 2. In this view it is apparent how the ridges on a first side
of the pressure moderator sheet 20 correspond to indentations on
the opposing side of the pressure moderator sheet and how the
indentations on the first side of the pressure moderator sheet
correspond to ridges on the opposing side of the pressure moderator
sheet. Specifically, ridges 350 on the top surface of the pressure
moderator sheet 20 correspond to the indentations 250 from FIG. 2,
and indentations 300 on the top surface of the pressure moderator
sheet 20 correspond to ridges 200 from FIG. 2. Ridge 308 is an
expanded ridge that corresponds to the indentation in FIG. 2 where
the pressure pads are positioned. Similarly, ridge 310 is an
expanded ridge that corresponds to the indentation in FIG. 2 where
the pressure pads are located.
[0062] FIG. 4 illustrates a top view of a shoe insert 10 according
to one embodiment of the present invention. The shoe insert
comprises a pressure moderator sheet 20 that is formed to have
surface ridges 350 and indentations (not visible in this view). In
this embodiment, the pressure moderator sheet 20 is clear, and the
pressure pads removable and replaceably attached to the opposing
side of the pressure moderator sheet are visible (shown as dashed
lines). Particularly illustrated are center pressure pads 35, 45,
55, 65, 75, 85, 95, 105 and peripheral pressure pads 30, 40, 50,
60, 70, 80, 90, 100. The shoe insert of this embodiment further
comprises an additional component, which is a polyurethane foam
material 400. The foam material 400 is positioned within the
indentations formed on the top surface of the shoe insert 10, thus
rendering the indentations not visible in this view. The filling of
the indentations is further illustrated in FIG. 4b, which shows a
cross-section of the insert from FIG. 4 along line B-B.
[0063] As seen in FIG. 4b, the pressure modulator sheet 20 again
has a relatively thin profile. The pressure modulator sheet 20 is
formed to have ridges 200 and indentations 250 in the bottom
surface thereof. Ridges 350 are also present on the top surface of
the shoe insert; however, the indentations of the top surface are
filled with the foam material 400. Residing in one indentation in
the bottom surface is the pressure pad unit for the heel area of
the shoe insert, specifically peripheral pressure pad 100 and
center pressure pad 105. As seen in this embodiment, the foam
material (or other coating material) can be specifically positioned
on the shoe insert to separate at least a portion of the pressure
moderator sheet from the foot of a user. The foam material can be
particularly described as a cushioning layer. Such cushioning layer
may cover substantially the entire area of the top surface of the
pressure moderator sheet. In other embodiments, the cushioning
layer may cover only discrete portions of the top surface of the
pressure moderator sheet (e.g., within the indentations 300 on the
top surface of the pressure moderator sheet 20).
[0064] The shoe insert of the present invention can be particularly
characterized by the utilization of the formed pressure modulator,
especially in combination with the series of pressure pads. The use
of padding material at pressure points has been tried for relieving
inordinate foot pressures. The present invention realizes, however,
the ability to evenly distribute pressures on the foot by both
applying beneficial pressure and simultaneously modulating that
pressure. This provides a unique system for providing foot comfort
through the use of a shoe insert.
[0065] This pressure modulation is particularly seen in reference
to the cross-section of FIG. 4b. For example, when pressure pads
100 and 105 are present, downward pressure by a foot in that area
is distributed across the pressure pads themselves. In other words,
there is even pressure distribution across the entire area. In
particular individuals, though, there may arise unnatural pressure
points, such as from an injury, from a deformation, or from an
unnatural gait. The unnatural pressure in the area may be relieved
by removal of one or both of pressure pads 100 and 105. If the foot
was directly interacting with the pressure pads, the removal of one
or both could cause a very unnatural feeling and a could actually
cause increased localized pressure on the foot. The separation of
the pressure pads from the foot, however, by the pressure moderator
sheet evens the change in pressure distribution across the foot
arising from the removal of the pressure pad. For example, if
pressure pad 105 was removed and the pressure moderator sheet was
not present, the foot would easily recognize a "hole" in the shoe
insert, and the uneven pressure in the area could cause injury. The
pressure moderator sheet, though, evens out the pressure changes
such that the decrease in pressure where the pressure pad is absent
is lessened and the increase in pressure where the adjacent
pressure pad is still present is also lessened. Thus, instead of
having to accommodate sharp pressure changes, the removal of the
pressure pad results in a comfortable, reduced pressure zone and
not an uncomfortable, zero pressure zone. This unique system for
pressure moderation is only achieved by embodiments of the present
invention through the combination of the various components as
described herein.
[0066] It should also be noted that, in certain embodiments, a shoe
insert according to the invention may be described as comprising
two layers, three layers, or even more layers. In preferred
embodiments, the shoe insert comprises at least the pressure
moderator sheet. In other embodiments, the shoe insert can comprise
at least the pressure moderator sheet and one or more pressure
pads. Thus, the shoe insert could be described as having two
layers: the pressure moderator sheet and the pressure pad(s). In
still other embodiments, the shoe insert can comprise the pressure
moderator sheet, one or more pressure pads, and an additional
component, such as a foam material. Thus, the shoe insert could be
described as comprising three layers: the pressure moderator sheet,
the pressure pad(s), and the foam material. The cross-section of
FIG. 4b illustrates a three-layer embodiment, wherein the foam
material 400 is the top layer (or cushioning layer), the pressure
moderator sheet 20 is the intermediate layer, and the pressure pads
100, 105 form the bottom layer. Of course, it is recognized that
each individual layer may comprise multiple components (e.g.,
multiple pressure pads or multiple, discrete areas of foam).
Preferably, the pressure moderator sheet is a single component
(i.e., a continuous, solid sheet). Moreover, it is not required
that all three layers be present in all areas of the shoe insert.
For example, in some embodiments, the cushioning layer can be
absent in the area of the pressure moderator sheet overlying the
pressure pads.
[0067] The use of the formed pressure moderator sheet is also
beneficial in that it allows for dynamic printing of graphics on
the shoe insert. For example, the use of a clear TPU pressure
moderator sheet allows for printing on one surface thereof to be
visible on the opposing surface. In some embodiments, the pressure
moderator sheet is provided with desired graphics through use of
water transfer printing techniques. Of course, any printing method
could be used for providing graphics on the shoe insert. Moreover,
decals and printing may be applied to one or both surfaces of the
moderator sheet and printing registration may be employed for
decorating both surfaces of the sheet while being able to view both
graphics from one vantage point.
[0068] Furthermore, the pressure pads and moderator sheet may be
formed of materials and/or configured to reduce noise during use.
In this regard, the pressure pads and/or moderator sheet may be
texturized to reduce if not eliminate noises while a user is
wearing the insert. For example, the pressure pads and/or moderator
sheet may be texturized in specific areas in order to reduce
frictional noise or squeaking between the insert and the interior
of the shoe. In one embodiment, the moderator sheet is texturized
using a micro finish (e.g., ridges and indentations) or mat finish.
For instance, portions of the moderator sheet that are expected to
interface with the shoe could be texturized, such as the sidewall
surfaces of the moderator sheet (i.e., those between the major
opposing surfaces of the moderator sheet), which could include
those surfaces in the region of the arch, heel cup, and/or other
outer edges of the moderator sheet. The moderator sheet could be
texturized using other techniques such as by adding an additional
layer of fabric or other material or adding a lubricant such as
silicone.
[0069] In another embodiment, the removable insert may be adaptable
for use with the iStep.RTM. technology (Aetrex Worldwide, Inc). For
example, the iStep.RTM. technology could be used in order to
customize a removable insert by adding or removing particular
pressure pads that correspond to pressure points indicated by the
iStep.RTM. technology. According to one embodiment, such a method
for detecting pressure areas and customizing an insert is disclosed
in U.S. Pat. No. 7,493,230, which is assigned to the present
assignee and incorporated herein by reference. Thus, a pressure
plate may be employed that is capable of detecting pressure areas
on the sole of a foot, and the insert with removable pressure pads
can be modified to account for and ease high pressure areas on the
sole of the foot. According to one aspect, the pressure plate
includes an array of pressure sensors that detect pressure and
collect data related to areas of high relative pressure in order to
generate a pressure map of the sole of the foot. Such data may be
received from the pressure plate by a computer-based apparatus, and
a display may show data associated with regions of high relative
pressure which correspond to specific removable pressure pads of
the insert. Regions of high relative pressure may be determined by
locating regions exceeding a predetermined relative pressure level
within the pressure map.
[0070] Many modifications and other embodiments of the inventions
set forth herein will come to mind to one skilled in the art to
which these inventions pertain having the benefit of the teachings
presented in the foregoing descriptions. Therefore, it is to be
understood that the inventions are not to be limited to the
specific embodiments disclosed and that modifications and other
embodiments are intended to be included within the scope of the
appended claims. Although specific terms are employed herein, they
are used in a generic and descriptive sense only and not for
purposes of limitation.
* * * * *