U.S. patent application number 14/323188 was filed with the patent office on 2015-01-01 for cushioned orthotic.
The applicant listed for this patent is MSD Consumer Care, Inc.. Invention is credited to Harold A. Howlett, Bin Xia, Philip C. Yang.
Application Number | 20150000159 14/323188 |
Document ID | / |
Family ID | 39040516 |
Filed Date | 2015-01-01 |
United States Patent
Application |
20150000159 |
Kind Code |
A1 |
Howlett; Harold A. ; et
al. |
January 1, 2015 |
CUSHIONED ORTHOTIC
Abstract
An orthotic is disclosed. The orthotic may include a cushioning
layer configured to extend from at least the metatarsal region to
the proximal heel region, the cushioning layer having a heel region
with a protruding heel piece integrally molded as part of the
cushioning layer. The orthotic may also include an outer shell
layer fixedly coupled to the cushioning layer, the outer shell
layer extending longitudinally from at least the medial
cuneiform-first metatarsal joint region to the calcaneus bone
region of the user, the outer shell layer configured to receive the
protruding heel piece.
Inventors: |
Howlett; Harold A.; (Horn
Lake, TN) ; Xia; Bin; (Dublin, OH) ; Yang;
Philip C.; (Memphis, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MSD Consumer Care, Inc. |
Memphis |
TN |
US |
|
|
Family ID: |
39040516 |
Appl. No.: |
14/323188 |
Filed: |
July 3, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13969949 |
Aug 19, 2013 |
8800169 |
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14323188 |
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13101782 |
May 5, 2011 |
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13969949 |
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11524979 |
Sep 21, 2006 |
7958653 |
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13101782 |
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Current U.S.
Class: |
36/44 |
Current CPC
Class: |
A43B 7/144 20130101;
A61B 5/1074 20130101; A61B 5/411 20130101; A61B 2562/046 20130101;
A61B 5/6892 20130101; A61F 5/14 20130101; A43D 999/00 20130101;
A61B 5/1036 20130101; A43B 7/223 20130101; A43B 13/386 20130101;
A43B 13/40 20130101; A43D 1/02 20130101; G06Q 30/06 20130101; A43B
17/023 20130101; A61B 2562/0247 20130101; A43B 17/006 20130101;
A43B 13/38 20130101; A43B 7/142 20130101 |
Class at
Publication: |
36/44 |
International
Class: |
A43B 13/38 20060101
A43B013/38 |
Claims
1. (canceled)
2. An article of manufacture comprising: a display; and a set of
pre-manufactured orthotic removably disposed on the display, the
set of pre, manufactured orthotics including a plurality of
different orthotic models, the plurality of orthotic models
including models with different respective lengths and models with
different respective levels of arch support, wherein the plurality
of orthotic models further comprises a first model with a shortest
length, a softest cushioning layer, and a lowest level of arch
support; a second model with the shortest length, the softest
cushioning layer, and a higher level of arch support; a third model
with the shortest length, a firmer cushioning layer, and the lowest
level of arch support; a fourth model with the shortest length, the
firmer cushioning layer, and the higher level of arch support; a
fifth model with a second length longer than the shortest length,
the softest cushioning layer, and the lowest level of arch support;
a sixth model with the second length, the softest cushioning layer,
and the higher level of arch support; a seventh model with the
second length, the firmer cushioning layer, and the lowest level of
arch support; an eighth model with the second length, the firmer
cushioning layer, and the higher level of arch support; a ninth
model with a third length longer than the second length, the
softest cushioning layer, and the lowest level of arch support; a
tenth model with the third length, the softest cushioning layer,
and the higher level of arch support; an eleventh model with the
third length, the firmer cushioning layer, and the lowest level of
arch support; a twelfth model with the third length, the firmer
cushioning layer, and the higher level of arch support; a
thirteenth model with the longest length, the firmer cushioning
layer, and the lowest level of arch support; a fourteenth model
with the longest length, the firmer cushioning layer, and the
higher level of arch support.
3-18. (canceled)
19. An orthotic comprising: a cushioning layer having a heel region
with a protruding heel piece integrally formed as part of the
cushioning layer; an outer shell layer fixedly coupled to the
cushioning layer, the outer shell layer having a pair of projecting
extensions, having a first end and second end, and embracing an
enclosure defining a aperture therethrough at the heel region.
20. The orthotic of claim 19, further comprising: an inner shell
layer operably attached between the outer shell layer, and the
cushioning layer, the inner shell layer configured to underlie and
support the arch region of the user.
21. An orthotic comprising: a cushioning layer having a heel region
with a protruding heel piece integrally formed as part of the
cushioning layer; and an outer shell layer fixedly attached to the
cushioning layer, the outer shell layer extending longitudinally
from at least the medial cuneiform-first metatarsal joint region to
the talus-navicular region, the outer shell layer having a pair of
projecting extensions on either side of the calcaneus bone region,
and an enclosure defining a aperture therethrough at the heel
region for receiving the protruding heel piece of the cushioning
layer.
22. The orthotic of claim 21, the outer shell layer further having
an upturned medial flange.
23. The orthotic of claim 21, the pair of projecting extensions on
either side of the calcaneus bone region are not joined at the back
of the heel region.
24. The orthotic of claim 21, the pair of projecting extensions on
either side of the calcaneus bone region are joined at the back of
the heel region.
25. The orthotic of claim 21, further comprising an inner shell
insert layer operably attached between the cushioning layer, and
the outer shell layer.
26. The orthotic of claim 21, the foam cushioning layer further
comprising a raised convex protrusion at the distal forefoot region
between the second to fourth metatarsal.
27. (canceled)
28. A set of pre-manufactured cushioned orthotics comprising: a
plurality of orthotics, the orthotics each having a cushioning
layer and an arch support, the plurality of orthotics including
orthotic models having at least two different respective lengths,
orthotic models having at least two different respective levels of
cushioning layer firmness, and orthotic models having at least two
different respective levels of arch support.
29. The set of pre-manufactured cushioned orthotics of claim 28,
wherein at least two orthotic models of the same length have arch
supports of different respective levels.
30. The set of pre-manufactured cushioned orthotics of claim 28,
wherein the different levels of arch support are made of a flexible
polymer with different hardness.
31. The set of pre-manufactured cushioned orthotics of claim 28,
wherein at least two orthotic models of the same length have arch
supports made of different materials.
32. The set of pre-manufactured cushioned orthotics of claim 31,
wherein the arch supports of different materials for an orthotic
model of a particular length are substantially dimensionally
identical.
33. The set of pre-manufactured cushioned orthotics of claim 28,
wherein no orthotics of the longest length have the softest
cushioning layer.
34. The set of pre-manufactured cushioned orthotics of claim 28,
wherein the orthotics include 3/4-length orthotics.
35. The set of pre-manufactured cushioned orthotics of claim 28,
wherein the orthotic models comprise fourteen different models with
at least four different lengths, at least two levels of cushioning
layer firmness, and at least two levels of arch support, wherein
for at least one of the lengths there are at least four models
comprising a first model series with a softest cushioning layer and
lowest level of arch support, a second model series with a softest
cushioning layer and a higher level of arch support, a third model
series with a firmer cushioning layer and a lowest level of arch
support, and a fourth model series with a firmer cushioning layer
and a higher level of arch support.
36. The set of pre-manufactured cushioned orthotics of claim 35,
wherein the orthotic model series comprises of 14 different models,
the models including: a first model with a shortest length, a
softest cushioning layer, and a lowest level of arch support; a
second model with the shortest length, the softest cushioning
layer, and a higher level of arch support; a third model with the
shortest length, a firmer cushioning layer, and the lowest level of
arch support; a fourth model with the shortest length, the firmer
cushioning layer, and the higher level of arch support; a fifth
model with a second length longer than the shortest length, the
softest cushioning layer, and the lowest level of arch support; a
sixth model with the second length, the softest cushioning layer,
and the higher level of arch support; a seventh model with the
second length, the firmer cushioning layer, and the lowest level of
arch support; an eighth model with the second length, the firmer
cushioning layer, and the higher level of arch support; a ninth
model with a third length longer than the second length, the
softest cushioning layer, and the lowest level of arch support; a
tenth model with the third length, the softest cushioning layer,
and the higher level of arch support; an eleventh model with the
third length, the firmer cushioning layer, and the lowest level of
arch support; a twelfth model with the third length, the firmer
cushioning layer, and the higher level of arch support; a
thirteenth model with the longest length, the firmer cushioning
layer, and the lowest level of arch support; a fourteenth model
with the longest length, the firmer cushioning layer, and the
higher level of arch support.
37. An article of manufacture comprising: a display; and a set of
pre-manufactured orthotics removably disposed on the display, the
set of pre-manufactured orthotics including a plurality of
different orthotic models, the plurality of orthotic models
including models with different respective lengths and models with
different respective levels of arch support.
38. The article of manufacture of claim 37, wherein the orthotics
models include a cushioning layer that are made of different
respective levels of cushion firmness.
39. The article of manufacture of claim 37, wherein the different
levels of arch support are provided for different models of
orthotic with the same length by having different arch support
dimensions.
40. The article of manufacture of claim 37, wherein the different
levels of arch support are provided for different models of
orthotics with the same length by using different arch support
materials.
41. The article of manufacture claim 37, wherein the arch supports
for different models with the same length have substantially the
same arch support dimension.
42. The article of manufacture claim 37, wherein the different
levels of arch support are provided for different models of
orthotics with the same length by using different arch support
materials.
43. The article of manufacture claim 42, wherein the arch supports
for different models with the same length have substantially the
same arch support dimension.
44. The article of manufacture claim 37, wherein the orthotics of
different lengths and levels of arch support have substantially
similar external designs.
45. The article of manufacture claim 37, wherein the orthotics
comprise %-length orthotics.
46. The article of manufacture claim 37, wherein the orthotics
models with the same size have substantially the same color
scheme.
47. The article of manufacture claim 37, wherein the orthotics
models with the same support level have substantially the same
color scheme.
48. The article of manufacture claim 37, wherein all components of
the orthotic models having the same length are substantially
dimensionally identical.
Description
FIELD OF THE INVENTION
[0001] The present invention is generally related to footwear
inserts, e.g., orthotics.
BACKGROUND
[0002] Conventional footwear inserts, such as orthotics, are
typically provided to users to meet a particular user's needs. Some
of these needs may include cushioning, arch support, and pronation
control.
[0003] Many known orthotics are intended to be custom-made for a
user. Custom-made orthotics tend to be relatively expensive, and
may require a trip to a special supplier, e.g., a podiatrist, for
measurement and fitting. Custom orthotics may also have relatively
short useful lives. In some situations, making custom orthotics
more durable or providing greater support may also make them
heavier, bulkier, or less comfortable.
[0004] Pre-manufactured orthotics and shoe inserts are also known.
These are typically significantly less expensive than custom
orthotics. Pre-manufactured orthotics and inserts include U.S. Pat.
Nos. 6,286,232, 6,301,805, 6,481,120, and 6,598,321. Some of
pre-manufactured orthotics that provide good support may have poor
cushioning properties. Other inserts that have good cushioning
properties may offer less support. Some of the known orthotics may
have good cushioning and support characteristics but may be
relatively expensive to manufacture. In addition, such
pre-manufactured orthotics are typically offered only in a limited
number of variations, e.g., a single size for men and a single size
for women, to minimize stocking and manufacturing costs. However,
the population of potential purchasers may have a broad range of
preferences for comfort and support.
[0005] While shoe inserts and orthotics with cushioned heels are
known, the inventors of the present application recognized the need
to provide a pre-manufactured orthotic that provides both good
cushioning, particularly in the heel region, while still providing
adequate arch support. At the same time, because the inventors have
focused on mass-produced products, there is a concurrent need to
reduce the number of components and produce orthotics of different
sizes and types using the same components. Accordingly, unlike
previous orthotics that may have had separate elements for heel
cushioning, the inventors of the present application have developed
an orthotic shoe insert where heel cushioning is provided by
integrally molding a protruding heel cushion as part of the overall
cushioning layer of the orthotic. This may provide improved
cushioning while reducing overall manufacturing cost.
[0006] In some previous shoe inserts, hard shell layers have been
used either under the arch area or under the entire shoe insert.
The inventors of the present application have recognized a need to
produce a hard shoe insert shell layer that provides lateral
stability in the heel region at while minimally interfering with
heel cushioning, an important comfort attribute of shoe inserts.
Accordingly, the inventors of the present application have
developed a shoe insert where a pair of projections, which may be
formed as part of the hard supporting shell of the shoe insert,
surround a protruding heel cushion.
[0007] Another issue in mass market pre-manufactured shoe inserts
is to provide a range of products suitable for use by
differently-sized customers. The cost of providing a large number
of sizes (as is commonly done for shoes) may well be prohibitive.
Accordingly features that allow the shoe insert to be used by at
least a range of differently-sized users with differently sized
footwear are desirable. The hard shell projections, described in
the previous paragraph, enhance the ability of an orthotic to be
used in different shoe sizes by provided a limited amount of
compressability in the heel region. Thus a given shoe insert may be
used in both wide and narrow heeled footwear--reducing the number
of models required to adequately fit the majority of the potential
customer population.
[0008] Previous mass-market shoe inserts and orthotics have
generally been provided in only a limited number of sizes and
types. At the same time, to produce a custom model for each
possible set of user requirements, e.g., shoe size, support, and
cushioning, would produce an unwieldy and economically infeasible
number of products to pre-manufacture for mass distribution. One
goal of the inventors of the present application has been to
provide a comfortable pre-manufactured orthotic for a wide range of
potential users, while minimizing the cost and number of
pre-manufactured product that must be provided to satisfy a wide
range of users. Typically, in the past, at most a large and small
model (and/or men's and women's) has been provided for mass market
shoe inserts. The inventors of the present application, based on
empirical analysis of large numbers of users, have found that a set
of orthotics of moderate size may provide suitable choices for a
large fraction of the population. The inventors have found that, in
particular, by varying size, cushioning, and degree of support, a
moderately-sized set of orthotics, e.g., 14, can satisfy the
majority of potential users. Moreover, the number of distinct
components required to produce this range of orthotics can be
significantly reduced by sharing components among the different
models.
[0009] Some prior art orthotics provide adjustable orthotics with
differently dimensioned inserts in order to alter the properties of
the orthotics. However, a problem with differently dimensioned
inserts, is that, for molded plastic products in particularly, each
differently dimensioned component requires an additional expensive
tooling. To help further reduce manufacturing cost while providing
a range of options to suite users with different preferences, the
inventors of the present application have developed identically
molded arch support elements made from different materials. These
components can further increase the range of available products,
satisfying a broader range of customers, while minimizing the
amount of required manufacturing costs. In the orthotic sets
disclosed herein, the arch support elements for different models
with the same length may have substantially the dimension. The
different levels of arch support provided for different models of
orthotics with the same length may be provided using different arch
support materials.
SUMMARY
[0010] Some example orthotics, according to some example
embodiments of the present invention, include cushion orthotics
that provide a balance of support and comfort, while minimizing
manufacturing cost. A cushioning layer may be provided for comfort
and cushioning, while a shell layer provides support and stability.
In particular, by only partly underlying a cushioning layer with a
more rigid support shell, maximum cushioning can be provided in
areas where the support structure is not present, while still
providing support and stability in other areas. For example, it may
be desirable to provide cushioning in the heel region and parts of
the forefoot, while providing arch support in the center of the
foot. The use of a relatively harder arch support insert between
the cushioning layer and the outer shell layer provides additional
arch support which may be easily varied in different versions of
the example orthotic by changing the dimension or properties of the
arch support insert, while minimizing the number of different types
of components required.
[0011] Some example orthotics, according to some example
embodiments of the present invention, have been found particularly
well-suited to being provided with different sizes and different
arch supports. By combining several variations in size and arch
support, an acceptable degree of fit, comfort, and support can be
provided for the vast majority of potential users with only a
limited number of models, e.g., 14 different models. These 14
different models may be provided using only four variants of outer
shell layer, seven variants of the cushioning layer, and eight
variants of an arch support, greatly reducing manufacturing and
inventory costs.
[0012] In some example orthotics, according to some example
embodiments of the present invention, different materials may be
combined for different types of support and cushioning needed for
different foot conditions and in different foot regions, e.g., the
example orthotic may have support for the medial arch, and
cushioning for the heel regions, with or without cushioning at the
forefoot region. In some example orthotics according to some
example embodiments of the present invention, the "cushion" at the
heel region may include an area that covers the entire heel, or
part of the heel region, without being enclosed by the outer shell
layer. In addition, the example orthotic may be constructed so as
to provide optimal support for users performing different
activities.
[0013] One example embodiment of the present invention is an
orthotic. The orthotic may include a covering layer on the top
surface, a foam cushioning layer fixedly coupled to the covering
layer, the foam cushioning layer configured to extend from at least
the proximal metatarsal region to the proximal heel region, the
cushioning layer is at its thinnest at the proximal region,
thickest at the proximal heel region, the cushioning layer having a
protruding heel piece integrally molded as part of the cushioning
layer at the proximal heel region, and an upturned medial flange
extending towards the proximal heel portion, wrapping around to the
opposite lateral side, and tapering towards the distal forefoot
portion. The orthotic may also include an outer shell layer fixedly
coupled to the cushioning layer, the outer shell layer configured
to extend longitudinally from at least the medial cuneiform-first
metatarsal joint region to the calcaneus bone region of the user,
the outer shell layer further having an upturned flange on the
medial side, parallel to the upturned medial flange of the
cushioning layer, an enclosure defining an aperture therethrough at
the heel region, the enclosure configured to receive the integral
protruding heel piece of the cushioning layer, and an inner shell
insert layer operably attached between the cushioning layer and the
outer shell layer, the inner shell insert layer extending from at
least the medial cuneiform-first metatarsal joint region to the
talus-navicular joint region of the user.
[0014] Another example embodiment of the present invention may be
an article of manufacture. The article of manufacture may include a
display and a set of pre-manufactured orthotic removably disposed
on the display, the set of pre-manufactured orthotics including a
plurality of different orthotic models, the plurality of orthotic
models including models with different respective lengths and
models with different respective levels of arch support, wherein
the plurality of orthotic models includes 14 different models, the
models including a first model with a shortest length, a softest
cushioning layer, and a lowest level of arch support; a second
model with the shortest length, the softest cushioning layer, and a
higher level of arch support; a third model with the shortest
length, a firmer cushioning layer, and the lowest level of arch
support; a fourth model with the shortest length, the firmer
cushioning layer, and the higher level of arch support; a fifth
model with a second length longer than the shortest length, the
softest cushioning layer, and the lowest level of arch support; a
sixth model with the second length, the softest cushioning layer,
and the higher level of arch support; a seventh model with the
second length, the firmer cushioning layer, and the lowest level of
arch support; an eighth model with the second length, the firmer
cushioning layer, and the higher level of arch support; a ninth
model with a third length longer than the second length, the
softest cushioning layer, and the lowest level of arch support; a
tenth model with the third length, the softest cushioning layer,
and the higher level of arch support; an eleventh model with the
third length, the firmer cushioning layer, and the lowest level of
arch support; a twelfth model with the third length, the firmer
cushioning layer, and the higher level of arch support; a
thirteenth model with the longest length, the firmer cushioning
layer, and the lowest level of arch support; a fourteenth model
with the longest length, the firmer cushioning layer, and the
higher level of arch support. In addition, for each of the example
orthotic models, the arch supports may be of different levels for
either the inner shell or outer shell layers.
[0015] Another example embodiment of the present invention may be
an orthotic. The orthotic may include a cushioning layer having a
heel region with a protruding heel piece integrally molded as part
of the cushioning layer; and an outer shell layer fixedly couple to
the cushioning layer, the outer shell layer having an enclosure
defining an aperture therethrough at the heel region, the enclosure
configured to receive the protruding heel piece. The orthotic may
also optionally include an inner shell layer operably attached
between the outer shell layer, and the cushioning layer, the inner
shell layer configured to underlie and support the arch region of
the user.
[0016] Another example embodiment of the present invention may be
an orthotic. The orthotic may include a cushioning layer configured
to extend from at least the metatarsal region to the proximal heel
region, the cushioning layer having a heel region with a protruding
heel piece integrally molded as part of the cushioning layer; and
an outer shell layer fixedly coupled to the cushioning layer, the
outer shell layer extending longitudinally from at least the medial
cuneiform-first metatarsal joint region to the calcaneus bone
region of the user, the outer shell layer configured to receive the
protruding heel piece. The orthotic may optionally be 3/4 in length
and extend forward from the outer shell layer. The orthotic may
optionally be full length and extends forward from the outer shell
layer. The orthotic may also optionally include an inner shell
layer operably attached between the outer shell layer, and the
cushioning layer, the inner shell layer configured to underlie and
support the arch region of the user. The inner shell layer may be
configured to extend from at least the medial cuneiform-first
metatarsal joint region to the distal end of the protruding heel
piece. The inner shell layer may be made from a thermoplastic
material, e.g., thermoplastic polyurethane; foamed materials, e.g.
EVA, polyurethane foam; or thermoset materials, e.g., composites.
The cushioning layer may be formed as a hell cup at the proximal
end. The outer shell layer may optionally further include an
upturned flanged on the medial side. The outer shell layer may
further optionally include a plurality of perforations in the mid
portion of the outer shell layer. The perforations in the mid
portion of the outer shell layer may optionally include a plurality
of parallel slots extending from the medial side to the lateral
side.
[0017] Another example embodiment of the present invention may be
an orthotic. The orthotic may include a covering layer on a top
surface; a foam cushioning layer fixedly coupled to the covering
layer, the foam cushioning layer is configured to extend from at
least the proximal metatarsal region to the proximal heel region,
the cushioning layer is thinnest at the distal forefoot region and
thickest at the heel region, the cushioning layer having an
upwardly raised convex protrusion between the second and fourth
metatarsal, the cushioning layer further having a heel region with
a protruding heel piece integrally formed as part of the foam
cushioning layer, the protruding heel piece supporting the entire
heel region and an upturned medial flange extending towards the
proximal heel portion, wrapping around to the opposite lateral
side, and tapering towards the distal forefoot portion. The
orthotic may also include an outer shell layer fixedly coupled to
the foam cushioning layer, the outer shell layer is configured to
extend longitudinally from at least the medial cuneiform-first
metatarsal joint region to the talus-navicular bone region,
extending on either side around the calcaneus bone portion, the
outer shell layer at the calcaneus bone region cut out to form an
enclosure defining an aperture therethrough for receiving the
protruding heel piece, the outer shell layer extending on either
side of the calcaneus region a pair of projecting extensions having
a first end and a second end, the projecting extensions embracing
the heel piece on either side with the first end and the second end
terminating just behind the heel region, the outer shell layer
further having an upturned medial flange, parallel to the upturned
flange of the cushioning layer; and an inner shell insert layer
operably attached between the cushioning layer and the outer shell
layer, the inner shell insert layer extending from at least the
medial cuneiform-first metatarsal joint region to the
talus-navicular joint region of the user.
[0018] Another example embodiment of the present invention may be
an orthotic. The orthotic may include a cushioning layer having a
heel region with a protruding heel piece integrally formed as part
of the cushioning layer; an outer shell layer fixedly coupled to
the cushioning layer, the outer shell layer having a pair of
projecting extensions, having a first end and second end, and
embracing an enclosure defining an aperture therethrough at the
heel region. The orthotic may also optionally include an inner
shell layer operably attached between the outer shell layer, and
the cushioning layer, the inner shell layer configured to underlie
and support the arch region of the user.
[0019] Another example embodiment of the present invention may be
an orthotic. The orthotic may include a cushioning layer having a
heel region with a protruding heel piece integrally formed as part
of the cushioning layer; and an outer shell layer fixedly attached
to the cushioning layer, the outer shell layer extending
longitudinally from at least the medial cuneiform-first metatarsal
joint region to the talus-navicular region, the outer shell layer
having a pair of projecting extensions on either side of the
calcaneus bone region, and an enclosure defining an aperture
therethrough at the heel region for receiving the protruding heel
piece of the cushioning layer. The outer shell layer may have an
upturned medial flange. The outer shell layer may extend to form a
pair of projecting extensions on either side of the calcaneus bone
region may not be joined at the back of the heel region.
Alternatively, the pair of projecting extensions on either side of
the calcaneus bone region may be joined at the back of the heel
region. The orthotic may also optionally include an inner shell
insert layer operably attached between the cushioning layer, and
the outer shell layer. The foam cushioning layer of the orthotic
may include a raised convex protrusion at the distal forefoot
region between the second to fourth metatarsal.
[0020] Another example embodiment of the present invention may be
an orthotic. The orthotic may include a covering layer on a top
surface; a foam cushioning layer fixedly coupled to the covering
layer, the foam cushioning layer is configured to extend from at
least the proximal metatarsal region to the proximal heel region,
the cushioning layer is thinnest towards the distal forefoot region
and thickest at the heel region, the cushioning layer having an
upwardly raised convex protrusion between the second and fourth
metatarsal, the cushioning layer further having a heel region with
a protruding heel piece integrally formed as part of the foam
cushioning layer, the protruding heel piece supporting the entire
heel region and an upturned medial flange extending towards the
proximal heel portion, wrapping around to the opposite lateral
side, and tapering towards the distal forefoot portion. The
orthotic may also include an outer shell layer fixedly coupled to
the foam cushioning layer, the outer shell layer is configured to
extend longitudinally from at least the medial cuneiform-first
metatarsal joint region to the talus-navicular bone region,
extending on either side around the calcaneus bone portion, the
outer shell layer at the calcaneus bone region cut out to form an
enclosure defining an aperture therethrough for receiving the
protruding heel piece, the outer shell layer extending on either
side of the calcaneus region a pair of projecting extensions having
a first end and a second end, the projecting extensions embracing
the heel piece on either side with the first end and the second end
joined at the heel region, the outer shell layer further having an
upturned medial flange, parallel to the upturned flange of the
cushioning layer; and an inner shell insert layer operably attached
between the cushioning layer and the outer shell layer, the inner
shell insert layer extending from at least the medial
cuneiform-first metatarsal joint region to the talus-navicular
joint region of the user.
[0021] Another example embodiment of the present invention may be a
set of pre-manufactured cushioned orthotics. The set of
pre-manufactured cushioned orthotics may include a plurality of
orthotics, the orthotics each having a cushioning layer and an arch
support, the plurality of orthotics including orthotic models
having at least two different respective lengths, orthotic models
having at least two different respective levels of cushioning layer
firmness, and orthotic models having at least two different
respective levels of arch support. The set of pre-manufactured
cushioned orthotics may include at least two orthotic models of the
same length that have arch supports of different respective levels.
The set of pre-manufactured cushioned orthotics having different
levels of arch support may be made of a flexible polymer with
different hardness. The set of pre-manufactured cushioned orthotics
may include at least two orthotic models of the same length having
arch supports made of different materials. The set of
pre-manufactured cushioned orthotics may include arch supports of
different materials for an orthotic model of a particular length
that may be substantially dimensionally identical. The set of
pre-manufactured cushioned orthotics of the longest length may omit
the softest cushioning layer. The set of pre-manufactured cushioned
orthotics may optionally include 3/4-length orthotics. The set of
pre-manufactured cushioned orthotics may include orthotic models
having fourteen different models with at least four different
lengths, at least two levels of cushioning layer firmness, and at
least two levels of arch support. For at least one of the lengths,
there may be at least four models which may include a first model
series with a softest cushioning layer and lowest level of arch
support, a second model series with a softest cushioning layer and
a higher level of arch support, a third model series with a firmer
cushioning layer and a lowest level of arch support, and a fourth
model series with a firmer cushioning layer and a higher level of
arch support. The set of pre-manufactured cushioned orthotics may
include the orthotic model series having 14 different models, the
models may have a first model with a shortest length, a softest
cushioning layer, and a lowest level of arch support; a second
model with the shortest length, the softest cushioning layer, and a
higher level of arch support; a third model with the shortest
length, a firmer cushioning layer, and the lowest level of arch
support; a fourth model with the shortest length, the firmer
cushioning layer, and the higher level of arch support; a fifth
model with a second length longer than the shortest length, the
softest cushioning layer, and the lowest level of arch support; a
sixth model with the second length, the softest cushioning layer,
and the higher level of arch support; a seventh model with the
second length, the firmer cushioning layer, and the lowest level of
arch support; an eighth model with the second length, the firmer
cushioning layer, and the higher level of arch support; a ninth
model with a third length longer than the second length, the
softest cushioning layer, and the lowest level of arch support; a
tenth model with the third length, the softest cushioning layer,
and the higher level of arch support; an eleventh model with the
third length, the firmer cushioning layer, and the lowest level of
arch support; a twelfth model with the third length, the firmer
cushioning layer, and the higher level of arch support; a
thirteenth model with the longest length, the firmer cushioning
layer, and the lowest level of arch support; a fourteenth model
with the longest length, the firmer cushioning layer, and the
higher level of arch support.
[0022] Another example embodiment of the present invention may be
an article of manufacture. The article of manufacture may include a
display; and a set of pre-manufactured orthotic removably disposed
on the display, the set of pre-manufactured orthotics including a
plurality of different orthotic models, the plurality of orthotic
models including models with different respective lengths and
models with different respective levels of arch support. The
article of manufacture may optionally include orthotics models
having a cushioning layer made of different respective levels of
cushion firmness. The article of manufacture may include orthotic
models having different levels of arch support for different models
of orthotic with the same length by having different arch support
dimensions. The different levels of arch support for different
models of orthotics with the same length may use different arch
support materials. The arch supports for different models with the
same length may have substantially the same arch support dimension.
The different levels of arch support provided for different models
of orthotics with the same length may use different arch support
materials. The arch supports for different models with the same
length may have substantially the same arch support dimension.
[0023] The article of manufacture may optionally include orthotics
of different lengths and levels of arch support having
substantially similar external designs. The article of manufacture
may include orthotics that may be 3/4-length orthotics. The article
of manufacture may include orthotics models with the same size
having substantially the same color scheme. The article of
manufacture may also include orthotics models with the same support
level having substantially the same color scheme. The article of
manufacture may optionally include all components of the orthotic
models having the same length substantially dimensionally
identical.
BRIEF DESCRIPTION OF DRAWINGS
[0024] FIG. 1 depicts the framework of a typical human foot.
[0025] FIG. 2 depicts a bottom view of an example orthotic,
according to an example embodiment of the present invention.
[0026] FIG. 3 depicts an exploded view of the example orthotic,
according to the example embodiment of the present invention.
[0027] FIG. 4 depicts an isometric bottom perspective of the
example orthotic, according to the example embodiment of the
present invention.
[0028] FIG. 5 depicts a medial side view of the example orthotic,
according to the example embodiment of the present invention.
[0029] FIG. 6 depicts an outer shell of the example orthotic,
according to the example embodiment of the present invention.
[0030] FIG. 7 depicts an inner shell layer of the example orthotic,
according to the example embodiment of the present invention.
[0031] FIG. 8 depicts a top view of the example orthotic, according
to the example embodiment of the present invention.
[0032] FIG. 9 depicts a distal top view of the example orthotic,
according to the example embodiment of the present invention.
[0033] FIG. 10 depicts an outer shell layer of a second example
orthotic, according to an alternative example embodiment of the
present invention.
[0034] FIG. 11 depicts a bottom and a top perspective of the second
example orthotic, according to the alternative example embodiment
of the present invention.
[0035] FIG. 12 depicts a third example orthotic, according to a
second alternative example embodiment of the present invention.
[0036] FIG. 13 depicts a bottom and a top perspective of the third
example orthotic, according to the second alternative example
embodiment of the present invention.
[0037] FIG. 14 depicts a bottom and a top perspective of a fourth
example orthotic, according to a third alternative example
embodiment of the present invention.
[0038] FIGS. 15A and 15B depicts the bottom perspectives of a fifth
and sixth example orthotics, according to a fourth alternative
example embodiment of the present invention.
[0039] FIG. 16A illustrates an example display set of orthotics of
the pre-manufactured model orthotics, according to an example
embodiment of the present invention.
[0040] FIG. 16B illustrates an example display set of
pre-manufactured orthotics, according to an example embodiment of
the present invention.
[0041] FIG. 17 illustrates an example display including the example
display set of pre-manufactured orthotics, according to an example
embodiment of the present invention.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0042] FIG. 1 depicts the bone framework of a typical human right
foot. The view depicts the various directional orientations. The
distal axis 101 points away from the point of attachment of the
foot to the rest of body, the toes being located in the distal
direction from the heel. The proximal axis 103 is the opposite of
the distal axis 101, i.e., the heels are in the proximal direction
from the toes. The medial axis 105 points to the inner side of the
body, towards the opposite foot. The lateral axis 106 is opposite
the medial axis 105, and points to the peripheral side of the body.
The medial side is the inner side of the foot, while the lateral
side is the outside region of the foot, opposite to the medial
side. The distal end of the foot, the forefoot, includes the five
metatarsal bones 201, along with the phalanges 202 that are the
bones of the toes or digits. The midfoot, or the arch region, is
formed by five of the seven tarsal bones (not shown), the navicular
203, cuboid 204, the medial cuneiform bone (not shown), the
intermediate cuneiform bone 205, and lateral cuneiform bone 206.
The midfoot is joined to the forefoot by the tarsometatarsal joints
(not shown). The talus 207 and calcaneus 208 bones at the proximal
end of the foot make up the hind foot. The calcaneus bone 208
articulates with the cuboid bone 204 to form the calcaneocuboid
joint, while the talus bone 207 articulates with the navicular bone
203 forming the talonavicular joint. The proximal part of the
calcaneus 208 has a large round projection, the calcaneal
tuberosity 209, which forms the back of the heel.
[0043] FIG. 2 depicts a bottom view of an example orthotic,
according to an example embodiment of the present invention. The
example shown is for a left foot orthotic. It will be appreciated
that the right foot orthotic may be a mirror image along the
centerline axis 100. FIG. 2 shows the orientations of the example
orthotic in relation to a user's left foot. The example orthotic
may be shaped so as to be inserted as an insole in a typical shoe.
The orthotic may extend from the distal end 502 to the proximal end
503. The proximal portion of the orthotic lies generally below the
heel of the user, with the proximal end 503 generally being
slightly behind the proximal end of the bottom of the user's foot.
The example orthotic depicted in FIG. 2 may be configured to be
"%-length". The distal portion of the example orthotic is
configured to lie generally beneath the metatarsals of the user,
when the orthotic is worn in the user's shoe. However, it will be
appreciated that the exact location of the distal end 502 of the
orthotic with respect to the user's foot when the orthotic is in
use may vary depending on the length of the user's foot. It will
also be appreciated that a full-length orthotic extending under or
past the user's toes may also be provided. Alternatively, a shorter
or a "1/2 length" orthotic, without a heel region, or with a
smaller heel region, may be provided. When inserted, the medial
portion of the orthotic is configured to lie generally below the
medial side of the user's foot, with the medial edge of the
orthotic being outside the medial edge of the bottom of the user's
foot. Similarly, the lateral portion of the orthotic lies generally
below the lateral side of the user's foot, with the lateral edge of
the orthotic slightly outside the lateral edge of the bottom of the
user's foot.
[0044] The example orthotic illustrated in FIG. 2 may include at
least two layers: an outer shell layer 301, and the molded
cushioning layer 501. It will be appreciated that because of the
perspective view in FIG. 2, only the perimeter, the distal, and
part of the proximal portions of the molded cushioning layer are
visible. The molded cushioning layer may have a protruding heel
piece 508. The protruding heel piece 508 extends from the main body
of the cushioning layer, so that, in the region where the heel
piece 508 is present, the bottom surface of the heel piece forms
the bottom surface of the orthotic. It will be appreciated that the
heel piece need not protrude so far as to extend past the bottom
line formed by the bottom surface of the main body of the outer
shell layer 301, although in some alternative configurations, a
more pronounced extension of the heel portion may be desirable.
[0045] The molded cushioning layer 501 of the example orthotic may
be configured so that the distal end 502 extends underneath at
least the metatarsal bone region of a user wearing the orthotic.
The heel region of the example orthotic may extend, at its proximal
end 503 to at least under the heel region of a user wearing the
orthotic. It will be appreciated that the example orthotic may
alternatively be provided as a full-length variant. The full-length
orthotic may extend from under the phalanges of the user to under
the heel of the user's foot. The width of the example orthotic may
be broadest at the distal end 502. The width of the example
orthotic gradually tapers towards the proximal end 503. It will
also be appreciated that other cushioning configurations may be
employed, e.g., cushions may be provided at only a portion of the
orthotic, such as the heel region.
[0046] The outer shell layer 301 in FIG. 2, described more fully
below, may be manufactured from rigid plastic material. The outer
shell layer 301 may provide a relatively rigid support for the
foot, particularly at the arch region. The outer shell layer 301
may be configured to extend longitudinally from at least the medial
cuneiform-first metatarsal joint region to the calcaneus bone
region of the user, when the orthotic is in use. The outer shell
layer 301 has a top surface and a bottom surface. The top surface
of the outer shell layer 301 may be operably attached to the bottom
surface of the molded cushioning layer 501 by gluing the top
surface of the outer shell layer 301 to the bottom surface of the
molded cushioning layer 501. It will be appreciated that, as an
alternative, the outer shell layer 301 may be operably attached to
the molded cushioning layer 501 by use of other adhesives, heat,
pressure, welding, etc., with or without an inner shell layer
described at below.
[0047] FIG. 3 depicts an exploded view of an example orthotic,
according to an example embodiment of the present invention. The
inner shell layer 401 is operably aligned and attached to the
molded cushioning layer 501. The molded cushioning layer 501 has an
impression 510 that may be similar in shape to the inner shell
layer 401. The inner shell layer 401 may be operably attached to
the molded cushioning layer 501 with or without a thermoplastic
polyurethane film in between the two layers. The outer shell layer
301 may have a receiving enclosure 302 shown in the top panel of
FIG. 3. The outer shell layer 301 may be placed over the inner
shell layer 401 and the molded cushioning layer 501. The molded
cushioning layer may have an impression 511 that has a similar
shape as the outer shell layer 301 and is configured to receive the
outer shell layer 301. The edge of the receiving enclosure 302 may
define an aperture through the outer shell layer 301. A pair of
projecting extensions 305 on either side of the outer shell layer
may embrace the outside edges of the heel piece 508. The molded
cushioning layer may have an impression 512 similar to that of the
projecting extensions. The ends of the projecting extensions 305 at
back of the heel piece 508 need not be joined at the back end of
the heel region, although they may be.
[0048] The different layers of the example orthotic may be operably
attached to each other by gluing the layers together as depicted in
FIG. 3 by first operably attaching the inner shell insert layer 401
to the molded cushioning layer 501. The outer shell layer 301 may
then be attached to the inner shell insert layer/cushioning layer
complex. The layers described above may be operably attached to
each successive layer by use of an adhesive, heat, pressure,
microwave, radiation, and other conventional methods.
[0049] FIG. 4 depicts an isometric perspective view of the bottom
of the example orthotic, according to an example embodiment of the
present invention as described in FIGS. 2 and 3 above. The example
orthotic shown may have an outer shell layer 301, and a molded
cushioning layer 501 having a protruding heel piece 508.
[0050] FIG. 5 depicts a right side view of the example orthotic
according to the example embodiment of the present invention. FIG.
5 shows the molded cushioning layer 501 and the outer shell layer
301 of a left foot orthotic viewed from the right side. The molded
cushioning layer 501 at the medial side of the orthotic forms an
upturned flange 505 that is parallel to the upturned medial flange
of the outer shell layer 309. The outer shell layer 301 may have a
pair of curve ribs 310 along the medial side of the upturned medial
flange 505. At the proximal end, the protruding heel piece 508 of
the molded cushioning layer 501 protrudes through a receiving
enclosure defining an aperture through the outer shell layer 301,
so as to be approximately flush with the bottom surface of outer
shell layer 301 that is adjacent the aperture.
[0051] FIG. 6 depicts a bottom view of an example outer shell
layer, according to the example embodiment of the present
invention. The outer shell layer 301 may be configured to extend
longitudinally from at least the medial cuneiform-first metatarsal
joint region to the calcaneus bone region of a user, when the
orthotic is in use.
[0052] The example outer shell layer 301 may be constructed from a
thermoplastic olefin polymer that may be stiff and flexible, e.g.,
polyethylene, polypropylene, polyurethane, or elastomers, or a
combination of thermoplastic polyurethane and
acrylonitrile-butadiene-styrene. One example may be UH-64D20
thermoplastic polyurethane (TPU) from Ure-tech Company, Cheng-Hwa
Hsien, Taiwan, Republic of China. Table I, below, includes entries
for example outer shell layers for a set of 14 different models of
the example orthotic. Each model may have a slightly different
thickness and weight. For various models, different polyurethanes
may be employed, having different Shore hardness levels which are
shown in column 4 of Table I. The higher the Shore hardness number,
the greater the resistance to an indenter.
TABLE-US-00001 TABLE I Specification of Example Orthotics for the
Outer Shell Layer 301 Outer Shell Layer Product Nos. Weight (g)
Thickness (mm) Hardness (Duro) 1 8.6 .+-. 1.0 1.1 .+-. 0.2 95 .+-.
5 Shore A 2 10.1 .+-. 1.0 1.3 .+-. 0.2 95 .+-. 5 Shore A 3 13.0
.+-. 1.0 1.4 .+-. 0.2 95 .+-. 5 Shore A 4 8.6 .+-. 1.0 1.1 .+-. 0.2
95 .+-. 5 Shore A 5 10.1 .+-. 1.0 1.3 .+-. 0.2 95 .+-. 5 Shore A 6
13.0 .+-. 1.0 1.4 .+-. 0.2 95 .+-. 5 Shore A 7 8.6 .+-. 1.0 1.1
.+-. 0.2 64 .+-. 5 Shore D 8 10.1 .+-. 1.0 1.3 .+-. 0.2 64 .+-. 5
Shore D 9 13.0 .+-. 1.0 1.4 .+-. 0.2 64 .+-. 3 Shore D 10 15.1 .+-.
1.0 1.5 .+-. 0.2 64 .+-. 5 Shore D 11 8.6 .+-. 1.0 1.1 .+-. 0.2 64
.+-. 5 Shore D 12 10.1 .+-. 1.0 1.3 .+-. 0.2 64 .+-. 5 Shore D 13
13.0 .+-. 1.0 1.4 .+-. 0.2 64 .+-. 5 Shore D 14 15.1 .+-. 1.0 1.5
.+-. 0.2 64 .+-. 5 Shore D
[0053] As shown in Table I, column 4, the outer shell layer 301 may
be configured from a thermoplastic polyurethane having a Shore
hardness of about 95.+-.5 Shore A to about 64.+-.5 Shore D. The
thickness of the outer shell layer 301 may range from about 0.9 mm
to about 1.7 mm. (See, column 3). The outer shell layer 301 may
weigh from about 7 g to about 16 g (See, column 2). The outer shell
layer 301 may be made from polyurethane of different base colors,
e.g., red, blue, green, yellow, and combinations of colors. The
colors may be chosen to indicate the various models.
[0054] The proximal or rear portion of the outer shell layer 301
may be configured to form a receiving enclosure 302 defining an
aperture through the outer shell layer 301 for receiving an
integrally molded protruding heel piece 508 of the molded
cushioning layer 501. The receiving enclosure 302 of the outer
shell layer 301 may be configured such that the main body of the
outer shell layer 301 terminates at the distal end 304. The
receiving enclosure 302 may curve upwards towards the lateral side
to form a "spur" 307. It will be appreciated that the receiving
enclosure 302 may be an aperture through the outer shell layer 301,
the receiving enclosure encompasses the entire portion of the heel
region. Alternatively, the receiving enclosure 302 may encompass
just the center of the heel region of the cushioning layer, with
the projecting portion of the heel region occupying only a portion
of the total area of the heel region.
[0055] The outer shell layer 301 continues to extend as projecting
extensions 305 on both sides of the orthotic towards the back of
the heel region to embrace the protruding heel piece 508 of the
molded cushioning layer 501. It will be appreciated that the ends
of the projecting extensions 305 need not be joined at the back of
the heel region, leaving a "gap" 306 between the ends of the
projecting extensions 305. The molded cushioning layer 501 may have
an exposed area or "gap" 306 at the back of the heel region where
the heel region of the cushioning layer is not covered by the
projecting extensions 305. However, it will be appreciated that,
alternatively, the projecting extensions 305 may be joined at the
back of the heel region to form a fully enclosed region for
receiving the heel piece.
[0056] As depicted in FIG. 6, the outer shell layer 301 may have a
plurality of perforations, e.g., a series of slots 308, in the mid
portion of the outer shell layer 301. The slots 308 may be located
just behind the cuneiform-first metatarsal joint region to the
talus-navicular joint region of the user. The slots may be
generally parallel to each other. The slots may extend from the
medial to the lateral sides of the orthotic. It will be appreciated
that, as an alternative, the series of parallel slots may extend
diagonally from the medial to the lateral side. Alternatively, the
perforations may include a plurality of circular perforations, or a
series of wave-like perforations with a generally sinusoidal shape.
It will be appreciated that the perforations at the mid portion are
not limited to a series of parallel slots, circular or wave-like
perforations. It will be appreciated that, alternatively, the outer
shell layer 301 may be a continuous piece without any perforations
at the mid portion.
[0057] On the medial side of the orthotic, the outer shell layer
301 may be configured to have a medial flange 309. The medial
flange 309 may turn upwards towards the molded cushioning layer
501. The medial flange 309 may provide support for the arch region
of the user's foot and may serve to prevent pronation of the foot.
The medial flange 309 of the outer shell layer 301 may have a pair
of curved ribs 310 along the sides.
[0058] FIG. 7 depicts an example embodiment of the inner shell
layer 401 of the example orthotic for the left foot. The inner
shell layer 401 may be shaped like a truncated version of the outer
shell layer 301. The inner shell layer 401 may extend
longitudinally from at least the medial cuneiform-first metatarsal
joint region at the distal end 402 to the proximal end 403. The
proximal end 403 of the inner shell layer 401 may abut at least the
distal edge 304 of the heel piece where the receiving enclosure 302
of the outer shell layer begins. (See, FIG. 6 above) The inner
shell layer 401 may be curved at the medial side. The inner shell
layer 401 may be broader at the distal end 402 than at the proximal
end 403. The inner shell layer 401 may provide further support for
the bottom of the longitudinal arch region (heel to toe) of the
foot by providing more rigidity and a spring component to the
orthotic.
[0059] The inner shell layer 401 may be a molded piece of
thermoplastic polyurethane, e.g., Dylon A 9500S from Dahin Co.
Ltd., Taipei, Taiwan, Republic of China, having a top surface, and
a bottom surface. The inner shell layer 401 may be operably
inserted and attached between the outer shell layer 301, and the
molded cushioning layer 501. Top surface of the inner shell layer
401 may be operably attached to the bottom surface the molded
cushioning layer 501, with or without a thermoplastic polyurethane
film. The bottom surface of the inner shell layer 401 may be
operably attached to the top surface of the outer shell layer 301,
with or without a thermoplastic polyurethane film.
[0060] The inner shell layer 401 of the example orthotic in the
example embodiment of FIG. 7 may be constructed from a stiff,
flexible fiberglass material or olefin polymer, e.g., polyethylene,
polypropylene, polyurethane, or elastomer. The inner shell layer
may also be constructed using acrylonitrile-butadiene-styrene or a
combination of thermoplastic polyurethane and
acrylonitrile-butadiene-styrene. The inner shell layer 401 may be
constructed from thermoplastic polyurethane having a range of
different Shore hardness. Examples of the inner shell layer 401 are
shown in Table II. The entries in Table II correspond to the same
14 example orthotic models previously described in Table I.
TABLE-US-00002 TABLE II Specification of Example Orthotics for the
Inner Shell Layer 401 Inner Shell Layer 401 Product Nos. Weight (g)
Thickness (mm) Hardness (Duro) 1 3.4 .+-. 0.5 1.0 .+-. 0.2 95 .+-.
5 Shore A 2 4.5 .+-. 0.5 1.1 .+-. 0.2 95 .+-. 5 Shore A 3 5.0 .+-.
0.5 1.1 .+-. 0.2 95 .+-. 5 Shore A 4 3.4 .+-. 0.5 1.0 .+-. 0.2 64
.+-. 5 Shore D 5 4.5 .+-. 0.5 1.1 .+-. 0.2 64 .+-. 5 Shore D 6 5.0
.+-. 0.5 1.1 .+-. 0.2 64 .+-. 5 Shore D 7 3.4 .+-. 0.5 1.0 .+-. 0.2
95 .+-. 5 Shore A 8 4.5 .+-. 0.5 1.1 .+-. 0.2 95 .+-. 5 Shore A 9
5.0 .+-. 0.5 1.1 .+-. 0.2 95 .+-. 5 Shore A 10 5.8 .+-. 0.5 1.1
.+-. 0.2 95 .+-. 5 Shore A 11 3.4 .+-. 0.5 1.0 .+-. 0.2 64 .+-. 5
Shore D 12 4.5 .+-. 0.5 1.1 .+-. 0.2 64 .+-. 5 Shore A 13 5.0 .+-.
0.5 1.1 .+-. 0.2 64 .+-. 5 Shore A 14 5.8 .+-. 0.5 1.1 .+-. 0.2 64
.+-. 5 Shore A
[0061] Table II provides information for the inner shell layers of
14 example model orthotics. The inner shell layers of the example
models have at least two different types of Shore hardness, e.g.
the inner shell layer may have a Shore hardness of 95.+-.5 Shore A.
Alternatively, the inner shell layer may have a Shore hardness of
64.+-.5 Shore D. All of the example inner shell layers are made
from thermoplastic polyurethane. In some models, the inner shell
has the same hardness as the corresponding outer shell layer, while
in other models, the inner shell is harder or softer than the
corresponding outer shell layer. The thickness of the example inner
shell layers may vary from about 0.8 mm to about 1.4 mm. The weight
of the inner shell layer 401 may be about 2.9 g to about 6.3 g.
[0062] FIG. 8 depicts a top perspective view of the example
orthotic, according to an example embodiment of the present
invention. It will be appreciated that because this is a top
perspective view, only the molded cushioning layer 501 and one of
the projecting extensions 305 of the outer shell layer 301 at the
heel region are visible. It will be appreciated that the molded
cushioning layer 501 may provide support and comfort to the feet.
The molded cushioning layer 501 may be constructed from a foamed
material that is relatively resilient to stress and light in
weight. The foamed material may be deformable when stressed, e.g.,
when the foot strikes during ambulation, and yet have sufficient
memory to return to its original state. The molded cushioning layer
501 may also be constructed from thermoplastic olefin polymer,
e.g., polyethylene, polypropylene, polyurethane, or elastomer. For
example, a cast urethane foam which is a mixture of isocyanate,
polyol, pigments, and stabilizer may be employed, e.g., SR-1088 A/B
with a 1:3.6 mixing ratio, from the Praise Victor Industrial Co.,
Ltd. of Taichung Taiwan. The example foam may be chosen to have a
minimum tear strength of approximately 10 lb/in. Other cushioning
materials include graphite, closed-cell polyethylene foams, or
opened-cell polyethylene foams. Other suitable examples of
closed-cell polyethylene foams include Plastizote, Enduro.TM.,
Super-All-Step or Korex. The molded cushioning layer 501 of the
example orthotic may be an integral piece molded from a single
material or a multi-laminate constructed by using multiple layers
of the same or different types of material. By integral, it is
meant to imply that the molded cushioning layer of the example
orthotic is molded as a single continuous unit with no divided
parts.
[0063] Table III provides additional data for fourteen example
models of the example orthotic. The example entries in Table III
correspond to the same models that were described in Tables I &
II. Exemplary lengths of the example orthotic measured along the
centerline axis 100, may be about 160 mm to about 220 mm. (See,
Table III, column 3). The heel thickness is measured at the center
of the heel of the cushioning layer, approximately 38 mm from the
back of the insole heel on the centerline. The insole length is
measured along the centerline. The cushioning layer weight is the
weight of the molded cushioning layer without the shells. The heel
thickness may be about 5 mm to about 10 mm when measured at the at
the center of the heel of the cushioning layer and may vary between
38-40 mm from the back of the orthotic of the centerline 100,
depending on the particular model).
TABLE-US-00003 TABLE III Specification of Example Orthotics
Cushioning Layers Heel Thickness Insole Length Cushioning Product
Nos. (mm) (mm) Layer Weight (g) 1 7.5 .+-. 1.0 172 .+-. 5.0 26.5
.+-. 3 2 8.0 .+-. 1.0 182 .+-. 5.0 30.5 .+-. 3 3 8.0 .+-. 1.0 194
.+-. 5.0 35.5 .+-. 3 4 7.5 .+-. 1.0 172 .+-. 5.0 26.5 .+-. 3 5 8.0
.+-. 1.0 182 .+-. 5.0 30.5 .+-. 3 6 8.0 .+-. 1.0 194 .+-. 5.0 35.5
.+-. 3 7 7.5 .+-. 1.0 172 .+-. 5.0 31.5 .+-. 3 8 8.0 .+-. 1.0 182
.+-. 5.0 37.5 .+-. 3 9 8.0 .+-. 1.0 194 .+-. 5.0 42.5 .+-. 3 10 8.4
.+-. 1.0 208 .+-. 5.0 47.5 .+-. 3 11 7.5 .+-. 1.0 172 .+-. 5.0 31.5
.+-. 3 12 8.0 .+-. 1.0 182 .+-. 5.0 37.5 .+-. 3 13 8.0 .+-. 1.0 194
.+-. 5.0 42.5 .+-. 3 14 8.4 .+-. 1.0 208 .+-. 5.0 47.5 .+-. 3
[0064] It will be appreciated that, as an alternative, the example
orthotic may be configured to extend the entire length of the foot,
from the forefoot region starting from the distal phalanges region
to the hind foot region. Alternatively, the example orthotic may be
configured from the middle, or proximal phalanges region to the
distal part of the hind foot region, rather than completely under
the user's heel.
[0065] The width of the example orthotic depicted in FIG. 8 is
broadest at the distal end 502, and it gradually tapers towards the
proximal end 503 to "cup" around the heel region of the user's
foot. The depression around the heel region forms the heel cup 507.
The heel cup 507 may provide support to the calcaneus bone region.
The thickness of the cushioning layer 501 is thinnest at the distal
end 502, and is about 0.5 mm to about 2 mm. The thickness of the
cushioning layer 502 of the example orthotic gradually increases
from the distal end 502 to the heel region at the proximal end 503,
where it is at its thickest.
[0066] The cushioning layer 501 at the heel region extends
downwards towards the bottom to form an integrally molded
protruding heel piece 508. The protruding heel piece 508 may extend
downwards into the receiving enclosure 302 of the outer shell layer
301. By integrally molded, it is understood that the protruding
heel piece is formed as a single continuous extension from the
molded cushioning layer 501. It will also be appreciated that the
protruding heel piece 508 may alternatively be attached as a
separate piece at the heel region, rather than being integrally
formed as part of the cushioning layer. The heel piece 508 may be
of any shape, e.g., it may be a round-, square-, oval-, or
oblong-shaped piece. The heel piece 508 may also be U-shaped,
C-shaped, or 3/4-crescent-shaped piece with one end of the crescent
slightly longer than the other to form a "spur" 307 at the lateral
side. Both the heel piece 508 and the heel cup 507 may provide
support for the entire calcaneus bone region. Alternatively, the
heel piece 508 and the heel cup 507 may provide support to the
central part of the calcaneus bone region.
[0067] FIG. 8 also shows that the molded cushioning layer 501 may
be raised to form an upwardly convex protrusion 504 between the
second and fourth metatarsal region at the distal end of the
orthotic 502. The convex protrusion 504 may be configured to press
against the soft tissues and muscles around the metatarsal region.
The convex protrusion 504 may provide cushioning and support to the
metatarsal region. The convex protrusion may also act to massage
the soft tissue around the metatarsal region.
[0068] At the midfoot region of the example orthotic, the molded
cushioning layer 501 may have an upturned medial flange 505. The
medial flange 505 may wrap around the foot from the medial side
towards the heel portion and the lateral side. The upturned medial
flange 505 of the molded cushioning layer 501 is parallel to the
upturned medial flange 309 of the outer shell layer 301. The
upturned medial flange 505 of the molded cushioning layer 501 in
combination with the upturned medial flange 309 of the outer shell
layer 301 may provide support to the arch region. In addition, the
upturned medial flanges of the cushioning 501 and outer shell 301
layers may prevent pronation of the foot.
[0069] The bottom surface of the molded cushioning layer 501 may be
operably attached to the top surface of the outer shell layer 301,
with or without an inner shell layer 401. The top surface of the
molded cushioning layer 501 may be operably attached to the bottom
surface of the covering layer 506. Approaches to operably attaching
the bottom surface of the covering layer 506 to the top surface of
the molded cushioning layer 501 include the use of a adhesive,
heat, pressure, microwave, radiation, and others, with or without a
thermoplastic polyurethane film.
[0070] The covering layer 506 has a top surface, and a bottom
surface and extends the full length of the example orthotic.
Alternatively, the covering layer 506 need not be present, or may
cover only a portion of the orthotic. The covering layer 506 may be
constructed from a fabric material, which may be stain-resistant,
or abrasion resistant. The fabric material may be a natural fabric
material or a synthetic fabric material. Further, the covering
layer 506 may be a non-allergenic material, or a biocompatible
material. For example, the covering layer 506 may be constructed
from natural fabric, e.g., a cotton fabric, a wool fabric, a linen
fabric, a hemp fabric, or a ramie fabric. The covering layer 506
may also be constructed from synthetic fabric, such as nylon,
Dacron.RTM., polyester, acetate, or felt material. In another
example, the covering layer 506 may be a polyester knit fabric with
a suede look.
[0071] FIG. 9 depicts a distal top view of the example orthotic,
according to an example embodiment of the present invention. As
shown, it will be appreciated that the medial region where it turns
outwards and upwards to form the upturned medial flange 505 of the
cushioning layer 501 is substantially wider than at the lateral
side 509. The raised convex protrusion 504 is shown relative to the
direction of the example orthotic.
[0072] FIG. 10 depicts a second example orthotic, according to a
first alternative example embodiment of the present invention. In
the second example orthotic, the outer shell layer 301 is
essentially similar in the first example orthotic described in FIG.
6. However, in the second example orthotic, the pair of projecting
extensions 305 of the outer shell layer 301 may be joined at their
ends to form a continuous piece around the back. (Compare FIG. 10
with that of FIG. 6). Thus, in the example orthotic of the second
embodiment, the outer shell layer 301 is constructed with a cut-out
receiving enclosure 302 defining an aperture through the outer
shell layer 301 at the heel region.
[0073] FIG. 11 depicts a bottom and a top perspective of the second
example orthotic, according to the first alternative example
embodiment of the present invention. The outer shell layer 301 of
the second example orthotic may be a single continuous piece, where
the ends of the projecting extensions are joined. The outer shell
layer 301 in the second example orthotic may extend from at least
the metatarsal of the user's foot to the heel region. The outer
shell layer 301 may have a receiving enclosure 302 defining an
aperture through the outer shell layer 301. The receiving enclosure
302 is the region of the outer shell layer for receiving the
protruding heel piece 508 of the cushioning layer 501. The
projecting extensions 305 of the outer shell layer 301 may be
molded to form a joined continuous piece, embracing the back of the
heel piece 508. (See, FIG. 11, Bottom). The outer shell layer 301
of the second example orthotic, according to the second alternative
example embodiment, is operably attached to the molded cushioning
layer 501 having an upwardly raised convex protrusion 504 between
the second and fourth metatarsal region. A partial view of the
projecting extension 305 of the outer shell layer 301 embracing the
heel region of the cushioning layer 501 is shown in FIG. 11,
Top.
[0074] FIG. 12 depicts a top perspective view of a third example
orthotic, according to a second alternative example embodiment of
the present invention. The third example orthotic need not have an
upwardly raised convex protrusion between the second and fourth
metatarsal region at the distal end 502 of the orthotic. Instead,
the molded cushioning layer 501 at the distal end 502 is a
continuous flat piece. The molded cushioning layer 501 of the third
example orthotic may also include a heel cup 507 at the proximal
end 503 of the orthotic. It will be appreciated that, although the
third example orthotic is illustrated as having an upturned medial
flange 505 and a covering layer 506, alternative versions may be
provided without these features.
[0075] FIG. 13 depicts a bottom and a top perspective of the third
example orthotic, according to the second alternative example
embodiment of the present invention. As depicted in FIG. 13, the
molded cushioning layer 501 need not have an upwardly raised convex
protrusion 504 between the second and fourth metatarsal region
(See, FIG. 13 Top). The molded cushioning layer 501 as shown in
FIG. 13 may be fixedly attached to an outer shell layer 301 having
a pair of projecting extensions 305 that need not be joined at
their ends, thus exposing a "gap" 306 of the molded cushioning
layer 501 at the back of the heel region. (See, FIG. 13 Bottom)
[0076] FIG. 14 depicts a bottom and a top perspective of the fourth
example orthotic, according to the third alternative example
embodiment of the present invention. The fourth example orthotic
may have a molded cushioning layer 501 that lacks the upwardly
raised convex protrusion 504 between the second and fourth
metatarsal region (See, FIG. 14 Top). The cushioning layer 501 may
be combined with the outer shell layer 301 that have a pair of
projecting extensions 305 joined at their ends at the back of the
heel region. (See, FIG. 14 Bottom). The outer shell layer 301 may
be configured as a continuous outer shell layer 301 with a cut-out
receiving enclosure 302 defining an aperture through the outer
shell layer 301. The protruding heel piece 508 extends through the
receiving enclosure 302 of the outer shell layer 301.
[0077] FIG. 15 depicts a bottom perspective of the heel piece of
the fifth and sixth example orthotics according to the fourth
alternative example embodiment of the present invention. The fifth
example orthotic may have a molded cushioning layer 501 that have a
protruding heel piece 508 which supports the entire calcaneus bone
region (FIG. 15A). Alternatively, the molded cushioning layer 513
may have a protruding heel piece 514 that supports only the central
portion of the calcaneus bone region (FIG. 15B). Both example
orthotics having either a protruding heel piece 508 or 514 may have
projecting extensions 305A or 305B of the outer shell layer joined
at the ends. Alternatively, the projecting extensions 305A or 305B
may be unjoined at the ends. As depicted in FIG. 15A, the heel
region 508 is larger in area than the heel region 514 of FIG.
15B.
[0078] FIG. 16 illustrates an example display set of
pre-manufactured orthotics, according to an example embodiment of
the present invention. The display set is depicted in an unpackaged
form in FIG. 16A. It will be appreciated that the different models
in the example display set may also be provided packaged in pairs
of matching left and right orthotics of the same model (See, FIG.
16B). The example display set may include a plurality of different
orthotics, e.g., the 14 different example model orthotics, with
characteristics described previously in Tables I-III. Each orthotic
in the example display set may, but need not, have a substantially
similar design, although the exact dimensions and material
properties of the different models of orthotic in the display set
may vary. For example, each orthotic in the display set may include
a molded cushioning layer 501 and a supporting outer shell layer
301, as illustrated above in FIGS. 1-8, or one of the alternative
example embodiments. All of the models in the set may be similar to
the embodiments in FIGS. 1-8, or other embodiments that may be used
alone or in combination.
[0079] The set of pre-manufactured cushioned orthotics may be a
"3/4 length" orthotic. The set of pre-manufactured orthotics may be
a plurality of orthotics or display set of orthotics which may vary
in length, width, cushioning and in the amount of arch support
provided. (See, FIG. 16A). The display set of orthotics may include
orthotic models having different respective lengths depending on
the length of the user's foot. For example the display set of
orthotics may have at least four different lengths: a first length
that may be the shortest length, a second length which may be
longer than the shortest length, a third length, which may be
longer relative to the second length and a fourth length which may
be the longest length.
[0080] The example display set of orthotics having different
lengths may be manufactured having different arch heights with
varying hardness, stiffness, or dimensions. For example, users
without a defined arch or with a low arch may need more support and
may prefer greater hardness. On the other hand, users with a high
arch or an arch that is more defined may prefer more cushioning
than hardness. A greater degree of support due to a harder or
stiffer outer and inner shell layers may even be uncomfortable to a
user with a high arch because, as their arch is defined, the harder
shell layers may stick into the arch which may become sensitive to
the hard feeling underneath the foot. In some example embodiment,
the arch support may have at least two different levels of arch
support having different hardness.
[0081] The example display set of orthotics having different
lengths may be composed of a cushioning layer and an arch support
with different arch heights. The cushioning layer may be
manufactured from foam of at least two different firmness, a soft
cushion layer and a firmer cushion layer. The orthotic models of
all different lengths in the example orthotic display set may be
manufactured from a firmer foam, except for the orthotic model
having the longest length, which may not be manufactured from the
softest foam.
[0082] The example display set of orthotics having the same lengths
may have at least two orthotic models with different size arch
supports and/or material. In another example embodiment, the arch
supports of different materials for the orthotic models of a
particular length of the example display set of orthotics may be
substantially dimensionally identical.
[0083] Some example set of pre-manufactured orthotics, according to
some example embodiments of the present invention, there may be
different models having different lengths combined with different
firmness of the cushioning layer and levels of arch support. For
example, at least one of the orthotic models may be composed of
fourteen different models with at least four different lengths.
There may be a first model series with the softest cushioning layer
and the lowest level of arch support (See, FIG. 16A, "The 100
series"), a second model series with the softest cushioning layer
and a higher level of arch support ("The 200 series), a third model
series with a firmer cushioning layer and the lowest level of arch
support ("The 300 series"), and a fourth model with a firmer
cushioning layer and a higher level of arch support ("The 400
series").
[0084] In another embodiment of the example set of pre-manufactured
cushioned orthotics in the example display set of orthotics, the
first model may have a shortest length with the softest cushioning
layer, and the lowest level of arch support. In a second model, the
orthotic with the shortest length and the softest cushioning layer
may have a higher level of arch support. Alternatively, a third
model orthotic with the shortest length may have a firmer
cushioning layer, combined with the lowest level of arch support
and a fourth model orthotic with the shortest length may have a
firmer cushioning layer, and a higher level of arch support.
[0085] Another embodiment of the example set of pre-manufactured
cushioned orthotics in the example display set of orthotics may
have a second length longer than the shortest length. For example,
the fifth model may have a second length that is longer than the
shortest length combined with the softest cushioning and the lowest
level of arch support. A sixth model with the second length and the
softest cushioning layer may have the higher level of arch support.
Alternatively, a seventh model with the second length may have a
firmer cushioning layer and the lowest level of arch support, while
an eighth model with the second length may have a firmer cushioning
layer, and a higher level of arch support;
[0086] The example set of pre-manufactured cushioned orthotics in
the example display set of orthotics may also have a third length
that is longer relative to the second length. The example cushioned
orthotic sets may be manufactured with the softest or a firmer foam
in combination with either a lower or higher arch support. For an
example, a ninth model with a third length that is longer than the
second length orthotics may have the softest cushioning layer with
the lowest level of arch support. A tenth model with the third
length may have the softest cushioning layer and a higher level of
arch support while an eleventh model may have a firmer cushioning
layer with the lowest level of arch support, and a twelfth model
may have the firmer cushioning layer and the higher level of arch
support;
[0087] The example set of pre-manufactured cushioned orthotics in
the example display set of orthotics may also have a fourth length
which may be the longest length in the set. For example, a
thirteenth model with the longest length may be manufactured with
the firmer cushioning layer and the lowest level of arch support.
In addition, a fourteenth model having the longest length may be
combined with the firmer cushioning layer, and the higher level of
arch support.
[0088] Although the combined total of 14 example models in the
example display set of orthotics have been found to provide an
acceptable fit for the vast range of potential users, it will be
appreciated that additional or fewer models may be included. For
example, each of the 14 example models in the example display set
of orthotics may have different combinations of outer shell layer
301 and inner shell layer 401 hardness, and/or different thickness
and size at the heel piece 508 or 513. The 14 example models in the
example display set of orthotics may also have an upwardly raised
convex protrusion 504 between the second and fourth metatarsal
region and may be of different heights.
[0089] FIG. 17 illustrates an example display 601 including the
example display set of pre-manufactured orthotics 602. The display
includes packaged pairs of different model orthotics 602 of the
example display set of orthotics described above that are removably
attached to the display. The packaging and/or the display may
prominently indicate the attributes of each particular model in the
display set. The display sets of pre-manufactured orthotics are
"removably disposed" in a manner that is visible and easily
accessible to potential customers.
[0090] For example, in one embodiment of the example display, the
set of pre-manufactured orthotic removably disposed on the display
may include a plurality of different orthotic models, such as the
14 different models described above. The set of pre-manufactured
orthotics may be "3/4 lengths" orthotics with different respective
lengths depending on the length of the user's foot and different
respective levels of arch support. For example, different orthotic
models having the same length may have different arch support
manufactured from different arch support material and substantially
the same arch support dimension. The different orthotic models of
the same length may also have substantially similar external
designs and color pattern. Alternatively, orthotics of the same
support type but of different sizes may have the same color
pattern.
[0091] Although the removably disposed orthotics are held in place
by wired racks 603 as illustrated in FIG. 17, it will be
appreciated that other approaches to removable attachments may be
employed, e.g., see-through drawers or cases, a windowed vending or
dispensing machine, etc. The display sets may also be "shelved" by
hooks, rods, etc. The example display of FIG. 17 may be provided as
part of an electronic kiosk which performs procedures for measuring
a user and recommending particular orthotics to the user. The
example kiosk includes a measurement device 604 on which a user
stands to have their foot measured. This electronic kiosk and
example procedures are described in a concurrently filed
application Footcare Product Dispensing Kiosk, filed U.S.
application Ser. No. 11/524,745 filed Sep. 21, 2006, assigned to
Schering-Plough Healthcare Products, Inc. the assignee of the
present application.
[0092] Several embodiments of the present invention are
specifically illustrated and described herein. However, it will be
appreciated that modifications and variations of the present
invention are covered by the above teachings and within the purview
of the appended claims without departing from the spirit and
intended scope of the invention.
* * * * *