U.S. patent application number 15/424883 was filed with the patent office on 2017-08-10 for customizable inserts for footwear.
The applicant listed for this patent is Sols Systems Inc.. Invention is credited to Jacy Krystal Bulaon, John D'Agostino, Stephen van Beek Faletti, Richard G. Ranky, Kegan L. Schouwenburg, Jeff E. Smith, Peter Yee.
Application Number | 20170224050 15/424883 |
Document ID | / |
Family ID | 59496048 |
Filed Date | 2017-08-10 |
United States Patent
Application |
20170224050 |
Kind Code |
A1 |
Schouwenburg; Kegan L. ; et
al. |
August 10, 2017 |
CUSTOMIZABLE INSERTS FOR FOOTWEAR
Abstract
An insert to be used with footwear is provided. In one
implementation, the insert includes a structural member that has a
first surface and a second surface opposite the first surface. The
first surface is shaped to correspond with contours of a user foot.
The second surface is adapted to rest on substantially planar
surface. The insert includes a recessed cavity defining an opening
from the first surface to the second surface of the structural
member. The recessed cavity is shaped to stabilize a region of the
user foot placed within the opening. An intermediate layer is
attached to the structural member in a mating relationship with
respect to the first surface. This foam layer is adapted to
distribute a determined amount of foot pressure from the user foot
with respect to the structural member.
Inventors: |
Schouwenburg; Kegan L.; (New
York, NY) ; Faletti; Stephen van Beek; (Brooklyn,
NY) ; Ranky; Richard G.; (Ridgewood, NJ) ;
D'Agostino; John; (Nanuet, NY) ; Bulaon; Jacy
Krystal; (Baldwin, NY) ; Yee; Peter;
(Brooklyn, NY) ; Smith; Jeff E.; (Brooklyn,
NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sols Systems Inc. |
New York |
NY |
US |
|
|
Family ID: |
59496048 |
Appl. No.: |
15/424883 |
Filed: |
February 5, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62292154 |
Feb 5, 2016 |
|
|
|
62292144 |
Feb 5, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 7/143 20130101;
A43B 7/1425 20130101; A43D 1/02 20130101; A43B 7/144 20130101; A43B
17/006 20130101; A43B 7/142 20130101; A43B 7/1435 20130101; A43B
7/1445 20130101; A43B 7/141 20130101; A43B 17/14 20130101; G06T
2210/41 20130101; A43D 2200/60 20130101; A43B 7/1485 20130101; A43B
7/24 20130101; A43B 17/02 20130101; A61F 5/0111 20130101; A61F 5/14
20130101 |
International
Class: |
A43B 7/24 20060101
A43B007/24; A43D 1/02 20060101 A43D001/02; A43B 17/14 20060101
A43B017/14; A43B 7/14 20060101 A43B007/14; A43B 17/00 20060101
A43B017/00; A43B 17/02 20060101 A43B017/02 |
Claims
1. An insert for footwear, comprising: a structural member having a
first surface and a second surface opposite the first surface, the
first surface is shaped to correspond with contours of a user foot
and the second surface is adapted to rest on an at least partially
planar surface; a recessed cavity defining an opening from the
first surface to the second surface of the structural member, the
recessed cavity is shaped to stabilize a region of the user foot
placed within the opening; and an intermediate layer attached to
the structural member in a mating relationship with respect to the
first surface, the intermediate layer to distribute a determined
amount of foot pressure from the user foot with respect to the
structural member.
2. The insert of claim 1, wherein the shape of the first surface of
the structural member is patient-matched and is fabricated based on
a 3D model of the user foot.
3. The insert of claim 1, wherein the structural member is
additively or subtractively fabricated.
4. The insert of claim 1, wherein the recessed cavity is surrounded
by material of the structural member.
5. The insert of claim 4, wherein the recessed cavity is positioned
at an arch region of the insert.
6. The insert of claim 4, wherein the recessed cavity is positioned
at a heel region of the insert.
7. The insert of claim 1, wherein the recessed cavity is positioned
along a center region of the insert.
8. The insert of claim 7, wherein the opening creates a center
channel that separates the structural member into a first panel and
a second panel at a forward region of the insert.
9. The insert of claim 8, wherein the first panel and the second
panel are each of lengths that accommodate the user foot.
10. The insert of claim 9, wherein the first panel and the second
panel of the structural member are joined together at a heel region
of the insert.
11. The insert of claim 1, wherein the intermediate layer is
comprised of a foam material.
12. The insert of claim 11, wherein the foam material is adapted to
conform to a topology corresponding to contours of the first
surface of the insert.
13. The insert of claim 1, wherein the intermediate layer comprises
an outline of an insole.
14. The insert of claim 1, further comprising a padding support to
be attached to the intermediate layer.
15. The insert of claim 14, wherein the padding support is attached
to a toe region of the intermediate layer.
16. The insert of claim 1, wherein the structural member further
comprises a computer-readable identifier disposed on the second
surface, the computer-readable identifier being associated with an
identify a user of the insert.
17. The insert of claim 16, wherein the structural member further
comprises a plurality of markings disposed on the second
surface.
18. The insert of claim 17, wherein the markings are arranged in a
determined pattern.
19. The insert of claim 18, wherein the markings are positioned to
adjust an amount of flexibility of material in a region of the
structural member.
20. The insert of claim 19, wherein when markings are worn such
that a wear pattern is formed thereon, and wherein the wear pattern
is predictive of an anatomical parameter of the user of the insert.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority of U.S.
Provisional Patent Application No. 62/292,154, filed on Feb. 5,
2016, and of U.S. Provisional Patent Application No. 62/292,144,
filed on Feb. 5, 2016, the disclosures of which are hereby
incorporated by reference herein in their entireties.
TECHNICAL FIELD
[0002] This disclosure relates to the field of corrective orthotic
devices, in particular, to customizable inserts for footwear.
BACKGROUND
[0003] An orthotic insert is a type of orthotic device that, when
inserted into a shoe and applied to a foot, supports the foot by
redistributing ground reaction forces while properly aligning foot
joints during motion. Orthotic inserts are typically used to treat
biomechanical deformities as well as inflammatory conditions (e.g.,
plantar fasciitis) in patients.
[0004] Various techniques have been employed to produce orthotic
inserts. Many of these techniques, however, are generally slow in
acquiring orthotic data, expensive, and are limited in the range of
characteristics that they can provide to the resulting orthotic
device. Moreover, the resulting orthotic device is implemented as a
one-size-fits-all solution that may be far from optimal for some
patients.
[0005] Furthermore, current techniques for orthotic insert
production are generally limited to the machining of hard materials
(top down approaches). This also limits the range of
characteristics (flexibility, shock absorption, weight, etc.) of
the end product. Shapes of the orthotic inserts tend to be mixed
and matched from a database, which may result in orthotic inserts
that are unique to a particular lab or production facility but not
to a particular patient.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present disclosure is illustrated by way of example, and
not by way of limitation, and will become apparent upon
consideration of the following detailed description, taken in
conjunction with the accompanying drawings, in which like reference
characters refer to like parts throughout, and in which:
[0007] FIG. 1 illustrates an example of an insert for footwear in
accordance with an implementation of the disclosure.
[0008] FIG. 2A illustrates another example of an insert for
footwear in accordance with an implementation of the present
disclosure.
[0009] FIG. 2B illustrates another example of an insert for
footwear in accordance with an implementation of the present
disclosure.
[0010] FIG. 2C illustrates another example of an insert for
footwear in accordance with an implementation of the present
disclosure.
[0011] FIG. 2D illustrates another example of an insert for
footwear in accordance with an implementation of the present
disclosure.
[0012] FIG. 3 illustrates yet another example of an insert for
footwear in accordance with an implementation of the present
disclosure.
[0013] FIG. 4 illustrates an example of an intermediate layer in
accordance with an implementation of the present disclosure.
[0014] FIG. 5 illustrates an example of padding support in
accordance with an implementation of the present disclosure.
[0015] FIG. 6A illustrates an example side view of an insert in
accordance with implementations of the present disclosure.
[0016] FIG. 6B illustrates an example side view of an insert in
accordance with implementations of the present disclosure.
[0017] FIG. 6C illustrates an example side view of an insert in
accordance with implementations of the present disclosure.
DETAILED DESCRIPTION
[0018] Implementations of the present disclosure provide
customizable inserts (a type of orthotic device) for footwear, such
as a shoe, boot, workout or running sneaker, tennis shoe, etc. The
term "orthotic device", as used herein, refers to any device worn
by or externally applied to an individual that provides
neuromuscular support to the individual, provides skeletal support
to the individual, and/or provides prophylactic functionality. The
term "corrective device", as used herein, refers to a type of
orthotic device that provides a therapeutic benefit to an
individual (e.g., who may be referred to herein as a "patient")
when worn by or externally applied by to the individual.
[0019] The techniques described herein provide an orthotic device
with the flexibility to meet various individual needs. For example,
the customizable insert as disclosed herein can aid in the
biomechanical alignment and support of the patient's body during
various activities. In an exemplary implementation, the
customizable insert includes a structural member (e.g., elastic
structural shell) that is three-dimensionally contoured to the
individual foot anatomy of the patient. In some implementations,
the structural member includes an upper surface and a lower surface
opposite the upper surface. The upper surface is shaped to
correspond with contours of the patient's foot to provide a balance
of comfort, shock-absorption, custom-fitted arch support, heel
stabilization, etc. The lower surface is adapted to rest on a
substantially planar surface, such as within the insole of a
shoe.
[0020] An intermediate layer (e.g., a foam layer) is attached to
the structural member in a mating relationship such that one or
more of their surfaces align. This layer is adapted to distribute a
determined amount of foot pressure from the user foot with respect
to the structural member. The insert further includes a recessed
cavity which may or may not define an opening (e.g., cut out) that
passes from the first surface to the second surface of the
structural member. The recessed cavity is shaped to stabilize a
region of the user foot placed within the opening with respect to
the structural member.
[0021] In accordance with the present disclosure, the structural
member of the insert can be constructed in several ways. In some
implementations, the structural member can be fabricated based on
the geometry of the patient's foot. This geometry (e.g.,
three-dimensional model, or "3D model") can be generated in
response to a foot analysis conducted by a system using, for
example, an image of the patient's foot as well as other inputs
regarding the patient, such as relevant activities, anatomical
measurements, personal preferences, etc. U.S. Provisional Patent
Application No. 62/292,154, which is incorporated by reference
herein, discloses an example of a type of system to produce a
geometry based on individual patient information, which can be used
in conjunction with the present disclosure. Alternatively, other
types of systems may be used to generate the geometry for
constructing the structural member of the insert.
[0022] The customizable insert is designed as an orthotic device
having an elastic exoskeleton to rest under the planar surface of a
patient's foot to help promote healthy biomechanical function. The
structural member or elastic structural shell provides the primary
support and shock absorption effects of the insert. While the
intermediate foam layer blends the comfort and dynamic loading
effects of the shell regions against the soft tissue of the
patient. When the intermediate foam layer is adhered to the elastic
structural shell, it can be pre-tensioned or compressed depending
on the differences in surface topology and contribute to how foot
pressure is redistributed during different activities, such as
walking, working, running, climbing, etc.
[0023] The present disclosure relates to an orthotic device as
described herein. In the following description, numerous details
are set forth. It will be apparent, however, to one skilled in the
art, that the present disclosure may be practiced without these
specific details. In some instances, well-known structures and
devices are shown in block diagram form, rather than in detail, in
order to avoid obscuring the present disclosure. In the foregoing
description, numerous details are set forth. It will be apparent,
however, to one of ordinary skill in the art having the benefit of
this disclosure, that the present disclosure may be practiced
without these specific details. In some instances, well-known
structures and devices are shown in block diagram form, rather than
in detail, in order to avoid obscuring the present disclosure.
[0024] FIG. 1 illustrates an example of an insert 100 for footwear
in accordance with an implementation of the disclosure. The insert
100 comprises a support or structural member 101 that has a
particular shape to fit within a base of footwear, such as a shoe.
In some implementations, the structural member 101 is
biomechanically designed to support regions of the patient's foot
and absorb different kinds of impact shock.
[0025] As shown in FIG. 1, the structural member 101 of the insert
100 extends along a longitudinal direction between opposite
regions, e.g., a forefoot or front region 103 and a rear or heel
region 105. In some implementations, the forefoot region 103 of the
insert 100 may continue as a flat layer underneath the forefoot of
the patient, or may terminate medial-laterally at the anterior arch
just prior to the metatarsal heads of a foot (i.e., long bones of
the foot). In one implementation, the structural member 101
includes an upper surface 102 that faces towards a patient's foot,
and a lower surface 104 that is opposite the upper surface 102
facing away from the patient's foot. As such, the lower surface 104
faces and engages an inner portion of the patient's footwear during
use of the insert 100 by the patient.
[0026] The structural member 101 may be made of a various types of
material. For example, these materials may be comprised of, but not
limited to, various kinds of fiber nylons, gypsum or rubber-like
materials, or other types of materials. In some implementations,
the material between the upper surface 102 and lower surface 104 of
the insert 100 can be solid or nearly hollow to vary or customize
the elastic profile of the structural member 101 in a linear or
nonlinear manner. For example, a spring constant of the material
can be represented as a function of deformation distance k=f(x)
[where k=spring constant and x=deformation distance].
[0027] Depending on the shoe type used with the insert 100 and
anatomical heel width of the patient, the interior and exterior
heel contours of the structural member 101 may work in balance to
expand when loaded enough to maintain a close fit with the shoe (by
applying appropriate shear friction) as well as the patient (by
applying comfortable and low level compression of the heel). In
some implementations, the intermediate foam layer (not shown) that
can be adhered to the structural member 101 may be compressed or
expanded by this heel shape in a manner custom to the heel anatomy
of the patient. This may help increase or decrease the insert's
control-contact at the heel region 105.
[0028] According to the present disclosure, the insert 100 may be
constructed using various techniques based on a foot analysis of
the patient. By analyzing the patient's foot, a 3D model for
constructing the insert may be individualized for each patient's
particular needs. In some implementations, this 3D model may be
fabricated using a type of additive or subtractive fabrication
system. Additive or subtractive systems, as referred to herein,
refers to a machine that can build or fabricate a kind of device or
real-world 3D objects by adding or subtracting successive layers of
a material (e.g., fiber nylon, powdered nylon, etc.) under the
control of a computing device. These objects can be of almost any
shape or geometry, and are produced from a 3D model or other
electronic data source. Alternatively, the inserts can be
constructed based on the 3D model using traditional manufacturing
techniques know in the art.
[0029] Contours 108 of the insert 100 are shaped in view of the
individual contours of the patient's foot. For example, the 3D
model for constructing the insert 100 as discussed above may be
based on contour data and other information with regards to a
patient's foot. When the insert 100 is constructed, the contours
108 are formed in a manner to take on the particular shape based on
this 3D model. In some implementations, the contours 108 are
customized in view of the 3D model in order to provide a level of
therapeutic and/or performance benefit for the patient. For
example, the contour 108 of the insert 100 may be customized to
alleviate a particular foot ailment associated with the patient or
to enhance a patient's stride performance by enhancing the amount
of energy return and/or absorption provided by the insert 100.
[0030] The heel region 105 of the insert 100 provides
medial-lateral stability during heel strike of the patient's gait
while also absorbing some impact loads and offloading the plantar
fascia (e.g., a flat band of tissue that connects the heel bone to
the toes of a foot). In this example, the insert 100 consists of a
roughly semi-circular contour around the sides and posterior of the
heel region 105, with a slope contoured to hold the heel.
[0031] An arch region 107 of the insert 100 comprises a structure
for the medial and lateral aspects of the arch to support during
static and dynamic conditions. This is intended to prevent the arch
of the patient foot from collapsing when standing or walking. The
medial and lateral aspects of the arch region are designed for
independent mechanical function, but may not be connected by a
material interface with the foot or with a nonfunctional aesthetic
design of the insert 100. Rather, they are connected through the
heel via matching contours and support the foot as gait progresses
from heel strike to mid-stance.
[0032] The heel region 105 and the arch region 107 of the insert
100 promote a loading profile concentrated at the midline of the
foot. The medial aspect is designed such that the peak of the
profile curve rests underneath the navicular bone found in the foot
and prevents pronation. The lateral aspect has a peak and curvature
designed to hold the foot and prevent over supination during
gait.
[0033] FIG. 2A-2C illustrates another example of an insert 200 for
footwear in accordance with an implementation of the present
disclosure. The insert 200 (which may be compared to insert 100 of
FIG. 1) includes an upper surface 202 and a lower surface 204
opposite the upper surface 202. In accordance with the present
disclosure, the upper surface 202 of the insert 200 is shaped to
correspond with contours of a user foot and the lower surface 204
is shaped to rest on an inner portion of footwear, such as a shoe.
Although the insert 200 is shown in a particular arrangement, it
should be appreciated that the insert 200 may be arranged in
different configurations and/or include different components than
what is shown.
[0034] In FIG. 2A, an example configuration of the insert 200 is
shown. In this example, the insert 200 includes as recessed cavity
210. Although for ease of understanding only one recessed cavity is
shown per implementation of insert 200, insert 200 may include
multiple recessed cavities based on the needs of the patient. In
some implementations, the recessed cavity 210 defines an opening
215 (e.g., cut out) that passes through the insert 200. For
example, the opening 215 may pass from the upper surface 202 of the
insert to the lower surface 204. The opening 215 in the insert 200
may be formed in several ways. In some implementations, the opening
may be formed during construction of the insert 200. In alternative
implementations, the opening may be created after an initial body
of the insert 200 is constructed. For example, the opening 215 may
be cut out of the body of the insert 200. Still further, other
techniques know in the art may be used to create the opening 215 of
the recessed cavity 210.
[0035] In FIG. 2A, the recessed cavity 210 is arranged near the
heel region 205 of the insert 200. As shown, the recessed cavity
210 is surrounded on all sides by material of the insert 200. The
opening 215 comprises a teardrop shaped cutout underneath the heel.
This shape is designed to offload the plantar fascia insertion at
the calcaneus by supporting and slightly raising the foot regions
around it. The exterior shape of the cavity 210 roughly follows the
interior with a wall thickness based off of patient kinetics, but
has an edge contoured on the lower surface 204 of the insert 200.
An advantage of this edge is that it stabilizes the heel by
widening its base to encourage the heel of the patient to become
more aligned with the sagittal plane during the early phases of
gait (e.g., a manner of walking).
[0036] Although in FIG. 2A the opening 215 is shown having a
particular shape in a certain position on the insert 200, other
shapes and configurations are possible. For example in FIG. 2B, the
recessed cavity 220 is arranged substantially near an arch region
225 of the insert 200. As shown, the recessed cavity 220 here is
similarly surrounded on all sides by material of the insert
200.
[0037] Turning to FIG. 2C, a recessed cavity 230 is arranged along
a center region 235 of the insert 200. As shown, the recessed
cavity 230 includes an opening in the forward region 203 of the
material used to construct the insert 200. In this example, the
recessed cavity 230 creates a center channel defining a first panel
207 and a second panel 209. An interior edge of the center channel
created by the recessed cavity 230 encourages offloading of the
2nd-3rd metatarsal bones of a patient's foot.
[0038] FIG. 3 illustrates yet another example of an insert 300 for
footwear in accordance with an implementation of the present
disclosure. The insert 300 (which may be compared to insert 100 of
FIG. 1 and any one of the configurations of insert 200 of FIGS.
2A-2C respectively) includes an upper surface 302 and a lower
surface 304 opposite the upper surface 302. In accordance with the
present disclosure, the upper surface 302 of the insert 300 is
shaped to correspond with contours of a user foot and the lower
surface 304 is shaped to rest on an inner portion of footwear.
Although the insert 300 is shown in a particular arrangement, it
should be appreciated that the insert 300 may be arranged in
different configurations and/or include different components than
what is shown.
[0039] In this example, the insert 300 includes a recessed cavity
330 (which may be compared to recessed cavity 230 of FIG. 2C) that
defines an opening from upper surface 302 of the insert to a lower
surface 304. As shown, the recessed cavity 330 is positioned along
a center portion of the insert 300. In this example, the recessed
cavity 330 creates a straight narrow channel defining a first panel
310 and a second panel 320. In this regard, the first panel 310 and
the second panel 320 of the insert 300 are still joined together at
a heel region 315 of the insert 300.
[0040] As shown in FIG. 3, each panel on the insert 300 may have a
determined length and width. For example, the first panel 310 may
have a length of L1 and a width of W1 while the second panel 320
may have a length of L2 and a width of W2. In some implementations,
the respective lengths and widths of the first panel 310 and second
panel 320 may correspond to each other. In alternative
implementations, the lengths and widths may differ. For example,
the length L1 of the first panel 310 may be a shorter or longer
than the length L2 of the second panel 320 and vice-versa.
Similarly, the width W1 of the first panel 310 may be a wider or
narrower than the width W2 of the second panel 320, or any
combination thereof.
[0041] In some implementations, an underside topology of the lower
surface 304 of insert 300 may be modified to contain certain
markings (e.g., 2D or 3D markings), for example, a textured surface
of shapes, such as shapes 340, and grooves, such as grooves 350,
which are slightly embossed or debossed (e.g., on the order of
.+-.0-3 mm) onto the lower surface 304 in a particular pattern.
Depending on the resolution of the patterns and magnitude of how
far these patterns are offset in a direction normal from the
surface, they may provide a certain biomechanical effect or
aesthetic impact based on user-specific inputs, such as activity
levels, anatomical measurements, or personal preferences.
[0042] The trajectory (e.g., path) of the patterns along the lower
surface 304 of the insert 300 may be along a spline in discrete
segments or continuous. The cross-section and configuration of the
pattern can impact the gait dynamics of the patient such as:
location of flexing of the device, providing mechanical limits on
deflection, realignment of center-of-force (COF), improving
symmetry of left-right feet pressure distribution, offloading zones
with high pressure, absorbing energy during heel strike, assisting
with tibial (e.g., pertaining to the largest long bone of the lower
leg) progression through mid-stance, or any combination thereof.
For regions of the insert 300 where it is desired to add rigidity
while minimizing material consumption or avoid adding thickness, an
embossed pattern may be added (e.g., ribs) to decrease bending in
the medial arch region. For other regions of the insert 300 where
it is desired to reduce rigidity while maintaining structural
integrity, a debossed pattern may be added (e.g., grooves) to
increase bending along axes perpendicular to the anterior arch.
[0043] In some implementations, the patterns on the lower surface
304 may also provide feedback regarding the patient's particular
use of the insert 300. For example, the patterns may be designed
such that over time the patient's unique wear pattern will provide
insight into anatomical and/or physiological parameters of the
patient's anatomy. For example, such parameters may include
indicators of the unique manner in which the patient loads their
feet during gait dynamics, how they apply normal and shear stresses
on the underside of the insert 300 and any wear away. These
indicators may indicate patterns of walking, such as
supination-pronation of the arch or inversion-eversion of the
heel.
[0044] In some implementations, the information regarding the
unique wear patterns of the patient may be provided to a system as
discussed above. This may be done to adjust the 3D model used to
fashion the insert for constructing subsequent inserts. To
accomplish this, in some implementations the insert 300 may include
a computer-readable identifier 360, such as a QR (Quick Response)
code, that can identify a particular user of the insert. In
operation, after using the insert for a while, the patient may take
a picture of the lower surface 304 to capture an image of the
computer-readable identifier 360 and the wear on the patterns at
the bottom of the insert 300. This picture can be then uploaded to
the system for analysis. Thereupon, an updated 3D model can be
generated by the system in response to the patient's unique use of
the insert 300. In some implementations, the patterns on the lower
surface 304 may serve as an identifier of the particular user. For
example, the orientations, sizes, and scale of various shapes that
form the pattern may structurally encode an identifier that is
associated with the user.
[0045] FIG. 4 illustrates an example of an intermediate layer 400
according to an implementation of the disclosure, which can be used
in conjunction with any one of the inserts of the present
disclosure. The intermediate layer 400 may be comprised of a
certain type of moldable material having a top portion 402 and a
bottom portion 404 opposite the top portion 402. In some
implementations, the intermediate layer 400 may be comprised of a
type of foam material of a determined thickness, such as a type of
environmentally friendly foam (EFF), or other types of similar
materials that provide a sufficient amount shock absorption
characteristics when compressed, as well as a sufficient amount of
spring back or rebound characteristics after compression.
[0046] The material of the intermediate layer 400 is formed to
provide a 3D contour approximate to the design variety for a
particular shoe size and type. A pre-forming process eases adhesion
of the intermediate layer 400 to the structural member of the
insert by reducing tension in the material from a flat sheet to a
3D contour. In some implementations, the shape of this layer will
be modified or otherwise deformed by adhesion to the structural
member of the insert. This adhesion may be accomplished using
certain techniques, such as compression molding. Due to preforming
and adhesion, the intermediate layer 400 becomes deformed at the
heel and arch region to match the topology of the insert.
[0047] In some implementations, a thin layer or top-cover of
material may be affixed to the intermediate layer 400 before the
pre-forming process. This top-cover may have properties specific to
the wearer's needs such as antimicrobial, textured, moisture
wicking, or heat wicking.
[0048] In use, the top portion 402 of the intermediate layer 400
faces upward towards the foot of the patient while the bottom
portion 404 faces towards the insert. In some implementations, the
inserts as described herein, such as insert 100 of FIG. 1, any one
of the configurations of insert 200 of FIGS. 2A-2C respectively, or
insert 300 of FIG. 3, can receive the intermediate layer 400 in a
mating relationship with respect to an upper surface of the insert.
For example, the intermediate layer 400 may be adhered to selected
regions of the structural member of the insert. This intermediate
layer 400 may be adhered to the using, for example, an epoxy or
alternative techniques such as heat treatment or ultrasonic
welding. In some implementations, a cutting process may be used to
remove excess material so that intermediate layer 400 and insert
can fit inside a shoe.
[0049] FIG. 5 illustrates an example 500 of padding support 501
according to an implementation of the disclosure. The padding
support 501 may be comprised of a certain type of material of a
determined thickness having a top portion 502 and a bottom portion
504. In some implementations, the padding support 501 may be
comprised of an ethylene-vinyl acetate (EVA) foam or similar
material which is soft enough to allow compression of the toes and
metatarsal heads during gait but avoid creating new high pressure
zones. In regions of the foot not covered by the insert, the
padding support 501 may be used as a secondary material to support
those regions of the foot during the latter phases of gait.
[0050] As shown in FIG. 5, the padding support 501 may comprises a
toe-bed reinforcement region underneath the metatarsal heads and
forefoot region of the patient's foot. In alternative
implementations, the padding support 501 may include different
shapes made up of one or more additional padding components. In
use, a top portion 502 of the padding support 501 may be attached
or placed under the intermediate layer 400. While a bottom portion
504 of the padding support 501 faces away from the patient and
towards a resting position within the patient's footwear.
[0051] FIGS. 6A-6C are example side views of an insert 600 in
accordance with implementations of the present disclosure. The
insert (which can be compared to insert 100 of FIG. 1, any one of
the configurations of insert 200 of FIGS. 2A-2C respectively, or
insert 300 of FIG. 3) comprises a structural member 601 that
includes an upper surface 602 and a lower surface 604 opposite the
upper surface 602. In accordance with the present disclosure, the
upper surface 602 of the structural member 601 is shaped to
correspond with contours of a user foot and the lower surface 604
is shaped to rest on an inner portion of footwear, such as a shoe.
Although the structural member 601 is shown in a particular
arrangement, it should be appreciated that the structural member
601 may be arranged in different configurations and/or include
different components than what is shown.
[0052] The structural member 601 may in itself act as an insert,
such as the insert 600, or may combine with other components to
form an insert. In these examples, steps for attaching the
structural member 601 to an intermediate layer 603 (which may be
compared to intermediate layer 400 of FIG. 4) to form an insert 610
are shown. In accordance with the present disclosure, the
intermediate layer 603 is comprised of a type of moldable material
of a determined thickness having a top portion 606 and a bottom
portion 608 opposite the top portion 606. In some implementations,
the intermediate layer 603 can be placed within a recess of the
structural member 601 such that the moldable material of the
intermediate layer 603 takes on a shape corresponding to the
structural member 601.
[0053] In FIG. 6A, a side view of the structural member 601 is
shown in a first position. For example, the structural member 601
may be positioned so that the lower surface 604 of the structural
member 601 is oriented downwards and facing away from a patient's
foot. With regards to FIG. 6B, a side view of the structural member
601 is shown in a second position with respect to the intermediate
layer 603. For example, the structural member 601 is positioned so
that the upper surface 602 is oriented towards the bottom portion
608 of the intermediate layer 603. At this point, the structural
member 601 and/or the intermediate layer 603 are moved in a certain
direction with respect to the second portion shown in FIG. 6B. For
example, the structural member 601 and the intermediate layer 603
may be moved in a manner in which the two components are brought
together.
[0054] Turning to FIG. 6C, a side view of the structural member 601
is shown in a third position with respect to the intermediate layer
603. In this example, the intermediate layer 603 is moved toward an
applied onto the structural member 601, for example, using a type
of adhesion. As shown, the intermediate layer 603 is placed within
a recess of the upper surface 602 of the structural member 601.
This configuration causes portions of the intermediate layer 603 as
indicated by arrows 607 to match to the topology, for example, at
the heel and arch region of the structural member 601. In some
implementations, a padding support 609 may further be included. The
padding support 609 may be similar to the padding support 501, and
may be applied to the intermediate layer 603. At least a portion of
the padding support 609 may contact the structural member 601.
Adhesives may be used, for example, to adhere the padding support
501 to the intermediate layer 603 and, optionally, the structural
member 601.
[0055] The above-described customizable inserts provides a level of
comfort and therapeutic/performance benefits to a patient while
performing different activities. This is accomplished, by
interfacing at the patient's foot, a pairing of an elastic
structural shell (e.g., structural member 601) with a soft
interface layer (e.g., intermediate layer 603). In this regard, the
health benefits provided by the inserts can include improved
posture, decreased foot fatigue, and decrease in common aches and
pains associated with the patient's feet.
[0056] Whereas many alterations and modifications of the present
disclosure will no doubt become apparent to a person of ordinary
skill in the art after having read the foregoing description, it is
to be understood that any particular implementation shown and
described by way of illustration is in no way intended to be
considered limiting. The words "example" or "exemplary" are used
herein to mean serving as an example, instance, or illustration.
Any aspect or design described herein as "example" or "exemplary"
is not necessarily to be construed as preferred or advantageous
over other aspects or designs. Rather, use of the words "example"
or "exemplary" is intended to present concepts in a concrete
fashion. As used in this application, the term "or" is intended to
mean an inclusive "or" rather than an exclusive "or". That is,
unless specified otherwise, or clear from context, "X includes A or
B" is intended to mean any of the natural inclusive permutations.
That is, if X includes A; X includes B; or X includes both A and B,
then "X includes A or B" is satisfied under any of the foregoing
instances. In addition, the articles "a" and "an" as used in this
application and the appended claims should generally be construed
to mean "one or more" unless specified otherwise or clear from
context to be directed to a singular form. Reference throughout
this specification to "an implementation" or "one implementation"
means that a particular feature, structure, or characteristic
described in connection with the implementation is included in at
least one implementation. Thus, the appearances of the phrase "an
implementation" or "one implementation" in various places
throughout this specification are not necessarily all referring to
the same implementation. Moreover, it is noted that the "A-Z"
notation used in reference to certain elements of the drawings is
not intended to be limiting to a particular number of elements.
Thus, "A-Z" is to be construed as having one or more of the element
present in a particular implementation.
[0057] It is to be understood that the above description is
intended to be illustrative, and not restrictive. Many other
implementations will be apparent to those of skill in the art upon
reading and understanding the above description. The scope of the
disclosure should, therefore, be determined with reference to the
appended claims, along with the full scope of equivalents to which
such claims are entitled.
* * * * *