U.S. patent application number 15/435052 was filed with the patent office on 2017-08-17 for custom formable footbed and shoe insert.
The applicant listed for this patent is NANO TERRA INC.. Invention is credited to Austin Arroco, Mark Somers, Noah Tremblay.
Application Number | 20170231321 15/435052 |
Document ID | / |
Family ID | 59559520 |
Filed Date | 2017-08-17 |
United States Patent
Application |
20170231321 |
Kind Code |
A1 |
Tremblay; Noah ; et
al. |
August 17, 2017 |
Custom Formable Footbed and Shoe Insert
Abstract
A customizeable footbed, a self-customizing footwear having a
customizable footbed, and a method for customizing a footbed to
conform to contours of a foot is provided. The customizable footbed
may include a plurality of packets, each packet comprising an
exterior membrane defining a chamber therein, and an interior
filling within the chamber. The interior filling may be selected
from a group consisting of two or more components of a curable
material that chemically react upon mixing of the components to
irreversibly form a solid or semi-solid resin or a gel. The
plurality of packets may be configured to burst upon application of
a pressure such that the interior fillings of the packets flow into
and mix within the intermediate space.
Inventors: |
Tremblay; Noah; (Pepperell,
MA) ; Somers; Mark; (Brighton, MA) ; Arroco;
Austin; (Billerica, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NANO TERRA INC. |
Cambridge |
MA |
US |
|
|
Family ID: |
59559520 |
Appl. No.: |
15/435052 |
Filed: |
February 16, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62295863 |
Feb 16, 2016 |
|
|
|
Current U.S.
Class: |
36/93 |
Current CPC
Class: |
A43B 1/0027 20130101;
A43B 17/14 20130101; A43B 7/28 20130101; B29D 35/128 20130101; A43B
17/006 20130101; A43B 17/02 20130101; A43B 1/0045 20130101; A43B
17/026 20130101; B29D 35/122 20130101 |
International
Class: |
A43B 7/28 20060101
A43B007/28; A43B 17/02 20060101 A43B017/02; A43B 1/00 20060101
A43B001/00; A43B 17/00 20060101 A43B017/00; A43B 17/14 20060101
A43B017/14 |
Claims
1. A customizeable footbed comprising: a top layer which, when the
footbed is in an operating configuration faces a bottom of a foot;
a bottom layer opposite the top layer which, when the footbed is
the operating configuration is positioned away from the bottom of
the foot, the top and bottom layers defining an intermediate space
therebetween; and a plurality of packets arranged within the
intermediate space, each packet comprising an exterior membrane
defining a chamber therein, and an interior filling within the
chamber, the interior filling being selected from a group
consisting of two or more components of a curable material that
chemically react upon mixing of the components to irreversibly form
a solid or semi-solid resin or a gel, wherein the plurality of
packets are configured to burst upon application of a pressure
corresponding to that of the foot being rocked back and forth on
the top layer such that the interior fillings of the packets flow
into and mix within the intermediate space.
2. The customizable footbed of claim 1, wherein the bottom layer
comprises an elastomeric polymer.
3. The customizable footbed of claim 1, wherein the exterior
membrane comprises a thermoplastic polymer.
4. The customizable footbed of claim 3, wherein the exterior
membrane comprises a low-density polyethlyene polymer.
5. The customizable footbed of claim 3, wherein the exterior
membrane has an average thickness from about 5 mm to about 10
mm.
6. The customizable footbed of claim 1, wherein the curable
material is a two-component or multi-component resin that
spontaneously reacts upon mixing of the components.
7. The customizable footbed of claim 6, wherein the curable
material is selected from a group consisting of polyurethane
resins, silicone resins, epoxy resins, and melamin resins.
8. The customizable footbed of claim 1, wherein the curable
material is a quick-curing material that solidifies into a desired
shape within 30 mins upon mixing of the components.
9. The customizable footbed of claim 1, wherein the plurality of
packets are configured to burst upon application of a pressure from
about 0.1 N/cm.sup.2 to 1 kN/cm.sup.2.
10. The customizable footbed of claim 1, wherein each of the
plurality of packets has a three-dimensional shape.
11. The customizable footbed of claim 1, wherein the
three-dimensional shape is selected from a group consisting of
hemis-spherical, cubic, hexagonal prism, pentagonal prism,
rectangular prism, square prism, cone, and tetragonal pyramid
shapes.
12. The customizable footbed of claim 11, wherein each of the
plurality of packets has a square prism shape
13. The customizable footbed of claim 12, wherein a ratio of a
width and a height of the square prism is from about 1:2 to about
2:1.
14. The customizable footbed of claim 13, wherein a ratio of a
width and a height of the the square prism is 1:1.
15. The customizable footbed of claim 1, wherein the plurality of
packets are uniformly sized and shaped, and arranged in a
two-dimensional array.
16. The customizable footbed of claim 15, wherein the packets are
spaced apart by a distance from about 0.05'' to about 0.1''.
17. The customizable footbed of claim 1, wherein the plurality of
packets are arranged to form at least a first two-dimensional array
across a first section of the footbed corresponding to a first
portion of the foot, and a second array forming a second section of
the footbed corresponding to a second portion of the foot.
18. The customizable footbed of claim 1, wherein the plurality of
packets are formed from a singly shaped polymeric film bonded to a
flat polymeric film.
19. A self-customizing footwear comprising: an upper, an insole,
and an outsole, wherein the insole comprises a top layer which,
when the insole is in an operating configuration is faces a bottom
of a foot; a bottom layer opposite the top layer which, when the
insole is the operating configuration is positioned away from the
bottom of the foot, the top and bottom layers defining an
intermediate space therebetween; and a plurality of packets
arranged within the intermediate space, each packet comprising an
exterior membrane defining a chamber therein, and an interior
filling within the chamber, the interior filling being selected
from a group consisting of two or more components of a curable
material that chemically react upon mixing of the components to
irreversibly form a solid or semi-solid resin or a gel, wherein the
plurality of packets are configured to burst upon application of a
pressure corresponding to that of the foot being rocked back and
forth while wearing the footware such that the interior fillings of
the packets flow into and mix within the intermediate space.
20. A method for customizing a footbed to conform to contours of a
foot, comprising: applying a pressure to burst a plurality of
packets, each packet comprising an exterior membrane defining a
chamber therein, and an interior filling within the chamber, the
interior filling being selected from a group consisting of two or
more components of a curable material; mixing the components of the
curable material to initiate a chemical reaction such that the
components irreversibly react to form a solid or semi-solid resin
or a gel; and holding the foot against the footbed for a period of
less than 30 mins such that the curable material reacts to form a
shape comforming to the courtours of the foot.
21. A customizeable footbed comprising: a top layer; a bottom
layer; and a plurality of blister packets arranged between the top
and bottom layers, each packet comprising an exterior membrane
defining a chamber therein, and an interior filling within the
chamber, the interior filling being selected from a group
consisting of two or more components of a curable material that
chemically react upon mixing of the components to irreversibly form
a solid or semi-solid resin or a gel, wherein the plurality of
blister packets are configured to rupture upon application of a
pressure corresponding to that of the foot being rocked back and
forth on the top layer such that the interior fillings of the
packets intermix.
Description
PRIORITY CLAIM
[0001] This application claims priority to U.S. Provisional Patent
Application Ser. No. 62/295,863 filed Feb. 16, 2016, the entire
contents of which is hereby incorporated by reference herein.
BACKGROUND
[0002] Shoe inserts have long been used to provide better fit, feel
and support for the foot within a shoe. Such inserts range from
simple linings, to contoured paddings, to support orthotics. They
also range from inexpensive standard insoles, to very expensive
custom-fit inserts. Inexpensive insole options, which often fail to
provide sufficient fit and comfort, are currently produced by one
of the following methods: "boil and wear" type solutions, ski-shop
spray or heat form solutions. More custom-fit or personalized shoe
inserts tend to be very expensive, and the fitting process
sometimes involves a trip to a physician's office or to a location
with specialized fitting equipment where a scan or mold of the foot
can be made. The customer will often have to wait days or weeks for
delivery of the final insert.
[0003] The present invention relates to an improved custom-fit,
personalized footbed or insole that is inexpensive and easy to
use.
SUMMARY OF THE INVENTION
[0004] In accordance with the foregoing objectives and others, one
embodiment of the present invention provides a customizable
footbed. The customizable footbed comprises a top layer which, when
the footbed is in an operating configuration faces a bottom of a
foot. The customizable footbed also comprises a bottom layer
opposite the top layer which, when the footbed is the operating
configuration is positioned away from the bottom of the foot. The
top and bottom layers defining an intermediate space therebetween.
For example, the bottom layer may comprise an elastomeric polymer.
The customizable footbed further comprises a plurality of packets
arranged within the intermediate space. Each packet may comprise an
exterior membrane defining a chamber therein, and an interior
filling within the chamber. The exterior membrane may comprise a
thermoplastic polymer, in particular a low-density polyethlyene
polymer. The exterior membrane may also have an average thickness
from about 5 mm to about 10 mm. The interior filling may be
selected from a group consisting of two or more components of a
curable material that chemically react upon mixing of the
components to irreversibly form a solid or semi-solid resin or a
gel. The curable material may be a two-component or multi-component
resin that spontaneously reacts upon mixing of the components. For
example, the curable material may be selected from a group
consisting of polyurethane resins, silicone resins, epoxy resins,
and melamin resins. In another example, the curable material may be
a quick-curing material that solidifies into a desired shape within
30 mins upon mixing of the components. The plurality of packets may
be configured to burst upon application of a pressure corresponding
to that of the foot being rocked back and forth on the top layer
such that the interior fillings of the packets flow into and mix
within the intermediate space. For example, the plurality of
packets may be configured to burst upon application of a pressure
from about 0.1 N/cm.sup.2 to 1 kN/cm.sup.2. In some examples, each
of the plurality of packets may have a three-dimensional shape. In
particular, the three-dimensional shape may be selected from a
group consisting of hemis-spherical, cubic, hexagonal prism,
pentagonal prism, rectangular prism, square prism, cone, and
tetragonal pyramid shapes. More particularly, the each of the
plurality of packets may have a square prism shape, in particular,
a ratio of a width and a height of the square prism is from about
1:2 to about 2:1, specifically 1:1. In one example, the plurality
of packets may be uniformly sized and shaped, and arranged in a
two-dimensional array. Furthermore, the packets may be spaced apart
by a distance from about 0.05'' to about 0.1''. In another example,
the plurality of packets may be arranged to form at least a first
two-dimensional array across a first section of the footbed
corresponding to a first portion of the foot, and a second array
forming a second section of the footbed corresponding to a second
portion of the foot. Furthermore, the plurality of packets may be
formed from a singly shaped polymeric film bonded to a flat
polymeric film.
[0005] In one aspect, a self-customizing footwear is provided. The
self-customizing footware may comprise an upper, an insole, and an
outsole. The insole comprises a top layer which, when the insole is
in an operating configuration is faces a bottom of a foot. The
insole also comprises a bottom layer opposite the top layer which,
when the insole is the operating configuration is positioned away
from the bottom of the foot. The top and bottom layers defining an
intermediate space therebetween. The insole further comprises a
plurality of packets arranged within the intermediate space, each
packet comprising an exterior membrane defining a chamber therein,
and an interior filling within the chamber. The interior filling
may be selected from a group consisting of two or more components
of a curable material that chemically react upon mixing of the
components to irreversibly form a solid or semi-solid resin or a
gel. The plurality of packets may be configured to burst upon
application of a pressure corresponding to that of the foot being
rocked back and forth while wearing the footware such that the
interior fillings of the packets flow into and mix within the
intermediate space.
[0006] In another aspect, a method for customizing a footbed to
coform to contours of a foot is provided. The method may comprise a
first step of applying a pressure to burst a plurality of packets.
Each packet comprising an exterior membrane defining a chamber
therein, and an interior filling within the chamber. The interior
filling may be selected from a group consisting of two or more
components of a curable material. The method may also comprise a
step of mixing the components of the curable material to initiate a
chemical reaction such that the components irreversibly react to
form a solid or semi-solid resin or a gel. The method may further
comprise a step for holding the foot against the footbed for a
period of less than 30 mins such that the curable material reacts
to form a shape comforming to the courtours of the foot.
[0007] In a futher aspect, an alternative embodiment for a
customizeable footbed is provided. The customizable footbed
comprises a top layer and a bottom layer. The customizable footbed
further comprises a plurality of blister packets arranged between
the top and bottom layers. Each packet comprises an exterior
membrane defining a chamber therein, and an interior filling within
the chamber. The interior filling may be selected from a group
consisting of two or more components of a curable material that
chemically react upon mixing of the components to irreversibly form
a solid or semi-solid resin or a gel. The plurality of blister
packets may be configured to rupture upon application of a pressure
corresponding to that of the foot being rocked back and forth on
the top layer such that the interior fillings of the packets
intermix.
[0008] These and other aspects of the invention will become
apparent to those skilled in the art after a reading of the
following detailed description of the invention, including the
figures and appended claims.
BRIEF DESCRIPTION OF THE FIGURES
[0009] FIG. 1A shows a top view of an exemplary embodiment of a
portion of a footbed having a plurality of burstable packets
containing different components of a curable material that when
mixed react to form a solid or semi-solid resin or a gel.
[0010] FIG. 1B shows a prospective view of the exemplary embodiment
of a portion of a footbed according to FIG. 1A.
[0011] FIG. 1C shows a side view of the exemplary embodiment of a
portion of a footbed according to FIG. 1A.
[0012] FIG. 2A shows a side profile of a portion of an exemplary
embodiment of a packet array sheet where the packets have been
filled with reactive components for forming a silicone resin prior
to sealing within elastomeric top and bottom layers.
[0013] FIG. 2B shows a top view of the exemplary embodiment of a
packet array sheet according to FIG. 2A.
[0014] FIG. 3 shows an exemplary embodiment of footbed forming
plates of the present invention.
DETAILED DESCRIPTION
[0015] This invention relates to an improved footbed technology
that provides a custom-fit, mold-on-demand footbed which molds to
the contours of the foot, is pliable, and has the feel of a gel.
Please note that in this application, the terms "footbed", insole",
and "insert" are used interchangeably. In particular, a
customizeable footbed comprising an elastomeric bottom layer and a
layer of burstable packets coupled to the bottom layer, wherein at
least one of the burstable packets have a curable liquid may be
provided. The footbeds of the present invention contain a top layer
and bottom layer with packets, capsules, blister packets, blisters
or bladders (hereinafter referred to as "packets") arranged in
between the two layers, e.g., the top layer and the bottom layer.
In one embodiment, the top layer and the bottom layer may define an
intermediate space therebetween. A plurality of packets may be
arranged in the intermediate space and may each have an exterior
membrane defining a chamber therein. The chambers may be filled
with an interior filling, which may comprise a component of a
two-component or multi-component curable material. The components
of the curable material may chemically react, e.g., crosslink, to
form a solid or semi-solid resin or a gel. The exterior membrane of
the packets may be formed from a material such that the packets
burst during a custom-fit molding process, thereby releasing
components of the curable material and allowing the components to
be mixed with each other. Packets may take different shapes, sizes,
two-dimensional positioning, or wall thickness in order to tune the
packet's burst strength. In some applications, it may be important
that certain packets burst before others so a mixture of burst
strengths may be desired.
[0016] More particularly, the packets may contain components that
set or cure upon release from the bursted packets and may combine
and react with contents of adjacent packets to initiate curing.
Upon mixture of the components, the curable material may begin to
cure or set, with or without further reaction or stimuli. In some
embodiments, the components of the curable material may
spontaneously react with each other upon mixing of the components.
In other embodiments, a portion of the packets may contain a
catalyst and/or a crosslinking reagent for inititiating a chemical
reaction, in particular, a cross-linking reaction between different
components of the curable material.
[0017] When in use, the footbed with the mixed components may be
held against a user's foot such that the curable material cures or
sets in a shape that conforms to the contours of the user's foot.
The different components released from the packets may flow into
each other and pool within the intermediate space, particularly in
areas under the foot where voides may exist, e.g., under the arch
area, or around the toes. The mixed components may begin to set and
cure and solidify after a period of time, preferably a short period
of time, such that the curable material surrounds and corresponds
to a contour of the foot, e.g., defining a perimeter of the foot
and flowing betwewn the toes, arch and metatarsal areas. For
example, the curable material may flow under the midfoot or an arch
area of the foot, which allows the material to cure and set to
provide a cured and lasting impression of the contours of midfoot,
arch or the entire foot.
[0018] In one exemplary embodiment, the top and bottom layers are
both made of an elastomeric film, and the packets arranged in
between the two layers are made from a thermoplastic material.
These packets can contain materials that begin to set or cure upon
release from the packets and mixing/reacting with contents of
adjacent packets. The packets are arranged in arrays and
compartments and can be configured to optimize fit upon cure. The
packets are arranged in arrays, separated into sections or
compartments that correspond to different parts of the foot, e.g.,
section for toes, section for arch, section for heel (See FIGS. 1A,
1B and 1C). During the custom-fit molding process, the user places
the footbed within the shoe, and places his or her foot within the
shoe on top of the footbed. The user then presses down on the
footbed and rocks the foot back and forth, causing the packets to
burst and the packets' contents to mix and react. The mixed
material cures to the contours of the foot.
[0019] As discussed above, the footbed may comprise a top layer.
The top layer may be configured such that in an operating
configuration, i.e., when the footbed is being worn by a user in
footwear (e.g., inserted into a shoe), the top layer faces a bottom
of a foot of the user. The top layer may comprise any suitable
material that is wearable against a body part, in particular, that
is comfortable against the bottom of the foot, for example, a
fabric and/or a polymeric film. In one embodiment, the top layer
may comprise a fabric. In another embodiment, the top layer may
comprise an elastomeric material, in particular in the form of an
elastomeric film. In an alternative embodiment, the top layer may
comprise a thermoplastic material, e.g., a thermoplastic polymer.
More particularly, the thermoplastic material may comprise a
thermoplastic polyurethane (TPU), e.g., a TPU laminate with fabric.
The top layer may have any suitable thickness. In some exemplary
embodiments, the top layer may have a thickness from about 0.5 mm
to about 10 mm, from about 0.5 mm to about 5 mm, or from about 1 mm
to about 3 mm.
[0020] The footbed may also comprise a bottom layer, which may be
configured such that in an operating configuration, i.e., when the
footbed is being worn by a user in footwear (e.g., inserted into a
shoe), the bottom layer is opposite the top layer away from the
bottom of the foot of the user. The bottom layer may also comprise
any suitable material, for example, a polymeric form former, that
is comfortable for insertion into footwear (e.g., a shoe). In one
embodiment, the bottom layer may comprise an elastomeric material,
in particular in the form of an elastomer film. In an alternative
embodiment, the bottom layer may comprise a thermoplastic material,
e.g., a thermoplastic polymer. More particularly, the thermoplastic
material may comprise a thermoplastic polyurethane (TPU) film. The
bottom layer may have any suitable thickness. In some exemplary
embodiments, the bottom layer may have a thickness from about 1 mm
to about 15 mm, from about 3 mm to about 12 mm, from about 5 mm to
about 10 mm, or from about 7 mm to about 9 mm.
[0021] In one exemplary embodiment, the top layer and/or the bottom
layer is preferably made from a breathable, anti-bacterial,
anti-fungal and/or anti-odor material. In another exemplary
embodiment, the top layer and/or bottom layer may comprise
anti-bacterial, anti-fungal and/or anti-order agent embedded within
a polymeric film (e.g., an elastomeric film or a thermoplastic
film).
[0022] FIGS. 1A, 1B and 1C show an exemplary embodiment of a
portion of a footbed 100 having a plurality of burstable packets 1
containing different components of a curable material that when
mixed react to form a solid or semi-solid resin or a gel. Each of
the packets 1 may comprise an exterior membrane defining a chamber
therein for holding an interior filling. The exterior membrane may
be formed of any suitable material that are configured to burst
upon application of pressure from the user of the footbed,
typically by natural motion of hand(s), foot or feet of a user. In
particular, the plurality of packets may be configured such that it
bursts upon the foot being rocked back and forth on the footbed. By
bursting, it is meant that the packets are releasing its interior
filling by any suitable means, for example, by rupturing the film
structure of the exterior member, or delaminating one or more,
seals, adhesives, seams of the exterior membrane that define the
chamber therein. Alternatively, the plurality of packets may be
configured to burst upon manual application of pressure from the
user's hands, such as a pressing or a twisting motion by the hands.
The plurality of packets may also be bursted upon bending,
crushing, wringing, rolling, folding of the footbed by the hand(s),
foot, or feet of the user. The packets may preferably be burstable
by hand or foot. In some embodiments, the packets may be burstable
with (i.e., have a burst strength of) a pressure ranging from 0.1
N/cm.sup.2 to 1 kN/cm.sup.2; more preferably the packets may be
burstable with (i.e., have a burst strength of) a pressure with
burst strength of between 5 and 100 N/cm.sup.2, and even more
preferably the packets may be burstable with (i.e., have a burst
strength of) less than 50 N/cm.sup.2. These metrics can easily be
converted to psi. In some embodiments, the plurality of packets
within the intermediate space may have different burst strengths.
For example, a first component of certain curable materials may
need to be released before mixing with a second component of that
curable material. Therefore, those packets that contain the first
component may have a lower burst strength than those packets that
contain the second component, and thereby releasing the first
componet into the intermediate space before release of the second
component to mix with the first component.
[0023] In some embodiments, the interior chamber of the packets may
be filled with liquids having high viscosities such that additional
mixing by an external source may be necessary. Typically, such
additional source for mixing may be applied by hand or by foot or
feet of a user with any type of motion, typically natural motion.
For example, such high viscosity fluids may have a viscosity of
greater than 1000 cps, greater than 1200 cps, or greater than 1500
cps. The user may burst some or all of the packets by hand prior to
putting the insert into the shoe, to aid in mixing, reduce mixing
time, or otherwise aid in the custom-molding. For example, the user
may apply pressure from the user's hands, such as a pressing or a
twisting motion by the hands. The user may also apply additional
pressure and mixing by foot, such as by rocking back and forth
while standing or pressing against the footbed.
[0024] The exterior membrane of the packets may be formed from any
suitable material that can discharge the interior filling therein
upon application of the desired pressure, as discussed above. In
one particulr embodiment, the exterior membrane comprises a
thermplastic polymer, e.g., a thermoplastic film former. More
particularly, the thermoplastic material may comprise a
thermoplastic polyurethane (TPU) or a low density polyethylene
(LDPE), which may be in the form of a polymeric film. The exterior
membrane may have any suitable thickness. In some exemplary
embodiments, the exterior membrane may have a thickness or an
average thickness from about 1 mm to about 20 mm, from about 3 mm
to about 18 mm, or from about 5 mm to about 15 mm, or from about 8
mm to about 12 mm. In one particular embodiment, the exterior
membrane may have an average thickeness from about 5 mm to about 10
mm. The exterior membrane may also be formed from two or more
separate sheets of polymer film that are sealed together by any
suitable means, including a seal, a weld, an adhesive, etc., which
are discussed further below.
[0025] As discussed above, the burstable packets 1 may contain
different components of a curable material that when mixed react to
form a solid or semi-solid resin or a gel. Generally, the packets
may contain solid, liquid or gaseous components (or mixtures
thereof or suspensions containing such) that, when mixed, result in
some chemical reaction that cures the materials to become a solid
in the desired shape and form. In some embodiments, the mixing or
reaction may also produce some other effect or attribute such as
heat, cold, light, or color change. The color change may aid in
identifying whether the bursting and mixing has been performed
sufficiently. Each packet may contain one or more of the solid,
liquid or gaseous component. In particular, the packets can be
filled with a range of two-component or multi-component reactive
liquids. For example, each packet may contain one or more of the
reactive liquids. Examples of reactive liquids are two-component
resins, such as polyurethane resins, silicone resins, epoxy resins,
melamin resins, and polyurea resins; multi-component liquid
reactants to affect the production of heat, such as in the
dissolution of calcium chloride into water; multi-component liquid
reactants to affect the lowering of the temperature, such as the
dissolution of ammonium chloride into water; and multi-component
liquid reactants to affect the production of light, such as the
mixing of luminol and hydrogen peroxide.
[0026] In some exemplary embodiments, the components of the curable
material may chemically react, e.g., crosslink, to form a solid or
semi-solid resin or a gel. Suitable curable materials may include
polyurethane resins, silicone resins, epoxy resins, melamin resins,
and polyurea resins. The components may further comprise additional
additives that may impart a detectable change upon reaction, e.g.,
a color change or activating chemiluminescence (e.g., mixing of
luminal and hydrogen perioxide). The reaction of the components of
the curable material may be either exothermic (i.e., generate heat)
or endothermic (i.e., reduces heat). However, the exothermic or
endothermic changes of the reaction should be within a tolerable
range of temperature changes to the human skin, for example, the
exothermic reaction should not release energy that raises the
temperature of the footbed to above 90.degree. C., prefereably the
temperature should be maintained below 75.degree. C., more
preferably below 50.degree. C. Similarly, the endothermic changes
of the reaction should not reduce the temperature of the footbed to
below 0.degree. C., preferably the temperature should be maintained
above 10.degree. C., more preferably above 20.degree. C.
[0027] In particular, the components of the curable material may
comprise a first component comprising monomers, and a second
component comprising crosslinking reagents. Alternatively, the
components of the curable materials, e.g., monomers for
crosslinking, may be reactive upon exposure to air or components
found within ambient air, such as moisture or oxygen. In other
embodiments, a portion of the packets may contain a catalyst and/or
a crosslinking reagent for initiating a chemical reaction, in
particular, a cross-linking reaction between different components
of the curable material. In some embodiments, the components of the
curable material may spontaneously react with each other upon
mixing of the components.
[0028] Suitable two-component curable materials may include a first
component (which is also referred to herein after as Component A),
and a second component (which is also referred to hereinafter as
Component B). In one particular embodiment, the two-component
curable material may be a silicone. For example, Component A and
Component B may comprise a vinyl-terminated dimethylpolysiloxane
and a silicon-hydride crosslinker with platinum catalyst,
respectively. In particular, the two-components may comprise
commerically available silicone components: Andisil.RTM. 204-37C
and Andisil.RTM. 204-37D.
[0029] In a preferred embodiment, the components of the curable
material may comprise different reagents for a quick-cure or
quick-set curable material. For example, the components of the
quick-cure or quick-set curable material may begin to cross-link
upon mixing of the components with each other. The quick-cure or
quick-set curable material may form a solid or semi-solid resin or
a gel in the desired shape, e.g., conforming to contours of a foot,
as it crosslinks within about 1 hour of initial mixing, preferably
within about 45 mins of initial mixing, more preferably within
about 30 mins of initial mixing, and even more preferably within
about 20 mins of initial mixining. Even more preferably, the
quick-cure or quick-set curable material may solidify or gel within
a short period of time, e.g., less than 5 mins, or less than 3
mins.
[0030] The plurality of packets may have any suitable shape. In
some embodiments, the packets may be made in different
three-dimensional structures, aspect ratios, and overall
dimensions, including but not limited to height, width, and wall
thickness for different applications. The three-dimensional
structure of the packets can be any three-dimensional closed solid
compromising flat, contoured and/or curved surfaces; some examples
are hemi-spherical, cubic, hexagonal prism, pentagonal prism,
square prism, rectangular prism, cone, and tetragonal pyramid
shapes. In some embodiments, the plurality of packets may all have
a uniform size and/or shape. For example, as shown in FIGS. 1A, 1B,
and 1C, the packets may each have a square prism shape. In one
exemplary embodiment, the packets may have a square prism shape
having an aspect ratio (i.e., a ratio of a side of a square to the
height of the prism) from about 1:2 to about 2:1. In a preferred
embodiment, the aspect ratio of the square prism may be about 1:1.
In certain exemplary embodiments, the width of a side of the square
prism may range from about 0.1'' to about 0.5'', preferably from
about 0.125'' to about 0.5''.
[0031] Alternatively, the packets may each have a regular or
irregular three-dimensional shape and may have any suitable aspect
ratio. For an irregular shape, the aspect ratio may be defined as a
ratio of an average lateral cross sectional diameter to a height of
the shape, which may range from about 1:2 to about 2:1, and
preferably about 1:1. The above describe aspect ratios are not
limited to irregular shapes, but may be also used for any suitable
polygonal three-dimensional shape.
[0032] Furthermore, the plurality of packets may be arranged
two-dimensionally on a flat or curved surface. For example, the
plurality of packets may be arrange across the bottom layer of the
footbed. The curvature of the two-dimensional array may be
optimized to maximize the ease of packet bursting by the user. The
spacing, distribution, shape, and size of the packets can also be
varied to maximize the ease of bursting by the user. The spacing
between the packets may vary between a nil thickness and 100
centimeters. More particularly, the spacing between packets may
range from about 0.01'' to about 0.5'', from about 0.03'' to about
0.3'', or from about 0.05'' to about 0.1''. Packets may be all the
same size and shape or comprise a variety of different shapes
within the same footbed. In one embodiment, the packets may be
arranged to form a two-dimensional arrange along the length and
width of the footbed. Such an arrangement may be useful for
optimizing fit against an entire contour of the foot upon mixing
and curing of the components of the curable material.
[0033] The most preferable arrangement of packets is a pattern of
identical shaped and sized close-packed polygonal prisms, such as
cubes, rectangular prisms, or hexagonal prisms. This arrangement
allows the air to be evacuated efficiently from the outside
thermoplastic, elastomeric bag. In this arrangement, a
two-component resin can be distributed in packets such that parts A
and B (i.e., the parts to be mixed) are spaced out in separate
packets an alternating fashion. Such an alternating arrangment may
further allow for through mixing of components A and B upon
bursting of the packets.
[0034] As shown in FIGS. 1A, 1B, and 1C, the plurality of packets
may be arranged into a two-dimensional array. For example, the
plurality of packets may have a square prism shape and arranged
into an array that resembles a grid. Each packet, which has a
square prism shape, may be spaced a predetermined distance from an
adjacent packet. More particularly, the spacing between packets may
range from about 0.01'' to about 0.5'', from about 0.03'' to about
0.3'', or from about 0.05'' to about 0.1''. In some embodiments,
the packets may contain two different interior fillers: a first
interior filler containing a first component of a two component
curable material (which is also referred to herein after as
Component A), and a second interior filler containing a second
component of a two component curable material (which is also
referred to hereinafter as Component B). Each of the plurality of
packets in the grid may be filled in an alternating such that no
packet contains the same type of filler as an adjacent packet, as
shown for example below:
TABLE-US-00001 A B A B A B B A B A B A A B A B A B B A B A B A A B
A B A B
[0035] In some embodiments, the plurality of packets may be
arranged to form multiple arrays arranged across different sections
of the foot. In one embodiment, the plurality of packets may be
arranged to form at least a first two-dimensional array across a
first section of the footbed corresponding to a first portion of
the foot, and second array forming a second section of the footbed
corresponding to a second portion of the foot. In one exemplary
embodiment, each section is sealed from the next section such that
no fluid communicates between the different sections. In some
embodiments, each section may be compartmentalized to control the
flow of the components of the curable material to different areas
of the foot. For example, an area of the footbed corresponding to
the toes may comprise one compartment/section of burstable packets,
an area of the footbed corresponding to an arch area of the foot
may comprise another compartment/section of burstable packets, and
an area of the footbed corresponding to a heel portion of the foot
may also comprise a futher compartment/section of burstable packets
to direct curable material to desired locations to allow for
improved shaping of the footbed to provide proper foot support in
these desired regions.
[0036] Each section may also include packets that are sized and
shaped suitable for that particular section, for example, a first
section may comprise an array having a first set of uniformly sized
and shaped packets that are different from a second set of
uniformly sized and shaped packets that are part of a second
section. Although two different sections are discussed above, it is
understood that more than two sections and therefore, more than two
two-dimensional arrays may be utilized in the footbed of the
present invention.
[0037] As can be seen in FIGS. 1A, 1B and 1C, the footbed may be
separated into compartments or regions such as a toe region 2, an
arch region 3, and a heel region 4. In addition, these figures show
a border surrounding the footbed area which allows the footbed to
be clamped during manufacturing processes.
[0038] In one exemplary embodiment, the plurality of packets may be
formed by bonding together two plastic sheets, preferably two
polymeric films, more particularly two thermoplastic films. The two
plastic sheets that bond together to form the packet may both be
thermoformed, blow molded, or otherwise shaped to define the packet
volume or only one sheet can be shaped. The preferred embodiment
for the moldable footbeds is a singly shaped low-density
polyethylene sheet bonded to a flat low-density polyethylene sheet.
In the preferred embodiment for the moldable footbed, the
polyethylene is thermally welded to the adjacent sheet to define
the seams of each packet.
[0039] Packets may be formed from any materials that can be sealed
to each other by some means. Methods of sealing the packet seams
include thermally welding, sonically welding, mechanically folded
together, using a curable adhesive, or using a hot-melt adhesive or
thermoplastic). For other applications, the packets could be formed
by thermal or sonic welding of thermoplastic sheets or it may be
desirable to use an adhesive or other material to form a
significantly stronger or weaker bond to tune the delamination of
the packet seam. For example, all inner seams of the individual
packets in the array may be tuned to delaminate while the outer
seams remain laminated such that the packet array becomes one
continuous pouch after bursting. The shaped plastic sheet could
also form packets with hard non-porous surfaces, such as glass,
metal, rock, or a coated surface.
[0040] In a preferred method of making the footbed of the present
invention, the packet arrays are formed by vacuum forming
thermoplastic sheets into bubble sheets. The thermoplastic material
can survive strenuous conditions during manufacturing, shipment and
handling but bursts when body weight pressure is applied. This
prevents premature curing and preserves on-demand molding
functionality. The arrayed packets are filled with resin and a
backing layer is thermally sealed to the open back of the packets
to form an arrayed sheet of packets, which can be seen in FIG. 2.
The arrayed packet spacing and individual packet volume can be
optimized in order to achieve the desired resin volume. When
multiple components are desired, packet characteristics can be
customized in order to contain the required volume. Also, an
arrayed packet design allows for quick mixing by holding components
in close proximity to each other. Upon bursting, each packet of
material can be in close proximity to other packets. The preferred
embodiment has an array of packets optimized for the desired volume
and with curing components in close proximity.
[0041] In another embodiment, the footbed of the present invention
may be enclosed in a compartment within the shoe. The footbed may
be enclosed in a way that it may be slid in and out, removed and
replaced, or permanently enclosed.
[0042] The footbed may be included in an item of self-customizing
footwear. The item of self-customizing footware may comprising an
upper, an insole, and an outsole, wherein the insole comprises an
elastomeric upper layer positioned to contact with the bottom of
the foot; an elastomeric bottom layer coupled to the outsole; and a
middle layer enclosed between the upper layer and lower layer; and
the middle layer comprising a plurality of burstable packets having
a curable liquid material. Additionally. at least some of the
burstable packets are configured to burst under pressure from a
foot subject to a weight bearing action, and wherein upon bursting,
the curable liquid material flows within the enclosed middle layer
to conform to and solidify in the shape of the foot. The middle
layer may also be divided into a plurality of compartments, wherein
the quantity and/or composition of curable liquid material differs
between each of the compartments. Furthermore, the compartments may
be configured to control flow of material and compensate for
different pressure applied by different portions of the foot during
the weight bearing action.
EXAMPLES
Example 1
[0043] The steps for producing footbeds of a preferred embodiment
of the present invention are as follows: First, materials are
prepared by cutting LDPE, TPU, fabric, and transfer adhesive to the
proper size required. With the LDPE sheeting, custom bubble arrays
are formed by vacuum thermoforming of the film. The LDPE sheeting
is brought into close proximity of a high temperature heat source,
kept at 275.degree. C. Once the material begins to soften and
exhibits characteristics of melting, the sheeting is then brought
into contact with a custom mold that is arranged on a vacuum plate,
allowing the softened material to form a net shape of the custom
mold. Once this custom bubble arrangement is formed, the piece is
then placed into a custom holder with rigid channels between the
formed bubbles, allowing the bubbles to hang freely. In this
holder, silicone components are then loaded into the bubbles in an
alternating fashion. Once the bubbles are filled, a sheet of LDPE
is then laid across the loaded bubbles. Using a high temperature
and high pressure pneumatic thermal press, this film is pressed
into the custom bubble arrays, forcing a high pressure gradient
where the rigid channel below lies, allowing the LDPE to seal to
itself through the silicone contamination. This completes the
formation of the silicone loaded bubble arrays.
[0044] Using the prepared TPU sheeting, two films are placed
directly on top of one another and a desired fabric top cover is
applied to the top surface using a double sided transfer tape
adhesive. With the fabric in place, the silicone loaded bubble
array is aligned in proper position in between the two TPU sheets.
With this array in place, three sides of the film stack are heat
sealed, creating TPU-TPU bonds around the outer edge. With these
seals completed, the final open side is then used to evacuate the
excess air held within the films, creating a vacuum tight seal of
the TPU sheeting around the custom bubble arrays. Once the air has
been evacuated, the TPU sheets are then heat sealed using a custom
sealing plate kept at high temperature and pressure, forming the
overall shape of an insole complete with sealed partitions in
specific areas of the insole to separate bubbles in certain regions
of the foot. Once this seal has been created, the net shape desired
for further manufacturing is then cut and the custom moldable layer
of the insole is completed.
[0045] The materials used for the production of the insoles,
including the commercial suppliers' information, are as follows:
[0046] a. Silicone filler material is Andisil 204-37 Parts C&D,
supplied by AB Specialty Silicones [0047] b. Bubble films formed
from LDPE, 10 mil film thickness, supplied by SC Johnson. Film with
no slip additive preferred. [0048] c. TPU sheeting is product
DT-7101, 8 mil film thickness, supplied by American Polyfilms Inc.
[0049] d. Fabrics provided by Cosmo Fabrics
Example II
[0050] In another embodiment, the packets may be formed in a square
prism blisters having the following aspect dimensions.
0.25''.times.0.25''.times.0.25'' (1:1 aspect ratio). The packets
may contain two different interior fillers (A and B) arranged in an
alternating fashion. Each packet may be spaced apart from an
adjacent packet by a gap between 0.05''-0.1''.
[0051] The materials used for the production of the insoles,
including the commercial suppliers' information, are as
follows:
[0052] Interior filling/silicone:
[0053] Andisil.RTM. 204-37C having a viscosity--1950 cps
[0054] Andisil.RTM. 204-37D having a viscosity--1450 cps
[0055] 1:1 mixed gel time (20 sec mix)--55 sec
[0056] Properties--cure 20 minutes at RT:
[0057] Bottom TPU Layer: Product: DT 7101, polyether TPU film
[0058] Top Fabric Specs:
[0059] Product: Jump Spacer+2 mil TPU Laminate+Print
[0060] Company: Cosmo Fabrics
[0061] Packet exterior membrane: LDPE
[0062] The invention described and claimed herein is not to be
limited in scope by the specific embodiments herein disclosed since
these embodiments are intended as illustrations of several aspects
of this invention. Any equivalent embodiments are intended to be
within the scope of this invention. Indeed, various modifications
of the invention in addition to those shown and described herein
will become apparent to those skilled in the art from the foregoing
description. Such modifications are also intended to fall within
the scope of the appended claims. All publications cited herein are
incorporated by reference in their entirety.
* * * * *