U.S. patent application number 15/567450 was filed with the patent office on 2018-04-26 for contoured support shoe insole.
This patent application is currently assigned to Implus Footcare, LLC. The applicant listed for this patent is Implus Footcare, LLC. Invention is credited to David Bradley Granger, Jacob Martinez.
Application Number | 20180110284 15/567450 |
Document ID | / |
Family ID | 57393719 |
Filed Date | 2018-04-26 |
United States Patent
Application |
20180110284 |
Kind Code |
A1 |
Granger; David Bradley ; et
al. |
April 26, 2018 |
Contoured Support Shoe Insole
Abstract
An insole having a top sheet and a base layer with three pieces
that include a base layer, a forefoot pad and a midfoot-to-heel
support cushion. The mid-foot/heel surface has a raised medial arch
and longitudinal curvilinear indentations, a flattened mid-foot
area with a metatarsal mid-foot tear-drop raised area, and a
surrounding the heel pod that cups the exterior back by a heel cup.
A heel pad opening goes through the entirety of the thickness of
base layer of the insole body and a heel pad is affixed to the
bottom surface of the base layer. There is also a supersoft heel
dome and a metatarsal raised dome on the top (foot contact) surface
of the insole which would be directly above the heel pod and the
metatarsal midfoot area, respectively.
Inventors: |
Granger; David Bradley;
(Lorena, TX) ; Martinez; Jacob; (Temple,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Implus Footcare, LLC |
Durham |
NC |
US |
|
|
Assignee: |
Implus Footcare, LLC
Durham
NC
|
Family ID: |
57393719 |
Appl. No.: |
15/567450 |
Filed: |
May 25, 2016 |
PCT Filed: |
May 25, 2016 |
PCT NO: |
PCT/US2016/034196 |
371 Date: |
October 18, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62167771 |
May 28, 2015 |
|
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62182060 |
Jun 19, 2015 |
|
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62234212 |
Sep 29, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 7/143 20130101;
A43B 7/142 20130101; A43B 7/1435 20130101; A43B 7/1425 20130101;
A43B 7/144 20130101; A43B 3/0063 20130101; A43B 7/1445 20130101;
A43B 7/141 20130101; A43B 7/148 20130101; A43B 17/026 20130101;
A43B 17/02 20130101; A43B 7/145 20130101 |
International
Class: |
A43B 7/14 20060101
A43B007/14; A43B 17/02 20060101 A43B017/02; A43B 3/00 20060101
A43B003/00 |
Claims
1. A contoured insole used inside a shoe and having a top side that
contacts the users foot, a bottom side that contacts the interior
of a shoe after insertion therein, a lateral side that lies
adjacent to the outer side of a user's foot in use and a medial
side that lies adjacent the inner side, or arch, of a user's foot,
said insole comprising: a base layer having a contoured shape which
receives and supports the foot of the user, a heel end, a toe end,
a top surface, a bottom surface, a lateral side and a medial side,
said lateral and medial sides extending approximately from said
heel end to said toe end, said base layer having: (a) a heel dome
raised above the top surface of the base layer and located over the
heel area of the insole; (b) a metatarsal dome raised above the top
surface of base layer and located over the metatarsal midfoot area
of the insole; (c) a forefoot pad indentation area on the bottom
surface of the insole extending from the midfoot to the toe area of
the base layer and supporting the insertion of a forefoot pad
therein, (d) a midfoot-to-heel stability cushion indentation area
on the bottom surface of the insole extending from the midfoot to
the heel area of the insole and supporting the insertion of a
stability cushion therein; (e) separation wall on the bottom
surface of the base layer and located between said forefoot pad
indentation area and said mid-foot-to-heel stability cushion
indentation area a stability cushion positioned on the bottom
surface of the base layer in the stability cushion indentation area
and having: (a) a raised arch support on the bottom surface of the
insole in the medial arch area; (b) a heel cup on the bottom
surface of the insole and surrounding the heel end of the insole
with vertical walls, (c) one or more ridges located on the bottom
surface of the midfoot area of the stability cushion surrounding a
flat surface, (d) a heel pad opening on the bottom surface of the
support cushion and surrounded by supporting grooves on the
periphery of said heel pad opening; and (e) a metatarsal arch dome
raised up from the bottom surface of the insole, said raised arch
support having a first set of curvilinear indentations on the
bottom surface of the insole in medial arch area and extending
generally lengthwise in a longitudinal toe-to-heel direction at a
first angle of inclination from the longitudinal axis of the
insole; a forefoot pad positioned on the bottom surface of the
insole in the forefoot indentation area; a heel pad positioned in
the heel pad opening of the stability cushion, and extending
through the stability cushion to be secured to the bottom surface
of the base layer; a top sheet that extends across the top surface
of the base layer from the heel end to the toe end of the
insole.
2. The insole of claim 1, wherein said first angle of inclination
is between 5-65 degrees compared to said longitudinal axis of said
insole.
3. The insole of claim 1, wherein said base layer is made of
polyurethane polyester glycol with a hardness 10-30 Asker.+-.3.
4. The insole of claim 1, wherein said forefoot pad made of a clear
TPR gel (thermoplastic rubber).
5. The insole of claim 4, wherein said TPR gel has a hardness
rating of 10-35 Asker.+-.3.
6. The insole of claim 1, wherein said forefoot pad has a groove
pattern with a width spacing of approximately 1.0 mm-1.50 mm.
7. The insole of claim 1, wherein said heel pad is made of
pre-blown EVA (ethylene-vinyl acetate) material.
8. The insole of claim 7, wherein said heel pad has a hardness
rating of 10-35 Asker.+-.3.
9. The insole of claim 1, wherein said heel pad has a groove
pattern with a width spacing of approximately 1.0 mm-1.50 mm.
10. The insole of claim 1, wherein said heel pad aperture is
surrounded by a flat mid-foot/heel surface and a heel ridge.
11. The insole of claim 1, wherein base layer is made of a durable
nylon fabric.
12. The insole of claim 1, wherein said first curvilinear
indentations have a groove depth of approximately 0.50 mm-1.5
mm.
13. The insole of claim 1, wherein said top sheet is made of 65%
Nylon/35% polyester.
14. The insole of claim 1, wherein said metatarsal dome on the top
side of the insole matches the upwardly-curved metatarsal arch dome
on the bottom surface of the insole.
15. The insole of claim 1, wherein said separation wall located on
the bottom surface of the base layer and is approximately 1 mm in
height.
16. The insole of claim 1, wherein said forefoot and heel pads are
made of rubber or synthetic rubber.
17. The insole of claim 1, wherein said forefoot and heel pads are
made of a neoprene synthetic rubber.
18. A contoured insole used inside a shoe and having a top side
that contacts the users foot, a bottom side that contacts the
interior of a shoe after insertion therein, a lateral side that
lies adjacent to the outer side of a user's foot in use and a
medial side that lies adjacent the inner side, or arch, of a user's
foot, said insole comprising: a base layer having a contoured shape
which receives and supports the foot of the user, a heel end, a toe
end, a top surface, a bottom surface, a lateral side and a medial
side, said lateral and medial sides extending approximately from
said heel end to said toe end, said base layer having: (a) a heel
dome raised above the top surface of the base layer and located
over the heel area of the insole; (b) a metatarsal dome raised
above the top surface of base layer and located over the metatarsal
midfoot area of the insole; a stability cushion positioned on the
bottom surface of the base layer in the stability cushion area and
having: (a) a raised arch support on the bottom surface of the
insole in the medial arch area; (b) a heel cup on the bottom
surface of the insole and surrounding the heel end of the insole
with vertical walls; (c) one or more ridges located on the bottom
surface of the midfoot area of the stability cushion surrounding a
flat surface, (d) a metatarsal arch dome raised up from the bottom
surface of the insole; and (e) a heel pad opening on the bottom
surface of the base layer in the heel area and surrounded by
supporting grooves around its periphery; said raised arch support
having a first set of curvilinear indentations on the bottom
surface of the insole in medial arch area and extending generally
lengthwise in a longitudinal toe-to-heel direction at a first angle
of inclination from the longitudinal axis of the insole; a forefoot
pad positioned on the bottom surface of the insole in the forefoot
area; a heel pad positioned in the heel pad opening of the
stability cushion, and extending through the stability cushion to
be secured to the bottom surface of the base layer; a top sheet
that extends across the top surface of the base layer from the heel
end to the toe end of the insole.
19. The insole of claim 18, wherein said base layer has separation
wall on the bottom surface of the base layer and located between
said forefoot pad indentation area and said mid-foot-to-heel
stability cushion indentation area.
20. The insole of claim 19, wherein said separation wall located on
the bottom surface of the base layer and is approximately 1 mm in
height.
21. The insole of claim 18, wherein said base layer has a heel dome
on the top surface of the base layer and raised over the heel area
of the insole.
22. The insole of claim 18, wherein said base layer has a
metatarsal dome on the top surface of base layer and raised over
the metatarsal midfoot area of the insole.
23. The insole of claim 18, wherein base layer is made of a durable
nylon fabric.
24. The insole of claim 18, wherein said first angle of inclination
is between 5-65 degrees compared to said longitudinal axis of said
insole.
25. The insole of claim 18, wherein said base layer is made of
polyurethane polyester glycol with a hardness 10-30 Asker.+-.3.
26. The insole of claim 18, wherein said forefoot pad is made of
clear TPR gel (thermoplastic rubber) gel.
27. The insole of claim 26, wherein said TPR gel has a hardness
rating of 10-35 Asker.+-.3.
28. The insole of claim 18, wherein said forefoot pad has a groove
pattern with a width spacing of approximately 1.0 mm-1.50 mm.
29. The insole of claim 18, wherein said heel pad made of pre-blown
EVA (ethylene-vinyl acetate) material.
30. The insole of claim 29, wherein said heel pad has a hardness
rating of 10-35 Asker.+-.3.
31. The insole of claim 18, wherein said heel pad has a groove
pattern with a width spacing of approximately 1.0 mm-1.50 mm.
32. The insole of claim 18, wherein said heel pad aperture is
surrounded by a flat mid-foot/heel surface and a heel ridge.
33. The insole of claim 18, wherein said first curvilinear
indentations have a groove depth of approximately 0.50 mm-1.5
mm.
34. The insole of claim 18, wherein said top sheet is made of 65%
Nylon/35% polyester.
35. The insole of claim 18, wherein said metatarsal dome on the top
side of the insole matches the upwardly-curved metatarsal arch dome
on the bottom surface of the insole.
36. The insole of claim 18, wherein said forefoot and heel pads are
made of rubber or synthetic rubber.
37. The insole of claim 18, wherein said forefoot and heel pads are
made of a neoprene synthetic rubber layer which is a polymer.
38. A method of making a contoured insole to be used inside a shoe
and having a top side that contacts the users foot, a bottom side
that contacts the interior of a shoe after insertion therein, a
lateral side that lies adjacent to the outer side of a user's foot
in use and a medial side that lies adjacent the inner side, or
arch, of a user's foot, said insole comprising: providing a base
layer with a contoured shape which receives and supports the foot
of the user, said base layer having a heel end, a toe end, a top
surface, a bottom surface, a lateral side and a medial side, said
lateral and medial sides extending approximately from said heel end
to said toe end, and said base layer having: (a) a heel dome raised
above the top surface of the base layer and located over the heel
area of the insole; (b) a metatarsal dome raised above the top
surface of base layer and located over the metatarsal midfoot area
of the insole; (c) a forefoot pad indentation area on the bottom
surface of the insole extending from the midfoot to the toe area of
the base layer and supporting the insertion of a forefoot pad
therein, (d) a midfoot-to-heel stability cushion indentation area
on the bottom surface of the insole extending from the midfoot to
the heel area of the insole and supporting the insertion of a
stability cushion therein; (e) separation wall on the bottom
surface of the base layer and located between said forefoot pad
indentation area and said mid-foot-to-heel stability cushion
indentation area positioning a stability cushion on the bottom
surface of the base layer in the stability cushion indentation
area, said stability cushion having: (a) a raised arch support on
the bottom surface of the insole in the medial arch area; (b) a
heel cup on the bottom surface of the insole and surrounding the
heel end of the insole with vertical walls; (c) one or more ridges
located on the bottom surface of the midfoot area of the stability
cushion surrounding a flat surface, (d) a metatarsal arch dome
raised up from the bottom surface of the insole; and (e) a heel pad
opening on the bottom surface of the base layer in the heel area
and surrounded by supporting grooves around its periphery; said
raised arch support having a first set of curvilinear indentations
on the bottom surface of the insole in medial arch area and
extending generally lengthwise in a longitudinal toe-to-heel
direction at a first angle of inclination from the longitudinal
axis of the insole; positioning a forefoot pad on the bottom
surface of the insole in the forefoot indentation area; positioning
a heel pad in the heel pad opening of the stability cushion, and
extending the heel pad through the stability cushion to be secured
to the bottom surface of the base layer; and, placing a top sheet
that extends across the top surface of the base layer from the heel
end to the toe end of the insole.
39. The method of making the insole of claim 38, wherein said first
angle of inclination is between 5-65 degrees compared to said
longitudinal axis of said insole.
40. The method of making the insole of claim 38, wherein said base
layer is made of polyurethane polyester glycol with a hardness
10-30 Asker.+-.3.
41. The method of making the insole of claim 38, wherein said
forefoot pad made of a clear TPR gel (thermoplastic rubber).
42. The method of making the insole of claim 41, wherein said TPR
gel has a hardness rating of 10-35 Asker.+-.3.
43. The method of making the insole of claim 38, wherein said
forefoot pad has a groove pattern with a width spacing of
approximately 1.0 mm-1.50 mm.
44. The method of making the insole of claim 38, wherein said heel
pad is made of pre-blown EVA (ethylene-vinyl acetate) material.
45. The method of making the insole of claim 44, wherein said heel
pad has a hardness rating of 10-35 Asker.+-.3.
46. The method of making the insole of claim 38, wherein said heel
pad has a groove pattern with a width spacing of approximately 1.0
mm-1.50 mm.
47. The method of making the insole of claim 38, wherein said heel
pad aperture is surrounded by a flat mid-foot/heel surface and a
heel ridge.
48. The method of making the insole of claim 38, wherein base layer
is made of a durable nylon fabric.
49. The method of making the insole of claim 38, wherein said first
curvilinear indentations have a groove depth of approximately 0.50
mm-1.5 mm.
50. The method of making the insole of claim 38, wherein said top
sheet is made of 65% Nylon/35% polyester.
51. The method of making the insole of claim 38, wherein said
metatarsal dome on the top side of the insole matches the
upwardly-curved metatarsal arch dome on the bottom surface of the
insole.
52. The method of making the insole of claim 38, wherein said
separation wall located on the bottom surface of the base layer and
is approximately 1 mm in height.
53. The method of making the insole of claim 38, wherein said
forefoot and heel pads are made of rubber or synthetic rubber.
54. The method of making the insole of claim 38, wherein said
forefoot and heel pads are made of a neoprene synthetic rubber.
55. The method of making the insole of claim 38 wherein said steps
of positioning include forming the material by molding in place.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 62/167,771 filed May 28, 2015, U.S.
Provisional Patent Application Ser. No. 62/182,060 filed Jun. 19,
2015, and U.S. Provisional Patent Application Ser. No. 62/234,212
filed Sep. 29, 2015.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
TECHNICAL FIELD
[0003] The present invention relates in general to an improved shoe
insole and more particularly to an insole providing improved
cushioning and support to the foot of a wearer.
BACKGROUND OF THE INVENTION
[0004] Insoles are inserted in the shoes of a user to provide one
or more advantages to the comfort of the wearer or the support of
the foot. Insoles are generally sold in pairs and one of each pair
is adapted for use in a right shoe and the other adapted for use in
a left shoe of a user. It is advantageous to provide appropriate
structure to an insole so that it serves the purposes of the
user.
[0005] The human foot is a very complex biological mechanism. The
load on the foot at heel strike is typically about one and a half
times a person's body weight when a person walks. When running or
carrying extra weight, such as a backpack, loads on the foot can
exceed three times the body weight. The many bones, muscles,
ligaments, and tendons of the foot function to absorb and dissipate
the forces of impact, carry the weight of the body and other loads,
and provide forces for propulsion. Properly designed shoe insoles
can assist the foot in performing these functions and protect the
foot from injury.
[0006] Insoles may be custom made to address the specific needs of
an individual. They may be made based on casts of the end user's
foot or may be made of a thermoplastic material that is molded to
the contours of the end user's foot. Like most custom made items,
custom insoles tend to be expensive because of the low volume and
extensive time needed to make and fit them properly. As such, it is
not practical to make such custom made insoles for the general
public.
[0007] To be practical for distribution to the general public, an
insole must be able to provide benefit to the user without
requiring individualized adjustment and fitting. A first type of
insole commonly available over-the-counter emphasizes cushioning
the foot so as to maximize shock absorption. For typical
individuals cushioning insoles perform adequately while engaged in
light to moderate activities, such as walking or running. That is,
a cushioning insole provides sufficient cushioning and support for
such activities. However, for more strenuous or technically
challenging activities, such as carrying a heavy backpack or
traversing difficult terrain, a typical cushioning insole will not
be adequate. Under such conditions, a cushioning insole by itself
would not provide enough support and control, and tends to bottom
out during use by fully compressing the cushioning insole.
[0008] Another type of over-the-counter insole emphasizes control.
Typically, such insoles are made to be relatively stiff and rigid
so as to control the bending and twisting of the foot by limiting
foot motion. The rigid structure is good at controlling motion, but
is not very forgiving. As a result, when motion of the foot reaches
a limit imposed by the rigid structure, the load on the foot tends
to change abruptly and increases the load on the structures of the
foot. Because biological tissues such as tendons and ligaments are
sensitive to the rate at which they are loaded, the abrupt change
in load causes injury or damage to the foot, ankle or leg.
[0009] In view of the foregoing, it would be desirable to provide
an over-the-counter insole that provides both cushioning and
control. It would also be desirable to provide an insole that
provides both cushioning and control and is practical for use by
the general public during cross-training or triathlon-related
activities.
[0010] The Applicant has received patents for insoles having a
support cushion and multiple pods located thereon. These patents
include U.S. Pat. Nos. 7,484,319; 7,665,169; 7,908,768; and,
8,250,784. These prior art patents, however, do not address the
problems of enhanced cushioning and stability, possible movement of
the insole during shoe operation, or establishing enhanced
cushioning characteristics to address running and walking
usages.
[0011] There is a need for insoles to be easier to construct and
made of materials that: (1) provide increased ankle and foot
stability, (2) cushion the heel and forefoot during push-offs and
landings, (3) custom-contour to the inside shape of all types of
shoes, (4) are extremely light-weight, (5) provide enhanced
cushioning capabilities and (6) have essentially zero movement or
sliding while placed inside a shoe.
SUMMARY OF THE INVENTION
[0012] It is an object of the present invention to provide an
insole that provides improved cushioning, support, and control and
is practical for use by the general public. The above, and other
objects and advantages of the present invention are provided by an
insole that provides improved motion control, support and
cushioning. The insole includes a system of interacting components
that cooperate to achieve a desired combination of foot cushioning,
support and motion control.
[0013] In accordance with principles of the present invention, the
shoe insole 100 has a bottom surface formed of three pieces
including: (1) a base layer extending from heel-to-toe, (2) a
forefoot pad positioned in a forefoot/toe indentation on a forefoot
base area of the insole, and, (3) a midfoot to heel support cushion
made of a soft polyurethane positioned in a midfoot to heel
indentation. The forefoot pad and the midfoot/heel support cushion
are secured adjacent to one another on the bottom surface of the
base layer. In one preferred embodiment the base bottom surface has
indentations dimensioned to receive cushioning pads. In an
alternative embodiment the base bottom surface has cushions and
pads molded into the base bottom surface. A thin layer of nylon
fabric may be positioned in the forefoot pad indentation between
the forefoot pad and the material of the base bottom surface to
increase the adhesion of the forefoot pad to the base material when
the forefoot pad and base bottom surface are made of differing
materials.
[0014] There is a raised separation wall located on the base layer
between the forefoot/toe layer and the midfoot/heel support
cushion, which is located laterally across the width of the insole
between the metatarsal and forefoot areas on the insole. The insole
has a top sheet layer that extends from heel to toe over the top
surface of the base layer. There is a heel dome on the top surface
of the insole and a metatarsal dome raised on the top surface of
the insole, each of which respectively improves the cushioning
characteristics of the insole at or near high impact points on the
insole. The forefoot pad has a diamond cube shaped groove pattern
on its bottom surface to improve forefoot cushioning
characteristics, and improve traction and adhesion of the insole
inside and along the interior bottom surface of the user's shoe. In
an alternate embodiment, the forefoot pad has a honeycomb-shaped
pattern. In yet another embodiment, the forefoot pad has a
texturized un-patterned surface.
[0015] The midfoot/heel cushion has a raised arch in the medial
arch area and longitudinal curvilinear indentations positioned
along a major angle compared to the longitudinal axis of the
insole, with the longitudinal axis extending from heel-to-toe on
the insole. The midfoot/heel cushion also possesses a flattened
midfoot area on the midfoot area and a metatarsal midfoot tear-drop
raised area positioned in a metatarsal tear-drop aperture of the
midfoot to heel support cushion. The flattened area on the midfoot
area of the midfoot/heel cushion is bordered on the medial side by
a medial side longitudinal ridge, on the lateral side by a lateral
side longitudinal ridge, and around the exterior of the heel pod
opening by a heel ridge. The midfoot/heel cushion also has a
surrounding heel cup that supports the exterior back of the user's
heel with the heel cup and extends to the raised arch area.
[0016] The heel pod opening extends through the entirety of the
thickness of the midfoot/heel support cushion to position the heel
pad on the bottom surface of the base layer. The heel pod opening
is surrounded by opening border grooves, which surrounds the
circumference of the heel pod opening. The heel pad is located on
the bottom surface of the insole and is made of a EVA or other
suitable material and extends through the full depth of the heel
pod opening and is attached to the bottom surface of the base
layer. The heel pad has a diamond cube shaped groove pattern and
there is a supersoft heel dome on the top (foot contact) surface of
the insole located above the heel pod in the bottom (shoe contact)
surface.
[0017] A shoe insole with the following features: (1) a base made
of molded of lightweight materials such as low density polyurethane
memory foam, ethylene glycol polyurethane, ethylene vinyl acetate
(EVA), pre-blown EVA, polyurethane (PU), or thermoplastic rubber
(TPR) or other suitable material with hardness of the molded base
material can range from less than 10 Asker.+-.3 to greater than 30
Asker.+-.3 extending the length and width of the insole curving up
in the medial arch area to form an arch support area and curving
around the heel area to form a heel cup on the foot contact
surface, with a separating wall between the base material and the
forefoot pad indentation area on the bottom surface; a heel pad
indentation under the calcaneal (heel) area on the bottom surface;
a raised arch in the medial arch area with integrally formed
longitudinal curvilinear indentations situated lengthwise,
integrally formed raised gripping ridges in the medial arch area on
the bottom surface; and a teardrop shaped indentation in the
metatarsal area of the midfoot which curves upwardly (concave) from
the bottom of the base bottom (shoe contact) surface and forms a
collapsible metatarsal support which is convex on the top (foot
contact) side of the base layer; (2) a forefoot pad of molded of
pre-blown ethylene vinyl acetate (EVA), polyurethane (PU), or
thermoplastic rubber (TPR) or other suitable material, which
extends from the toe end of the insole to the lateral midfoot/arch
area from the medial side to the lateral side of the forefoot area
with a diamond-cube pattern molded and having pattern spacing of
about 1 mm, groove depth of approximately 1 mm, and a thickness of
the forefoot pad of about 1.5 mm.+-.0.5 mm, the forefoot pad molded
into the PU insole base distal to the separating wall on the base
bottom surface with a knitted fabric layer secured between the
forefoot pad and the PU base material; (2) a heel pad on the bottom
surface of the insole made of pre-blown ethylene vinyl acetate
(EVA), molded of EVA, polyurethane (PU), or thermoplastic rubber
(TPR) or other suitable material with a hardness of approximately
35 Asker C.+-.3, a thickness of approximately 3.0 mm.+-.0.5 mm, or
alternatively, integrally formed in the material of the base bottom
surface of the insole, and having a modified oval shape that is
wider on the proximal end of the heel pad and narrows on the distal
end of the heel pad with a diamond-cube pattern molded in the EVA
having pattern spacing of about 1 mm, groove depth of approximately
1 mm, and a thickness of the heel pad of about 1.5 mm.+-.0.5 mm and
which is secured in the heel pad indentation of the base bottom
surface; (3) a supersoft heel dome on the top (foot contact)
surface of the insole which would be directly above the heel pad in
the bottom (shoe contact) surface providing heel cushioning
directly under a user's heel bone and also providing shock
absorption on the insole bottom; (4) a metatarsal dome shaped like
a teardrop on the top (foot contact) midfoot surface of the insole
which would normally be located below the foot metatarsal bones;
and, (5) a top sheet of polyester covering the entire foot contact
surface of the insole which is treated with an antimicrobial
agent.
[0018] In an alternate embodiment, the heel pad has a
honeycomb-shaped pattern. In yet another embodiment, the heel pad
has a texturized un-patterned surface, and a thin layer of nylon
fabric may be positioned in the heel pad indentation between the
heel pad and the material of the base bottom surface to increase
the adhesion of the heel pad to the base material when the heel pad
and base bottom surface are made of differing materials.
[0019] In a preferred embodiment, the heel pad is surrounded by a
flat midfoot/heel surface and cupped along the back by a heel cup,
nylon fabric between forefoot/heel pads and base (for adhesion of
pads to PU), a raised oval heel pad on top dome on the foot-contact
side made of super-soft low density PU, a medial arch that has
raised and indented curvilinear lines extending longitudinally
along arch with vent holes, a groove depth on bottom 0.50 mm-1.5
mm, a top cloth made of 65% Nylon/35% polyester, a teardrop
metatarsal dome on the top side is integrally formed as an
upwardly-curved indentation from bottom surface, a diamond-shaped
groove pattern on the forefoot pad and the heel pad, and a
separation wall added between base and forefoot pad of
approximately 1 mm.
[0020] Overall, the above features appear to be novel
characteristics for this insole, and seem to be patentably distinct
from the other insoles. The method of construction of the present
insole is also a unique and novel feature of the present invention.
In accordance with principles of the present invention, a
cushioning core or base is combined with a relatively stiff support
cushion and a number of other pads to form an insole that provides
greater cushioning, stability, and control than was conventionally
known in the state of the art. The pads can have a different
firmness than the base or the support cushion. The pads and support
cushion assist with prevention of supination, and the supplemental
heel pad assists with the prevention of pronation. The current
invention is an insole that provides a balanced approach to
improving longitudinal arch support, prevention of pronation and
prevention of supination by incorporation of the combination of the
above elements.
[0021] The characteristics of the components, their size and shape,
and their position are selected to provide a desired blend of
improved cushioning and control, and more specifically to achieve a
desired biomechanical function. The size and compression
characteristics of the pads can be adjusted to address issues of
over/under pronation, over/under supination, and other problems
related to foot motion, including altering the size, shape, and
material properties of the pads. The firmness of the pads and
support cushion can be adjusted to address issues of over/under
pronation, over/under supination, and other problems related to
foot motion by altering the size, shape, and material properties of
the pads. The present invention accomplishes the goals to: (1)
improve ankle and foot stability, (2) cushion the heel and forefoot
during push-offs and landings, (3) help prevent over pronation and
over supination conditions, and (4) provide enhanced cushioning
features to the heel, midfoot, arch and forefoot areas. In a
preferred embodiment of the present invention, the components of an
insole are permanently affixed to each other to create an insole
designed for an intended type or category of activity. Many
different insole designs can be made to address a broad range of
different activities.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The above, and other objects and advantages of the present
invention will be understood 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:
[0023] FIG. 1A is a bottom perspective view of an illustrative
embodiment of an insole in accordance with the principles of the
present invention;
[0024] FIG. 1B is a exploded perspective view of an illustrative
embodiment of an insole in accordance with the principles of the
present invention;
[0025] FIG. 2 is a bottom planar view showing the base bottom
surface of the insole;
[0026] FIG. 3 is a top (dorsal) view of the insole;
[0027] FIG. 4 is a medial (inner arch area) side view of the
insole;
[0028] FIG. 5 is a lateral (outer) side view of the insole;
[0029] FIG. 6 is front (proximal) view of the insole; and,
[0030] FIG. 7 is a rear (proximal) view of the insole.
DETAILED DESCRIPTION
[0031] In accordance with principles of the present invention, the
present invention is a shoe insole has a base bottom (shoe contact)
surface with cushioning and supporting elements in the arch,
metatarsal, forefoot and heel areas, and a top (foot contact)
surface with cushioning and supporting elements in the heel and
metatarsal areas. The shoe insole fits securely in the bottom of a
user's shoe to provide support and cushioning to the user's
foot.
[0032] Referring to FIG. 1A, 1B and 2, these views are perspective
and top views of the bottom surface (shoe side) of an insole 100
according to the invention. The insole 100 extends from a heel end
(proximal) to a toe end (distal) and has a medial border or side on
the arch side of the foot, connecting said toe end to said heel end
along the arch side of the insole and a lateral border or side on
the other side (opposite side from medial side) thereof, connecting
said toe end to said heel end on the other side of the insole.
[0033] The insole 100 surface is generally foot-shaped extending
longitudinally from the from the toe end to the heel end and from
the medial side to the lateral side of the insole. In one preferred
embodiment, the base layer 102 surface has indentations dimensioned
to receive cushioning pads. In an alternative embodiment, the base
bottom surface has cushioning pads molded into the base bottom
surface.
[0034] The invention possesses a base layer 102, support cushions
105 and pads 107 that can be made of molded or lightweight
materials such as low density polyurethane memory foam, ethylene
glycol polyurethane, ethylene vinyl acetate (EVA), pre-blown EVA,
polyurethane (PU), or thermoplastic rubber (TPR) or other suitable
material. Hardness of the molded base material can range from less
than 10 Asker.+-.3 to greater than 30 Asker.+-.3. The insole 100
encompasses support and cushioning features for the following
functional areas: forefoot cushioning area; medial arch support
area, metatarsal support area, and a heel cushioning area. In a
preferred embodiment, the base layer 102 has indentations in the
forefoot area 108 dimensioned to receive a forefoot pad 107, and/or
in the heel area 104 dimensioned to receive a heel pad 118. In an
alternate embodiment, the forefoot pad 107 and the heel pad 118 are
molded into the base material.
[0035] The base layer 102 extends the length and width of the
insole curving up in the medial arch area to form an arch support
119 and curving around the heel area to form a heel cup 104 on the
foot contact surface, with a separating wall 151 between the base
material and the forefoot pad indentation area on the bottom
surface; a heel pad indentation 102B under the calcaneal (heel)
area on the bottom surface; a raised arch 119 in the medial arch
area with integrally formed longitudinal curvilinear indentations
132 situated lengthwise, the curvilinear indentations 132
integrally formed raised gripping ridges in the medial arch area on
the bottom surface; and a teardrop shaped metatarsal indentation
134 on the bottom surface of the insole 100 that curves upwardly
(concave) from the bottom of the base bottom (shoe contact) surface
and forms a collapsible metatarsal support which is convex on the
top (foot contact) side of the base layer 102. The insole also has:
(1) a forefoot pad 107 that extends from the toe end of the insole
100 to the midfoot area and from the medial side to the lateral
side of the forefoot area with a diamond-cube pattern 117 molded
having pattern spacing of about 1 mm and a depth of about 1.5 mm,
the forefoot pad molded into the PU insole base distal to the
separation wall 151 on the base bottom surface with a knitted
fabric layer secured between the forefoot pad 107 and the base
layer 102 material; (2) a heel pad 118 on the bottom surface of the
insole made of pre-blown EVA, polyurethane (PU), or thermoplastic
rubber (TPR) or other suitable material with a hardness of
approximately 10-35 Asker C.+-.3 having a modified oval shape that
is wider on the proximal end of the heel pad and narrows on the
distal end of the heel pad with a diamond-cube pattern molded in
the EVA having pattern spacing of about 1 mm and a depth of about
1.5 mm and which is secured in the heel pad indentation of the base
bottom surface; (3) a soft heel dome 118A (shown in FIGS. 3 and 6)
on the top (foot contact) surface of the insole 100 which would be
directly above the heel pad 118 in the bottom (shoe contact)
surface providing heel cushioning directly under a user's heel bone
and also providing shock absorption on the insole bottom; (4) a
soft metatarsal dome 134 shaped like a tear drop on the top (foot
contact) surface (shown in FIGS. 3, 5 and 6) providing cushioning
directly over the metatarsal area of the foot; and, (5) a top sheet
128 of polyester covering the entire foot contact surface of the
insole 100 which is treated with an antimicrobial agent.
[0036] The combination of the base layer 102, support cushion 105,
and a heel pad 118 specified herein provides a "degree" of medial
longitudinal arch support, which provides a couple of degrees of
improved pronation "control." A "degree" of medial longitudinal
arch support is approximately 1-2 degrees based on research
evidence. By pronation "control," we mean the increase in
supination moments acting around the joints of the rearfoot and the
decrease in the magnitude of pronation moments. The current
invention is an insole 100 that provides a balanced approach to
improving longitudinal arch support, prevention of pronation and
prevention of supination.
[0037] The insole 100 also has a forefoot area 108 that correlates
with the metatarsal area and near the phalanges of the foot located
over the forefoot pad 107 of the insole 100, a raised arch support
119 along the medial arch side, a heel area just forward of the
heel cup 104, and a midfoot area 106 between the heel area 104 and
forefoot area 108. A user's right shoe and left shoe are mirror
images of one another as are the insoles adapted to be inserted in
a right shoe and a left shoe respectively. Only the left insole is
illustrated in the Figures. It will be understood by those of skill
in the art that the right insole has a mirror image construction of
the left insole.
[0038] In one preferred embodiment, the base layer 102 has
indentations 102A, 102B dimensioned to receive cushioning pads. In
an alternative embodiment, the base bottom surface 102 has
cushioning pads molded into the base bottom surface. The base layer
102 may be molded of lightweight materials such as low density
polyurethane memory foam, ethylene glycol polyurethane, ethylene
vinyl acetate (EVA), pre-blown EVA, polyurethane (PU), or
thermoplastic rubber (TPR) or other suitable material. Hardness of
the molded base layer 102 material can range from less than 10
Asker.+-.3 to greater than 30 Asker.+-.3.
[0039] The present invention is an insole that fits within the
interior of a user's shoe, and rests on the interior bottom surface
of that shoe with the user's foot being positioned over and on top
of the insole. The insole 100 shown in FIG. 1A, 1B and 2 has a
bottom (shoe side) and a top (foot side) and the insole 100
comprises a base layer 102 having a contoured shape which receives
and supports the foot of the user. The insole 100 is intended to be
used inside a shoe and the bottom side thereof will contact the
interior of a shoe after insertion therein. In many cases, the
insole will be used to replace an insole that previously was used
in the shoe.
[0040] The base layer 102 has a heel end, a toe end, a lateral side
and a medial side, said sides extending approximately from said
heel end to said toe end. The lateral side lies adjacent the outer
side of a user's foot in use and the medial side lies adjacent the
inner side, or arch, of a user's foot in use, including the arch of
the foot. The contoured shape includes an integrally formed raised
arch support 119 that extends generally upwardly on the medial side
of the insole. This upward extension arch support 119 allows the
raised arch support to lie adjacent to a user's foot arch during
use in the shoe.
[0041] As an example, approximate dimensions are given for a men's
size 9 insole. Length and width of the insole are 28.1 cm (11.063
inches) and 9.7 cm (3.813 inches). The length and width will vary
according to the shoe size for which the insole is intended. The
total thickness of the insole can range from 6.8 millimeters near
the toe area to 12 millimeters in the arch area. Arch height is
about 15 millimeters. The forefoot and heel cushions have a
thickness of approximately 4.0 millimeters. The preferred depth of
the heel cup which is measured from the top side of the insole near
the center of the heel area vertically to the top of the upraised
heel area or heel raised edge is approximately 15-16
millimeters.
[0042] The base layer 102 has a base top surface and a base bottom
surface. The base layer 102 defines a heel cup 104 adjacent said
heel end, a contoured arch support 119 adjacent said medial side, a
midfoot area 106 between said arch support 119 and the lateral
midfoot area, a forefoot area 108 located between the metatarsal
area to the toe end of the insole 100. There is a heel dome 118A on
top surface of insole (shown in FIGS. 3 and 6) and a metatarsal
dome 134 raised on the top surface of insole 100 (shown in FIGS. 3,
5 and 6), each of which respectively improves the cushioning
characteristics of the insole at or near high impact points on the
insole.
[0043] Base layer 102 is preferably made of foam or other material
having suitable cushioning properties, including a fabric layer.
Preferably, base layer 102 comprises an Ethylene vinyl acetate
("EVA") foam, which is a copolymer of ethylene and vinyl acetate, a
Thermoplastic Rubber ("TPR")/EVA mix, or a blown EVA material. A
preferred blown EVA, EVA or TPR/EVA mix has a durometer (hardness)
of about Asker C 45-50. It is desirable to minimize the total
weight of the insoles by selection of materials that promote the
structural features of the insole. It is desirable that the total
weight of the preferred embodiment of the insole (men's size 10/11)
be about 4.0 ounces. It is desirable that the total weight of an
alternate embodiment of the insole be about 5.0 to 6.0 ounces for a
men's size 10/11 and about 6.5 to 7.5 ounces for a men's size
12/13. Other sizes will be proportional. The base layer may be
formed from a gel material or made of polyurethane polyester glycol
with a hardness of 30 Asker.+-.3, or alternatively, can be made of
a durable nylon fabric.
[0044] The base layer 102 is covered by a top sheet 128 that
extends across the top surface of the base layer 102 from heel to
toe end, and creates a top surface of the insole 100. The top sheet
128 is made of polyester or jadeite covering the entire foot
contact surface of the insole, and is treated with an antimicrobial
agent. Top sheet 128 is typically made of a non-woven fabric layer
with a low coefficient of friction so as to minimize the
possibility of blisters, or preferably, top sheet 128 is made of a
cooling fabric which contains a special low temperature jade
obtained from a natural source.
[0045] The top sheet 128 bottom surface is secured by an adhesive
to base layer 102 top surface and a top sheet upper surface which
contacts the foot of a user during use. The top sheet 128 is
oriented to engage the user's foot on the top surface of the
insole, and it serves an upper cooling and ventilation function,
and the top sheet 128 can be made of suitable materials, such as a
jadeite top cloth material. Preferably, the top sheet 128 is made
of a low-friction fabric which prevents blisters on the user's
foot. The top sheet 128 may also contain an antimicrobial treatment
in order to keep bacteria from multiplying and therefore reduce
odor. A suitable treatment is Silpure.RTM. antimicrobial treatment
(Thomson Research Associates, Inc., Ontario, Calif.).
[0046] In accordance with principles of the present invention and
as shown in FIG. 1A, 1B and 2, the shoe insole 100 has a bottom
surface formed of three pieces including: (1) a base layer 102
extending from heel-to-toe, (2) a forefoot pad layer 107 positioned
in a forefoot pad indentation area 102A on a forefoot area 108 of
the insole 100, and, (3) a midfoot-to-heel support cushion 105 made
of a soft polyurethane positioned in a midfoot-to-heel indentation
102B. The three-piece bottom surface construction makes fabrication
easier than known methods, and allows for different combinations of
materials and cushioning characteristics and support by adjusting
the materials used in the forefoot pad 107, base layer 102, the
midfoot-to-heel support cushion 105, and the heel pad 118.
[0047] In a preferred embodiment, the insole 100 has a base layer
102, which can be a polyurethane or fabric sheet, coupled to a
midfoot-to-heel support cushion 105 made of low density
polyurethane memory foam, ethylene glycol polyurethane, ethylene
vinyl acetate (EVA), pre-blown EVA, polyurethane (PU),
thermoplastic rubber (TPR) or other suitable material having a
midfoot surface 148 with a small diamond pattern and having a
hardness of the molded base material can range from less than 10
Asker.+-.3 to greater than 30 Asker.+-.3; a forefoot pad 107 molded
of lightweight materials such as low density polyurethane memory
foam, ethylene glycol polyurethane, ethylene vinyl acetate (EVA),
pre-blown EVA, polyurethane (PU), or thermoplastic rubber (TPR) or
other suitable material (hardness 10-35 Asker.+-.3) (diamond cube
pattern 117 spacing 1.0 mm-1.50 mm), a heel pad 118 made of
pre-blown EVA, PU, or other suitable material (hardness 10-35
Asker.+-.3) (diamond cube pattern spacing 1.0 mm-1.50 mm)
surrounded by a flat surface 152 on the base layer 102 and cupped
along the back by a heel cup 104, nylon fabric between
forefoot/heel pads and base (for adhesion of pads to PU), a raised
oval heel dome 118A on top surface of the insole on the
foot-contact side (shown in FIGS. 3 and 6) made of super-soft low
density PU, a raised medial arch 119 that has raised and indented
curvilinear lines extending generally longitudinally along arch
with vent holes, a groove depth on bottom 0.50 mm-1.5 mm, a top
cloth made of 65% Nylon/35% polyester, a teardrop metatarsal dome
134 on top side of the insole 100 (shown in FIGS. 3, 5 and 6) and
integrally formed as upwardly-curved indentation raised above the
bottom layer 102, a diamond cube pattern 117, 120 on the bottom
surface of the forefoot pad 107 and the heel pad 118, respectively,
and a separation wall 151 added between midfoot-to-heel cushion 105
and forefoot pad 107 of approximately 1 mm.
[0048] The metatarsal support 134 in formed in a metatarsal support
aperture 134A, which is integrally formed in the bottom surface of
the support cushion 105 on the bottom surface of the insole and it
has a concave surface oriented toward the bottom (shoe contact)
surface and a convex surface oriented toward the top (foot contact)
surface. The metatarsal support 134 is positioned in the midfoot
area 106 of the insole 100 to provide cushioning and support in the
area approximately under the second and third metatarsal bones. The
metatarsal support 134 is compressible with the convex top surface
being compressed by foot pressure downward toward the concave
portion of the base bottom surface allowing the support provided to
vary with the pressure of the user's foot.
[0049] In a preferred embodiment, the metatarsal support 134 is
teardrop shaped with the wider part of the shape oriented distally
to the insole under the second and third metatarsal bones and the
narrow part of the shape oriented proximally towards the tarsal
bones. In an alternate embodiment, the metatarsal support may have
another shape, such as diamond, rectangle or other shape suitable
for providing metatarsal support in the midfoot area of the
insole.
[0050] The metatarsal support 134 is integrally formed in the
material forming the base bottom surface of the insole 100 which is
preferably molded of low density polyurethane memory foam, but may
also be ethylene glycol polyurethane, ethylene vinyl acetate (EVA),
pre-blown EVA, polyurethane (PU), thermoplastic rubber (TPR) or
other suitable material. Hardness of the molded base material can
range from less than 10 Asker.+-.3 to greater than 30
Asker.+-.3.
[0051] Forefoot pad 107 is shaped essentially the same as forefoot
pad indentation area 102A and is secured therein. Forefoot pad 107
has a medial edge, a lateral edge, a proximal (back) edge and a
distal (front) edge. The medial edge of forefoot pad 107 extends
along a line spaced laterally from said medial border of said
insole. The proximal edge extends from said medial edge laterally
and proximally to said rear apex, laterally and distally towards
the 3.sup.rd metatarsal head, then laterally and proximally to the
lateral edge approximately along the 3.sup.rd through 5.sup.th
metatarsal heads.
[0052] The forefoot pad 107 generally extends from the proximal
region of the metatarsal head area to the distal toe end of the
insole and extends from the medial side to the lateral side of the
insole. In one embodiment, the forefoot pad 107 is secured within a
forefoot pad indentation 102A. The forefoot pad 107 has a thickness
of approximately 1.5 mm.+-.0.5 mm. In another embodiment, the
forefoot pad 107 is integrally formed in the material of the base
layer 102 of the insole 100. The forefoot pad 107 is preferably
molded of pre-blown ethylene vinyl acetate (EVA). The forefoot pad
107 may also be molded of EVA, polyurethane (PU), or thermoplastic
rubber (TPR) or other suitable material.
[0053] Preferably, the forefoot pad 107 has a diamond-cube pattern
117 on the forefoot pad 107 surface to provide traction,
compressive cushioning and lateral movement support to the forefoot
area. The diamond cube pattern 117 has a depth of approximately 1.0
mm 0.5 mm and has a surface pattern spacing of about 1.0 mm to
about 1.5 mm. In an alternate embodiment, the forefoot pad 107 has
a honeycomb-shaped pattern 117. In yet another embodiment, the
forefoot pad 107 has a texturized un-patterned surface 117. A thin
layer of nylon fabric may be positioned in the forefoot pad
indentation 102A between the forefoot pad 107 and the material of
the base layer 102 to increase the adhesion of the forefoot pad 107
to the base layer 102 when the forefoot pad 107 and base layer 102
are made of differing materials.
[0054] The forefoot pad 107 extends from the toe end of the insole
to the lateral midfoot/arch area from the medial side to the
lateral side of the forefoot area with a diamond-cube pattern 117
having pattern spacing of about 1 mm and a depth of about 1.5 mm.
The forefoot pad 107 made of molded of lightweight materials such
as low density polyurethane memory foam, ethylene glycol
polyurethane, ethylene vinyl acetate (EVA), pre-blown EVA,
polyurethane (PU), or thermoplastic rubber (TPR) or other suitable
material (hardness 10-35 Asker.+-.3) (pattern spacing 1.0 mm-1.50
mm). The firmness of the forefoot pad 107 can be adjusted to
address issues of over/under pronation, over/under supination, and
other problems related to foot motion by altering the size, shape,
and material properties of the pads. The configuration, material
and position of the forefoot pad 107 provides cushioning and works
in association with other items to stabilize the ankle. The
forefoot pads and heel pads are made of rubber or synthetic rubber,
which includes being made of a neoprene synthetic rubber layer
which is a polymer.
[0055] The lateral edge of the forefoot pad 107 connects said
proximal edge to said top edge of said forefoot pad 107. In use,
forefoot pad indentation area 102A and forefoot pad 107 underlie a
portion of the big toe of a user's foot, and the "ball" of the
foot, excluding the first metatarsal head or medial ball of the
user's foot. The forefoot pad 107 provides cushioning and energy
return on landing from a vertical jump. It serves as a propulsion
pad and support for the metatarsal heads of a user's foot,
especially the 1.sup.st and 2.sup.nd metatarsal heads. The forefoot
pad 107 has a diamond cube pattern 117 on its bottom surface to
improve forefoot cushioning characteristics, which improves
traction and adhesion of the insole inside and along the interior
bottom surface of the user's shoe and improves durability and
cushioning aspects of the forefoot pad over known materials.
[0056] The support cushion 105 is made of polyurethane polyester
glycol (hardness 10-30 Asker.+-.3--low density). The support
cushion indentation area 102B is located in the midfoot and heel
areas of the bottom surface of the insole. The midfoot-to-heel
support cushion indentation area 102B extends from a medial edge
approximate the medial border to a lateral edge approximate the
lateral border of the base layer 102 and from a distal edge
slightly proximal of the forefoot pad indentation area 102A to a
proximal edge approximate the heel end 104 of the base. A medial
portion of the distal edge is shaped to accommodate downward motion
of the 1st metatarsal during toe off. Support cushion 105 is shaped
essentially the same as midfoot-to-heel support cushion indentation
area 102B and has a base facing surface and a shoe facing surface.
The base facing surface is secured to said midfoot-to-heel support
cushion indentation area 102B.
[0057] The midfoot/heel support cushion 105 has a raised arch 119
in the medial arch area and curvilinear indentations 132 positioned
along at least two or more major angles from the longitudinal axis,
with the longitudinal axis extending from heel-to-toe on the insole
100. Longitudinal curvilinear indentations 132 extend in a first
angled direction compared to the longitudinal axis of the insole
100. The first angled directions is measured compared to the major
axis lengths of the longitudinal curvilinear indentations 132. The
first angled direction is approximately 5 degrees to 65 degrees
compared to the longitudinal axis, which is the lengthwise axis
extending from heel to toe on the insole 100. The longitudinal
curvilinear indentations 132 in the raised arch area 119 provide
additional rigidity to the raised arch support, which improves
support raised arch 119 in the support cushion 105. These
indentations 132 in this formation also promote polyurethane
material flow in the area of the midfoot while assisting to
minimize voids caused by air entrapment. The curvilinear
indentations 132 on the bottom surface of the raised arch 119 also
allow the raised arch 119 to collapse to fit the shoe thus
providing a more accommodative design.
[0058] The midfoot/heel cushion 105 also possesses a flattened
midfoot area 148 on the bottom surface of the insole 100 in midfoot
area 106 and a metatarsal midfoot tear-drop raised area 134
positioned in a metatarsal tear-drop aperture 134A (e.g. metatarsal
opening 134A) of the midfoot to heel support cushion 105. The
flattened midfoot area 148 on the bottom surface of the insole 100
in the midfoot area 106 of the midfoot/heel cushion 105 is bordered
on the medial side by a medial side longitudinal ridge 142
extending from midfoot to heel, on the lateral side by a lateral
side longitudinal ridge 143 extending midfoot to heel, and around
the exterior of the heel pod opening 112 by a heel ridge 152. This
ridge 143, 142 and 152 improves the support and durability of the
support cushion 105 and helps prevent pronation and supination
rotations on the user's foot during use, which enhances and
improves the performance of the insole. The midfoot/heel support
cushion 105 also has a surrounding heel cup 104 that supports the
exterior back of the user's heel with the heel cup 104 and extends
to the raised arch area 119, which also improves the support
provided to the user's foot during use.
[0059] Support cushion 105 has side and end walls that wrap up the
sides and rear of base layer 102 to provide support for the foot by
cupping the outside areas of the heel, providing stability
stiffness from the midfoot to the heel area, and providing an
upward support in the medial arch area of the user's foot.
Preferably, midfoot-to-heel support cushion 105 ranges from
approximately 0.5 mm to 3 mm thick and the walls taper from
approximately 3 mm to about 0.5 mm. The first or second set of
longitudinal indentations have a groove depth of approximately 0.50
mm-1.5 mm.
[0060] There is a raised separation wall 151 located on the base
layer 102 between the forefoot pad 107 and the midfoot/heel support
cushion 105, which is located laterally across the width of the
insole 100 between the metatarsal and forefoot areas on the insole
100. The separation wall provides isolation of the forefoot pad 107
from the midfoot-to-heel support cushion 105, which improves the
cushioning characteristics of those materials as well as improving
the support of the insole 100. The separation wall 151 located on
the bottom surface of the base layer 102 and is approximately 1 mm
in height. At the beginning of the propulsion or toe off phase of a
step, the heel begins to lift from the ground and weight shifts to
the ball of the foot. Forefoot pad 107 is located under this part
of the foot. Preferably, forefoot pad 107 is formed of a relatively
resilient material so that energy put into compressing forefoot pad
107 is returned to help propel the foot at toe off.
[0061] During toe off, the first metatarsal naturally flexes
downward. Preventing this natural downward flex of the first
metatarsal causes the arch of the foot to flatten and the foot to
over pronate, increasing stress on the ankles and knees. To
accommodate the downward flex, the forefoot pad 107 extends
rearward into a corresponding concave edge portion of the distal
edge of separation wall 151. The shape of the forefoot pad 107
permit the first metatarsal to flex more naturally and thereby
encourage loading of the great toe during toe off.
[0062] The heel pod opening 112 extends through the entirety of the
thickness of the midfoot/heel support cushion 105 to position the
heel pad 118 on the bottom surface of the base layer 102. The heel
pad aperture is surrounded by a flat midfoot/heel surface with
surrounding grooves. The heel pod opening 112 is surrounded
circumferentially by heel pod opening border grooves 138, which
surrounds the circumference of the heel pod opening 112. These
grooves isolate the heel pad 118 from the midfoot-to-heel support
cushion 105, which improves the performance of the heel pad 118 by
isolating the heel pad 118 and preventing migration of the
cushioning effect laterally (cushioning effect absorbs directional
impact force better with supporting grooves). The heel pad 118 is
located in the heel pod opening 112 and affixed to the bottom
surface of the insole 100, and the heel pad 118 that extends from
the proximate end of the heel (calcaneal bone) area to an area
adjacent the proximal portion of the medial arch support area. In a
preferred embodiment, the heel cushioning area has a heel pad 118
secured within a heel pad opening 112 formed in support cushion 105
with the heel pad 118 being secured to base layer 102 of the insole
100.
[0063] The heel pad 118 has a thickness of approximately 3.0
mm.+-.0.5 mm. In an alternate embodiment, the heel pad 118 is
integrally formed in the material of the base bottom surface of the
insole. The heel pad 118 provides compressive cushioning and
support under the heel (calcaneal) bone. Preferably, the heel pad
118 has a diamond-cube pattern 120 on the heel pad 118 surface to
provide compressive cushioning and support to the heel area. The
diamond cube pattern 120 has a depth of approximately 1.5 mm.+-.0.5
mm and has a surface pattern spacing of about 1.0 mm to about 1.5
mm. In an alternate embodiment, the heel pad 118 has a
honeycomb-shaped pattern, and, in yet another embodiment, the heel
pad 118 has a texturized un-patterned surface.
[0064] The heel pad 118 is preferably molded of pre-blown ethylene
vinyl acetate (EVA). The heel pad 118 may also be molded of EVA,
polyurethane (PU), or thermoplastic rubber (TPR) or other suitable
material. A thin layer of nylon fabric may be positioned in the
heel pad 118 between the heel pad 118 and the material of the base
layer 102 to increase the adhesion of the heel pad 118 to the base
layer 102 when the heel pad 118 and base layer 102 are made of
differing materials.
[0065] The heel pad 118 has a diamond cube pattern 120 to improve
heel cushioning characteristics and improve traction and adhesion
of the insole inside and along the interior bottom surface of the
user's shoe. The heel pad 118 can be made from a TPR gel or made of
pre-blown EVA (ethylene-vinyl acetate) material, and the heel pad
has a hardness rating of 10-35 Asker.+-.3. The heel pad has a
diamond cube pattern 120 with a width spacing of approximately 1.0
mm-1.50 mm. There is a soft heel dome 118A on the top (foot
contact) surface of the insole (shown in FIGS. 3 and 5) located
above the heel pad 118 in the bottom (shoe contact) surface
providing heel cushioning directly under a user's heel bone and
also providing shock absorption on the insole bottom.
[0066] Insole 100 production can be accomplished by an open-pour
molding process. The process consists of pouring mixed polyurethane
or TPR into an open mold. Once poured in the mold, the polyurethane
mixture will expand to fill the cavity. Once cured, the base insole
is removed from the mold. The forefoot cushion and heel cushion if
employed can be secured to the indentations by adhesive or can be
secured in place during the polyethylene pouring operation. Bonding
occurs to a fabric that is bonded to the forefoot cushion or the
heel cushion.
[0067] Alternatively, the forefoot pad 107 can be molded onto the
bottom surface of the insole base layer 102 from the forefoot pad
indentation 102A up to the separation wall 151 on the base bottom
surface of the base layer 102. A fabric layer may be inserted
between the forefoot pad 107 and the base layer 102 in the forefoot
pad indention 102A. And, the midfoot/heel cushion 105 can be molded
onto the bottom surface of the insole base layer 102 from the
indentation 102B up to the separation wall 151 on the base bottom
surface of the base layer 102. A fabric layer may be inserted
between the midfoot-to-heel support cushion 105 and the base layer
102 in the indentation 102B. Also, the heel pad 118 can be molded
onto the bottom surface of insole base layer 102 in the heel pod
opening 112. A fabric layer may be inserted between the heel pad
118 and the base layer 102 in the support cushion indentation area
102B. The forefoot pad 107, the heel pad 118, and the midfoot/heel
support cushion 105 can also be secured adjacent to one another on
the bottom surface of the base layer 102 with an adhesive that is
suitable for creating a semi-permanent (or permanent) bond or
adhesive, which may be liquid upon application but firms into a
solid. The curvilinear indentations 132 are preferably molded into
the support cushion 105 during manufacture.
[0068] FIG. 3 illustrates the top (foot side) of an insole
according to the invention with a top sheet 128 covering the top
side of the insole 100, which is placed over the base layer 102. A
heel dome 118A is located on the top surface of insole 100 and a
metatarsal dome 134 raised on the top surface of insole 100, each
of which respectively improves the cushioning characteristics of
the insole at or near high impact points on the insole 100. The
medial side of the base layer 102, the heel cup 104, and the
lateral side of the base layer 102 are shown in FIG. 3. The
teardrop metatarsal pad 134 on top side is integrally formed as
upwardly-curved indentation from bottom surface of the insole.
[0069] On the foot contact surface of the insole 100, the base
layer 102 has a raised heel dome 118A and a metatarsal dome 134.
The heel dome 118A is positioned under the heel bone to provide
additional cushioning to the user's heel while walking or standing.
The metatarsal dome 134 is positioned under the heel bone to
provide additional cushioning to the user's heel while walking or
standing. The heel dome 118A curves upward from the insole 100 top
(foot contact) surface to make a dome-like contact surface under
the heel of the user and the metatarsal dome 134 curves upward from
the insole 100 top (foot contact) surface to make a dome-like
contact surface under the metatarsal area of the foot. The heel
dome 118A and the metatarsal dome 134 are preferably molded as a
cushion separate from the base layer 102 and secured to the top
side of the base layer 102 in the heel area 104. The heel dome 118A
is covered by the top sheet 128 providing a continuous contact
surface to the user's foot on the top (foot contact) surface of the
insole. In an alternative embodiment, the heel dome 118A and the
metatarsal dome 134 are integrally formed in the material
comprising the top side of the base layer 102.
[0070] The heel dome 118A and the metatarsal dome 134 are
preferably formed of super soft low density polyurethane, but may
be formed of polyurethane memory foam, ethylene glycol
polyurethane, ethylene vinyl acetate (EVA), pre-blown EVA,
polyurethane (PU), thermoplastic rubber (TPR) or other suitable
material. Hardness of the heel dome 118A and the metatarsal dome
134 material can range from less than 10 Asker.+-.3 to greater than
30 Asker.+-.3.
[0071] The heel dome 118A on the top (foot contact) surface of the
insole 100 is located directly above the heel pad 118 in the bottom
(shoe contact) surface (shown in FIGS. 1A, 1B and 2) of the base
layer 102, and heel dome 118A provides heel cushioning directly
under a user's heel bone and also provides shock absorption on the
insole bottom from the top surface of the insole 100. A soft
metatarsal dome 134 is located on the top (foot contact) surface
providing cushioning directly over the metatarsal area of the
foot.
[0072] The top sheet 128 is shown in FIG. 3. The top sheet 128
covers the entire foot contact surface of the insole 100 which is
treated with an antimicrobial agent. The top surface of the insole
100 is covered by a top sheet 128 that extend across the top
surface from heel to toe end. Top sheet 128 is typically made of a
non-woven fabric layer with a low coefficient of friction so as to
minimize the possibility of blisters, or preferably, top sheet 128
is made of a cooling fabric which contains a special low
temperature jade obtained from a natural source. The top sheet can
be made of 65% Nylon/35% polyester.
[0073] Referring to FIG. 4, the medial side view of the insole 100
is shown with curvilinear indentations 132 shown in the raised arch
area 119. Also illustrated is a forefoot pad 107 located in the
forefoot area 108, a base layer 102, a support cushion 105, the
heel cup 104, and a top sheet 128. Insole 100 preferably comprises
a top sheet 128 and a base layer 102 having a top surface secured
to said top sheet and an opposite bottom surface. Base layer 102
also defines a raised arch support 119 that extends upwardly along
the medial side of the insole to provide extra cushion and support
to the raised arch 119 of the foot.
[0074] Referring to FIG. 5, the insole 100 lateral side view is
shown with the raised arch 119, the metatarsal dome 134, a forefoot
pad 107 located in the forefoot area 108, a base layer 102, the
heel cup 104, the lateral side 106 of the support cushion 105, and
a top sheet 128. FIG. 5 shows insole 100 preferably comprises a top
sheet 128 and a base 102 having a top surface secured to said top
sheet 128 and an opposite bottom surface. Base layer 102 also
defines a raised arch support 119 that extends upwardly along the
medial side of the insole to provide extra cushion and support to
the arch area of the foot.
[0075] As shown in FIGS. 4 and 5, the shoe insole 100 has a bottom
surface formed of three pieces including: (1) a base layer 102
extending from heel-to-toe, (2) a forefoot pad 107 positioned in a
forefoot pad indentation area 102A (shown in FIG. 1B) on a forefoot
base area 108 of the insole 100, and, (3) a midfoot-to-heel support
cushion 105 positioned in a midfoot to heel indentation area 102B
(shown in FIG. 1B). The three-piece bottom surface construction
makes fabrication easier than known methods, and allows for
different combinations of materials and cushioning characteristics
and support by adjusting the materials used in the forefoot pad
107, base layer 102, the support cushion 105, and the heel pad 118
(shown in FIGS. 1A, 1B and 2).
[0076] The forefoot pad 107 extends from the toe end of the insole
to the lateral midfoot area and from the medial side to the lateral
side of the forefoot area with a diamond-cube pattern molded in the
gel having pattern spacing of about 1 mm and a depth of about 1.5
mm. The firmness of the forefoot pad 107 can be adjusted to address
issues of over/under pronation, over/under supination, and other
problems related to foot motion by altering the size, shape, and
material properties of the pads. The configuration, material and
position of the forefoot pad 107 provides cushioning and works in
association with other items to stabilize the ankle. The forefoot
pad 107 has a diamond cube pattern 117 on its bottom surface (shown
in FIGS. 1A, 1B and 2) to improve forefoot cushioning
characteristics, which improves traction and adhesion of the insole
inside and along the interior bottom surface of the user's shoe and
improves durability and cushioning aspects of the forefoot pad 107
over known materials.
[0077] The midfoot/heel support cushion 105 has a raised arch 119
in the medial arch area, which has longitudinal curvilinear
indentations 132 positioned along at least two or more major angles
from the longitudinal axis, with the longitudinal axis extending
from heel-to-toe on the insole 100. As shown in FIG. 4,
longitudinal curvilinear indentations 132 extend in a first angled
direction compared to the longitudinal axis of the insole 100. The
longitudinal curvilinear indentations 132 in the raised arch 119
provide additional rigidity to the raised arch support 119, which
improves support provided by the raised arch 119 on the support
cushion 105. These indentations 132 in this formation also promote
polyurethane material flow in support cushion 105 formation while
assisting to minimize voids caused by air entrapment. The
curvilinear indentations 132 in the arch area 119 also allow the
arch area to collapse to fit the shoe thus providing a more
accommodative design.
[0078] There is a raised separation wall 151 shown in FIGS. 4 and 5
located on the base layer 102 between the forefoot pad 107 and the
midfoot-to-heel support cushion 105, which is located laterally
across the width of the insole 100 between the metatarsal and
forefoot areas on the insole 100. The separation wall 151 provides
isolation of the forefoot pad 107 from the midfoot-to-heel support
cushion 105, which improves the cushioning characteristics of those
materials as well as improving the support of the insole 100. At
the beginning of the propulsion or toe off phase of a step, the
heel begins to lift from the ground and weight shifts to the ball
of the foot. Forefoot pad 107 is located under this part of the
foot.
[0079] The top sheet 128 bottom surface is secured to base layer
102 top surface and a top sheet upper surface which contacts the
foot of a user during use. The top sheet 128 is oriented to engage
the user's foot on the top surface of the insole, and it serves an
upper cooling and ventilation function, and the top sheet 128 can
be made of suitable materials, such as a jadeite top cloth
material. Preferably, the top sheet 128 is made of a low-friction
fabric which prevents blisters on the user's foot. The top sheet
128 may also contain an antimicrobial treatment in order to keep
bacteria from multiplying and therefore reduce odor.
[0080] Now referring to FIG. 6, the front end view of insole 100 is
shown from the front toe end looking toward the heel end 104 with
the upraised heel area visible at the heel end 104 and raised arch
support 119 shown in FIG. 6. FIG. 6 shows forefoot pad 107 in
forefoot area 108, base layer 102, raised arch area 119, and top
sheet 128. FIG. 7 shows the heel end view of the insole 100 looking
from the heel area towards the toe area, with the top sheet 128
shown in this figure. From this view, one can see the features of
insole 100 including heel cup 104, lateral side and medial side of
the base layer 102, the raised arch 119 with placement of
curvilinear indentations 132, and the top sheet 128.
[0081] As shown in FIGS. 6 and 7, the shoe insole 100 has a bottom
surface formed of three pieces including: (1) a base layer 102
extending from heel-to-toe, (2) a forefoot pad layer 107 positioned
in a forefoot pad indentation 102A (shown in FIG. 1B) on a forefoot
base area 108 of the insole 100, and, (3) a midfoot-to-heel support
cushion 105 positioned in a midfoot to heel indentation 102B (shown
in FIG. 1B). The three-piece bottom surface construction makes
fabrication easier than known methods, and allows for different
combinations of materials and cushioning characteristics and
support by adjusting the materials used in the forefoot pad 107,
base layer 102, the support cushion 105, and the heel pad 118
(shown in FIGS. 1A, 1B and 2).
[0082] In a preferred embodiment, the insole 100 has a base layer
102, a forefoot pad 107, a heel pad surrounded by a flat
midfoot/heel surface and cupped along the back by a heel cup 104.
The midfoot/heel cushion 105 has a raised arch 119 in the medial
arch area and longitudinal curvilinear indentations 132 positioned
along at least two or more major angles from the longitudinal axis,
with the longitudinal axis extending from heel-to-toe on the insole
100. A teardrop metatarsal dome 134 shown in FIGS. 6 and is located
on top side of the insole 100 is integrally formed from the
upwardly-curved metatarsal raised area 134 on the bottom surface,
and a diamond cube pattern 117, 120 (shown in FIGS. 1A, 1B and 2)
is located on the bottom surface of the forefoot pad 107. A
separation wall 151 (shown in FIGS. 1A, 1B and 2) is located
between cushion 105 and forefoot pad 107 with an approximate height
of 1 mm.
[0083] The forefoot pad 107 extends from the toe end of the insole
to the midfoot area and extends from the medial side to the lateral
side of the forefoot area with a diamond-cube groove pattern molded
in the gel having pattern spacing of about 1 mm and a depth of
about 1.5 mm. The forefoot pad 107 has a firmness that can be
adjusted to address issues of over/under pronation, over/under
supination, and other problems related to foot motion by altering
the size, shape, and material properties of the pads. The
configuration, material and position of the forefoot pad 107
provides cushioning and works in association with other items to
stabilize the ankle. The forefoot pad 107 has a diamond shaped
groove pattern 117 (shown in FIGS. 1A, 1B and 2) on its bottom
surface to improve forefoot cushioning characteristics, which
improves traction and adhesion of the insole inside and along the
interior bottom surface of the user's shoe and improves durability
and cushioning aspects of the forefoot pad 107 over known
materials.
[0084] The midfoot/heel cushion 105 has a raised arch 119 in the
medial arch area of the insole 100 and longitudinal curvilinear
indentations 132 positioned along at least one major angle of
inclination from the longitudinal axis, with the longitudinal axis
extending from heel-to-toe on the insole 100. As shown in FIG. 7,
longitudinal curvilinear indentations 132 extend in a first angled
direction compared to the longitudinal axis of the insole 100.
[0085] The top sheet 128 bottom surface is secured to base layer
102 top surface and a top sheet upper surface which contacts the
foot of a user during use. The top sheet 128 is oriented to engage
the user's foot on the top surface of the insole, and it serves an
upper cooling and ventilation function, and the top sheet 128 can
be made of suitable materials, such as a jadeite top cloth
material. Preferably, the top sheet 128 is made of a low-friction
fabric which prevents blisters on the user's foot. The top sheet
128 may also contain an antimicrobial treatment in order to keep
bacteria from multiplying and therefore reduce odor.
[0086] Foot contact with the ground is generally divided into three
phases: heel strike, midfoot support, and toe off. During heel
strike, the heel of the foot impacts the ground with significant
force. Following the initial impact of the heel with the ground,
the foot twists, or pronates, bringing the medial side of the heel
into contact with the ground. The foot is sensitive to the amount
of pronation as well as the rate at which the pronation occurs.
Pronation is natural, and some degree of pronation is desirable
because it serves to absorb the stresses and forces on the foot
during walking or running. However, an excessive amount or rate of
pronation can result in injury.
[0087] All of the above components work in conjunction with each
other to accomplish the goals of the invention, such as: (1)
improving ankle and foot stability, (2) cushioning the heel and
forefoot during push-offs and landings, (3) helping prevent over
pronation and over supination conditions, and (4) providing
enhanced cushioning features to the heel, midfoot, arch and
forefoot areas. Support cushion 105 provides firm support along the
medial portion of the foot, including the medial arch area and
surrounding the heel area, to help control the amount of foot
pronation.
[0088] In a first preferred embodiment of the present invention,
the various components of an insole which are secured to base layer
102 in the indentation areas defined by base layer 102 on the
bottom surface are permanently affixed to base layer 102 using an
appropriate means such as an adhesive. The components are secured
during the molding process using techniques known in the art of
molding insoles. The indentation areas are also lined with a cloth
having a base surface and a pad surface, secured to said base layer
102 along said base surface and said pad along said pad surface.
Alternatively, a cloth is secured to said pad and then the
composite structure secured to the indentation area.
[0089] An improved insole 100 has been disclosed. It will be
readily apparent that the illustrative embodiments of an insole
thus disclosed may be useful in cushioning the foot and controlling
pronation during activities such as hiking, backpacking, and the
like. However, one will understand that the components of the
insole system may be modified to accommodate other activities or to
control other kinds of foot motion. Thus, the description provided
herein, including the presentation of specific thicknesses,
materials, and properties of the insole components, is provided for
purposes of illustration only and not of limitation, and that the
invention is limited only by the appended claims.
* * * * *