U.S. patent application number 15/574289 was filed with the patent office on 2018-05-17 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 | 20180132565 15/574289 |
Document ID | / |
Family ID | 57393702 |
Filed Date | 2018-05-17 |
United States Patent
Application |
20180132565 |
Kind Code |
A1 |
Granger; David Bradley ; et
al. |
May 17, 2018 |
Contoured Support Shoe Insole
Abstract
An insole having a top sheet, a base layer, a forefoot pad, a
heel cushion, and support cushion, as well as a strength layer
inserted between those components to strengthen and enhance the
durability of the insole. The forefoot pad can be made a blown EVA
or other material, and the heel cushion can be made of a clear TPR,
soft polyurethane or blown EVA. The support cushion has a raised
lateral arch and a raised medial arch, the later of which has
longitudinal curvilinear indentations, a flattened central midfoot
area with a metatarsal mid-foot tear-drop raised area and
longitudinal ridges on the flat midfoot area. A heel cup surrounds
the exterior back by a heel cup, and a heel pod opening goes
through the entirety of the thickness of base layer of the insole
body for placement of the heel pad so the heel pad is affixed to
the bottom surface of the base layer. There is also a supersoft
metatarsal raised dome on the top (foot contact) surface of the
insole which would be directly above the metatarsal midfoot
area.
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: |
57393702 |
Appl. No.: |
15/574289 |
Filed: |
May 26, 2016 |
PCT Filed: |
May 26, 2016 |
PCT NO: |
PCT/US2016/034417 |
371 Date: |
November 15, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62167797 |
May 28, 2015 |
|
|
|
62182162 |
Jun 19, 2015 |
|
|
|
62214595 |
Sep 4, 2015 |
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62216496 |
Sep 10, 2015 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 7/144 20130101;
A43B 13/226 20130101; A43B 17/026 20130101; A43B 17/006 20130101;
A43B 13/223 20130101; A43B 17/18 20130101 |
International
Class: |
A43B 13/22 20060101
A43B013/22; A43B 17/00 20060101 A43B017/00; A43B 17/02 20060101
A43B017/02; A43B 17/18 20060101 A43B017/18; A43B 7/14 20060101
A43B007/14 |
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 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, (b) 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; (c) a
metatarsal dome on the top surface of base layer and raised over
the metatarsal midfoot area of the insole; (d) 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 medial arch support on
the bottom surface of the insole in the medial arch midfoot area,
(b) a raised lateral arch support on the bottom surface of the
insole in the lateral midfoot area, (c) a heel cup on the bottom
surface of the insole and surrounding the heel end of the insole
with vertical walls, (d) a metatarsal arch dome raised up from the
bottom surface of the insole, (e) one or more longitudinal ridges
on the bottom surface of the support cushion, and (f) a heel pad
aperture on the bottom surface of the base layer in the heel area,
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 aperture 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 base layer is formed of a
gel material.
3. The insole of claim 1 further comprising a strength layer
affixed to said base layer and at least partially extending from
heel to toe across said insole.
4. The insole of claim 1, wherein said base layer is made of
polyurethane polyester glycol with a hardness 10-30 Asker
.+-.3.
5. The insole of claim 1, wherein said forefoot pad made of a clear
TPR gel (thermoplastic rubber).
6. The insole of claim 5, wherein said TPR gel has a hardness
rating of 10-20 Asker .+-.3.
7. 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.
8. The insole of claim 1, wherein said heel pad is made of
pre-blown EVA (ethylene-vinyl acetate) material.
9. The insole of claim 8, wherein said heel pad has a hardness
rating of 10-35 Asker .+-.3.
10. 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.
11. The insole of claim 1, wherein said heel pad aperture is
surrounded by heel aperture grooves.
12. The insole of claim 1, wherein base layer is made of a durable
nylon fabric.
13. The insole of claim 1, wherein said first curvilinear
indentations have a groove depth of approximately 0.50 mm-1.5
mm.
14. The insole of claim 1, wherein said top sheet is made of 65%
Nylon/35% polyester.
15. 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.
16. 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.
17. The insole of claim 1, wherein said forefoot and heel pads are
made of rubber or synthetic rubber.
18. The insole of claim 1, wherein said forefoot and heel pads are
made of a neoprene synthetic rubber.
19. 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
forefoot pad 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, (b) a midfoot-to-heel
stability cushion 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; a
stability cushion positioned on the bottom surface of the base
layer in the stability cushion area and having: (a) a raised medial
arch support on the bottom surface of the insole in the medial arch
midfoot area, (b) a raised lateral arch support on the bottom
surface of the insole in the lateral midfoot area, (c) a heel cup
on the bottom surface of the insole and surrounding the heel end of
the insole with vertical walls, (d) a metatarsal arch dome raised
up from the bottom surface of the insole, (e) one or more
longitudinal ridges on the bottom surface of the support cushion,
and (f) a heel pad aperture on the bottom surface of the base layer
in the heel area, 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 aperture 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.
20. The insole of claim 19, 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.
21. The insole of claim 19 further comprising a strength layer
affixed to said base layer and at least partially extending from
heel to toe across said insole.
22. 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.
23. The insole of claim 19, 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.
24. The insole of claim 19, wherein base layer is made of a durable
nylon fabric.
25. The insole of claim 19, wherein said base layer is formed from
a gel material.
26. The insole of claim 19, wherein said base layer is made of
polyurethane polyester glycol with a hardness 30 Asker .+-.3.
27. The insole of claim 19, wherein said forefoot pad is made of
clear TPR gel (thermoplastic rubber) gel.
28. The insole of claim 27, wherein said TPR gel has a hardness
rating of 10-20 Asker .+-.3.
29. The insole of claim 19, wherein said forefoot pad has a groove
pattern with a width spacing of approximately 1.0 mm-1.50 mm.
30. The insole of claim 19, wherein said heel pad made of pre-blown
EVA (ethylene-vinyl acetate) material.
31. The insole of claim 30, wherein said heel pad has a hardness
rating of 10-35 Asker .+-.3.
32. The insole of claim 19, wherein said heel pad has a groove
pattern with a width spacing of approximately 1.0 mm-1.50 mm.
33. The insole of claim 19, wherein said heel pad aperture is
surrounded by heel pad aperture grooves.
34. The insole of claim 19, wherein said first curvilinear
indentations have a groove depth of approximately 0.50 mm-1.5
mm.
35. The insole of claim 19, wherein said top sheet is made of 65%
Nylon/35% polyester.
36. The insole of claim 19, 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.
37. The insole of claim 19, wherein said forefoot pad and support
cushion are made of rubber or synthetic rubber.
38. The insole of claim 19, wherein said forefoot pad and support
cushion are made of a neoprene synthetic rubber layer which is a
polymer.
39. 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 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, (b) 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; (c) a
metatarsal dome on the top surface of base layer and raised over
the metatarsal midfoot area of the insole; (d) 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
medial arch support on the bottom surface of the insole in the
medial arch midfoot area, (b) a raised lateral arch support on the
bottom surface of the insole in the lateral midfoot area, (c) a
heel cup on the bottom surface of the insole and surrounding the
heel end of the insole with vertical walls, (d) a metatarsal arch
dome raised up from the bottom surface of the insole, (e) one or
more longitudinal ridges on the bottom surface of the support
cushion, and (f) a heel pad aperture on the bottom surface of the
base layer in the heel area, said raised medial 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 aperture
of the stability cushion, and extending the heel pad through the
stability cushion to be secured to the bottom surface of the base
layer; 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.
40. The method of making the insole of claim 39, wherein said base
layer is formed of a gel material.
41. The method of making the insole of claim 39, further comprising
the step of: positioning a strength layer onto said base layer and
at least partially extending from heel to toe across said
insole.
42. The method of making the insole of claim 39, wherein said base
layer is made of polyurethane polyester glycol with a hardness
10-30 Asker .+-.3.
43. The method of making the insole of claim 39, wherein said
forefoot pad made of a clear TPR gel (thermoplastic rubber).
44. The method of making the insole of claim 43, wherein said TPR
gel has a hardness rating of 10-20 Asker .+-.3.
45. The method of making the insole of claim 39, wherein said
forefoot pad has a groove pattern with a width spacing of
approximately 1.0 mm-1.50 mm.
46. The method of making the insole of claim 39, wherein said heel
pad is made of pre-blown EVA (ethylene-vinyl acetate) material.
47. The method of making the insole of claim 46, wherein said heel
pad has a hardness rating of 10-35 Asker .+-.3.
48. The method of making the insole of claim 39, wherein said heel
pad has a groove pattern with a width spacing of approximately 1.0
mm-1.50 mm.
49. The method of making the insole of claim 39, wherein said heel
pad aperture is surrounded by heel pad aperture grooves.
50. The method of making the insole of claim 39, wherein base layer
is made of a durable nylon fabric.
51. The method of making the insole of claim 39, wherein said first
curvilinear indentations have a groove depth of approximately 0.50
mm-1.5 mm.
52. The method of making the insole of claim 39, wherein said top
sheet is made of 65% Nylon/35% polyester.
53. The method of making the insole of claim 39, 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.
54. The method of making the insole of claim 39, wherein said
separation wall located on the bottom surface of the base layer and
is approximately 1 mm in height.
55. The method of making the insole of claim 39, wherein said
forefoot pad and support cushion are made of rubber or synthetic
rubber.
56. The method of making the insole of claim 39, wherein said
forefoot pad and support cushion are made of a neoprene synthetic
rubber.
57. The method of making the insole of claim 39 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. 62/167,797 filed May 28, 2015, U.S.
Provisional Patent Application Ser. No. 62/182,162 filed Jun. 19,
2015, U.S. Provisional Patent Application Ser. No. 62/214,595 filed
Sep. 4, 2015, and U.S. Provisional Patent Application Ser. No.
62/216,496 filed Sep. 10, 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.
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 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 has 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/toe layer made of a clear TPR gel and
positioned in a forefoot/toe indentation on a forefoot base area of
the insole, and, (3) a midfoot to heel stability cushion made of a
soft polyurethane positioned in a midfoot to heel indentation. The
forefoot/toe insert and the midfoot/heel cushion are secured
adjacent to one another on the bottom surface of the base layer. A
strength layer composed of a woven fabric, a composite material or
an enhanced fabric is also inserted between those components to
strengthen and enhance the durability of the insole.
[0014] The insole has a base layer is made of clear TPR gel having
a hardness of about 24 Asker .+-.3 (range 10-30 Asker .+-.3)
extending the length and width of the insole with an integrally
formed indentation to receive a support cushion in area of the
medial arch and encompassing the heel; an integrally formed
forefoot pad extending from the medial to the lateral sides from
the toe end of the insole to the medial arch/midfoot area having a
diamond-cube pattern with a pattern spacing of about 1 mm and a
depth of about 2.0 mm; an integrally formed support cushion with a
diamond shaped honeycomb pattern in the lateral midfoot area with a
pattern spacing of about 1 mm and a depth of about 0.5 mm; and a
teardrop shaped indentation in the metatarsal area of the support
cushion 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.
[0015] The support cushion is made of clear TPR gel having a
hardness of about 70 Asker .+-.3 (range 50-80 Asker .+-.3)
dimensioned to fit in the support cushion indentation integrally
formed in the base layer in the medial arch area to heel area with
integrally formed longitudinal curvilinear indentations extending
lengthwise in the medial arch area and an integrally formed heel
pad opening or aperture in the heel area to receive a heel pad
under the calcaneal (heel) bone.
[0016] The heel pad is made of TPR gel having a hardness of 20
Asker .+-.3 (range 10-30 Asker .+-.3) having an integrally formed
diamond-cube pattern with a pattern spacing of 1.5 mm and a depth
of about 2 mm dimensioned to fit in the heel pad indentation of the
support cushion. The insole also possesses a strength support layer
with a minimum pull strength of 2 pounds laminated to the underside
of the top sheet and secured to the top side of TPR base, and the
strength support layer can be positioned above or below the base
layer. 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.
[0017] The insole also has a top sheet of knitted or woven
polyester covering the entire foot contact surface of the insole
which is treated with an antimicrobial agent. The insole has a top
sheet layer that extends from heel to toe over the top surface of
the insole. The forefoot pad has a diamond cube or diamond 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.
[0018] The present invention is an insole having a top sheet, a
base layer, a forefoot pad, a heel cushion, support cushion, and a
strength layer inserted between those components to strengthen and
enhance the durability of the insole. The forefoot pad can be made
of a blown EVA or other material, and the heel cushion can be made
of a clear TPR, soft polyurethane or blown EVA. The support cushion
has a raised arch with longitudinal curvilinear indentations, a
flattened midfoot area with a metatarsal mid-foot tear-drop raised
area and longitudinal ridges on the flat midfoot area. A heel cup
surrounds the exterior back of the heel, and a heel pod opening
goes through the entirety of the thickness of base layer of the
insole body for placement of the heel pad so the heel pad is
affixed to the bottom surface of the base layer. There is a
supersoft metatarsal raised dome on the top (foot contact) surface
of the insole which would be directly above the metatarsal midfoot
area.
[0019] 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 cushions and 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.
[0020] The midfoot/heel support 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 support cushion also has a lateral
midfoot arch that offers additional support to the lateral midfoot
area. The midfoot/heel cushion also possesses a flattened central
midfoot area on the midfoot area with a square grid pattern 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 heel cup that supports the exterior
back of the user's heel with the heel cup and extends to the raised
arch area.
[0021] 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 surround the
circumference of the heel pod opening. The heel pad is located on
the bottom surface of the insole and is made of a clear TPR gel,
blown 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 shaped groove
pattern, but can be have a flat un-patterned surface.
[0022] A shoe insole with a base layer made 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 ranging 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. A raised medial
arch on the support cushion is located 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
is located 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.
[0023] The forefoot pad can be made of clear TPR gel (thermoplastic
rubber), where said TPR gel has a hardness rating of 10-20 Asker
.+-.3. Alternatively, the forefoot pad can be made of molded
pre-blown ethylene vinyl acetate (EVA), polyurethane (PU), or
thermoplastic rubber (TPR) or other suitable material, so that it
extends from the toe end of the insole to the midfoot area and from
the medial side to the lateral side of the forefoot area with a
hardness of approximately 10-30 Asker C .+-.3. If the forefoot pad
has a patterned surface, the pattern spacing is 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 is 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.
[0024] A heel pad on the bottom surface of the insole is made of
clear TPR (thermoplastic rubber) or pre-blown ethylene vinyl
acetate (EVA), molded of EVA, polyurethane (PU), or other suitable
material with a hardness of approximately 10-35 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. The heel pad can have 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, with groove depth of
approximately 1 mm, and a thickness of the heel pad of about 1.5
mm.+-.0.5 mm. This heel pad is secured on the bottom surface of the
base layer. 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.
[0025] A supersoft metatarsal dome shaped like a teardrop is
located on the top (foot contact) midfoot surface of the insole
which would normally be located below the foot metatarsal bones.
And, a top sheet of polyester covers the entire foot contact
surface of the insole which is treated with an antimicrobial
agent.
[0026] 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 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.
[0027] 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.
[0028] 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
[0029] 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:
[0030] FIGS. 1A and 1C are bottom perspective views of an
illustrative embodiment of an insole in accordance with the
principles of the present invention;
[0031] FIG. 1B is a exploded perspective view of an illustrative
embodiment of an insole in accordance with the principles of the
present invention;
[0032] FIG. 2A-2C are bottom planar views showing the base of the
insole;
[0033] FIGS. 3A and 3B are top (dorsal) views of the insole;
[0034] FIGS. 4A and 4B are medial (inner arch area) side views of
the insole;
[0035] FIGS. 5A and 5B are lateral (outer) side views of the
insole;
[0036] FIGS. 6A and 6B are front (proximal) views of the insole;
and,
[0037] FIGS. 7A and 7B are rear (proximal) views of the insole.
DETAILED DESCRIPTION
[0038] Referring to FIGS. 1A, 1B, 1C, 2A, 2B and 2C, these views
are perspective and bottom 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. FIGS. 1A, 1B and 2A and 2B show the heel
pad 118 with a diamond cube heel 120 pattern; FIGS. 1A, 1B and 2A
and 2C having clear TPR gel support cushion 105 and forefoot pads
107, and FIGS. 1C and 2B show a non-gel material used in the
support cushion 105 and forefoot pad 107, and FIG. 2C show a gel
material support cushion 105 and forefoot pad 107 with a diamond
shaped heel 120 pattern.
[0039] The insole 100 surface is generally foot-shaped extending
longitudinally along an axis 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.
[0040] The invention possesses a base layer 102, a support cushion
105 and a forefoot pad 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 a forefoot pad
indentation 102B in the forefoot area dimensioned to receive a
forefoot pad 107, and/or a support cushion indentation area 102A in
the midfoot-to-heel area dimensional to receive the support cushion
105. In an alternate embodiment, the forefoot pad 107 and the
support cushion 105, as well as the heel pad 118 are molded
directly onto the base layer 102.
[0041] Preferably, the insole 100 has a base layer 102 made of
clear TPR gel having a hardness of about 24 Asker .+-.3 (range
10-30 Asker .+-.3) extending the length and width of the insole 100
with an integrally formed indentation 102B to receive a support
cushion 102 in the medial arch area and encompassing the heel; an
integrally formed forefoot pad 107 positioned in a forefoot pad
indention 102A and extending from the medial to the lateral sides
from the toe end of the insole to the medial arch/midfoot area
having a diamond-cube pattern with a pattern spacing of about 1 mm
and a depth of about 2.0 mm; an integrally formed support cushion
105 with a diamond shaped honeycomb pattern in the central midfoot
area with a pattern spacing of about 1 mm and a depth of about 0.5
mm; and a teardrop shaped indentation 134 in the metatarsal area of
the support cushion 105 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 102.
[0042] The support cushion 105 is made of clear TPR gel having a
hardness of about 70 Asker .+-.3 (range 50-80 Asker .+-.3)
dimensioned to fit in the support cushion indentation 102B
integrally formed in the base layer 102 in the medial arch area to
heel area with integrally formed longitudinal curvilinear
indentations 132 extending lengthwise in the medial arch area and
an integrally formed heel pad opening or aperture 112 in the heel
area to receive a heel pad 118 under the calcaneal (heel) bone.
[0043] The heel pad 118 is made of TPR gel having a hardness of 20
Asker .+-.3 (range 10-30 Asker .+-.3) having an integrally formed
diamond-cube pattern with a pattern spacing of 1.5 mm and a depth
of about 2 mm dimensioned to fit in the heel pad indentation of the
support cushion 105. The insole 100 also possesses a strength
support layer 103 with a minimum pull strength of 2 pounds
laminated to the underside of the top sheet and secured to the top
side of TPR base layer 102, and the strength support layer 103 can
be positioned above or below the base layer.
[0044] The insole 100 also has a top sheet 128 of knitted or woven
polyester covering the entire foot contact surface of the insole
100, which is treated with an antimicrobial agent. The insole has a
top sheet 128 that extends from heel to toe over the top surface of
the insole 100. The forefoot pad 107 has a diamond cube or diamond
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.
[0045] The insole 100 having a top sheet 128, a base layer 102, a
forefoot pad 107, a heel pad 118, a support cushion 105, and a
strength layer 103 inserted between those components to strengthen
and enhance the durability of the insole. The forefoot pad 107 can
be made of a blown EVA or other material, and the heel cushion 118
can be made of a clear TPR, soft polyurethane or blown EVA. The
support cushion 105 has a raised arch with longitudinal curvilinear
indentations, a flattened midfoot area 148 with a metatarsal
mid-foot tear-drop raised area 134 extending through a metatarsal
opening 134A and longitudinal ridges 142, 143 on the flat midfoot
area and a heel ridge 152 extending around the heel pad opening
112. A heel cup 104 surrounds the exterior back of the heel, and a
heel pod opening 112 goes through the entirety of the thickness of
base layer 102 of the insole 100 for placement of the heel pad 118
so the heel pad 118 is affixed to the bottom surface of the base
layer 102. There is a supersoft metatarsal raised dome 134 on the
top (foot contact) surface of the insole 100 which would be
directly above the metatarsal midfoot area.
[0046] The forefoot pad 107 and the midfoot/heel support cushion
105 are secured adjacent to one another on the bottom surface of
the base layer 102. In one preferred embodiment the base bottom
surface has indentations dimensioned to receive cushions and pads.
In an alternative embodiment the base bottom surface has cushions
and pads molded into the base layer 102. 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 and base bottom surface are made of
differing materials.
[0047] The midfoot/heel support cushion 105 has a raised arch 119A
in the medial arch area and longitudinal curvilinear indentations
132 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 support cushion 105
also has a lateral midfoot arch 119B that offers additional support
to the lateral midfoot area. The midfoot/heel cushion 105 also
possesses a flattened central midfoot area 148 on the midfoot area
with a square grid pattern and a metatarsal midfoot tear-drop
raised area 134 positioned in a metatarsal tear-drop aperture 134A
of the midfoot to heel support cushion. The flattened area 148 on
the midfoot area of the midfoot/heel cushion 105 is bordered on the
medial side by a medial side longitudinal ridge 143, on the lateral
side by a lateral side longitudinal ridge 142, and around the
exterior of the heel pod opening by a heel ridge 152. The
midfoot/heel cushion 105 also has a heel cup 104 that supports the
exterior back of the user's heel with the heel cup and extends to
the raised arch area 119A.
[0048] The heel pod opening 112 is surrounded by heel pod opening
border grooves 138, which surround the circumference of the heel
pod opening. The heel pad 118 is located on the bottom surface of
the insole 100 and is made of a clear TPR gel, blown 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 112 has a diamond shaped groove pattern, but
can be have a flat un-patterned surface.
[0049] A shoe insole 100 with a base layer 102 made 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 ranging 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. A raised medial
arch 119A on the support cushion is located in the medial arch area
with integrally formed longitudinal curvilinear indentations 132
situated lengthwise, integrally formed raised gripping ridges in
the medial arch area on the bottom surface; and, a teardrop shaped
indentation 134 is located in the metatarsal area of the midfoot
which curves upwardly (concave) from the bottom of the base layer
102 (shoe contact) surface and forms a collapsible metatarsal
support which is convex on the top (foot contact) side of the base
layer 102.
[0050] The forefoot pad 107 can be made of clear TPR gel
(thermoplastic rubber), where said TPR gel has a hardness rating of
10-20 Asker .+-.3. Alternatively, the forefoot pad 107 can be made
of molded pre-blown ethylene vinyl acetate (EVA), polyurethane
(PU), or thermoplastic rubber (TPR) or other suitable material, so
that it extends from the toe end of the insole to the midfoot area
and from the medial side to the lateral side of the forefoot area
with a hardness of approximately 10-30 Asker C .+-.3. If the
forefoot pad 107 has a patterned surface, the pattern spacing is
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 107 is
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.
[0051] A heel pad 118 on the bottom surface of the insole is made
of clear TPR (thermoplastic rubber) or pre-blown ethylene vinyl
acetate (EVA), molded of EVA, polyurethane (PU), or other suitable
material with a hardness of approximately 10-35 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. The heel pad 118 can have a modified oval shape that is
wider on the proximal end of the heel pad 118 and narrows on the
distal end of the heel pad with a diamond-cube pattern 120 molded
in the EVA having pattern spacing of about 1 mm, with groove depth
of approximately 1 mm, and a thickness of the heel pad of about 1.5
mm.+-.0.5 mm shown differently in FIGS. 1A-C and 2A-2B, and
alternatively in FIG. 2C. This heel pad 118 is secured on the
bottom surface of the base layer 102. In an alternate embodiment,
the heel pad 118 has a honeycomb-shaped pattern. In yet another
embodiment, the heel pad 118 has a texturized un-patterned surface,
and a thin layer of nylon fabric may be positioned in the heel pad
indentation 112 between the heel pad 118 and the bottom surface of
the base layer 102 to increase the adhesion of the heel pad 118 to
the base layer 102.
[0052] A supersoft metatarsal dome 134 shaped like a teardrop is
located on the top (foot contact) midfoot surface of the insole
which would normally be located below the foot metatarsal bones.
And, a top sheet 128 of polyester covers the entire foot contact
surface of the insole which is treated with an antimicrobial
agent.
[0053] In a preferred embodiment, the heel pad 118 is surrounded by
a flat midfoot/heel surface 148 and cupped along the back by a heel
cup 104, nylon fabric between forefoot/heel pads 105, 107 and base
layer 102 (for adhesion of pads to PU), a medial arch 119A has
raised and indented curvilinear lines 132 extending longitudinally
along arch with vent holes, a groove depth on bottom 0.50 mm-1.5
mm, a top cloth 128 made of 65% Nylon/35% polyester, a teardrop
metatarsal dome 134 on the top side is integrally formed as an
upwardly-curved indentation from bottom surface, a diamond-shaped
groove pattern 117, 120 on the forefoot pad 107 and the heel pad
128, and a separation wall 151 added between base layer 102 and
forefoot pad 107 of approximately 1 mm.
[0054] A strength layer 103 is positioned above the base layer 102,
or alternatively, positioned between the base layer 102 and the
forefoot pad 107 and/or support cushion 105, and it is composed of
a woven fabric, a composite material or a fortified or enhanced
fabric is also inserted between those components to strengthen and
enhance the durability of the insole. Alternatively, this strength
layer 103 can be made of knitted or woven high-strength fabric
secured to the top surface of the EVA base material, but this
strength layer 103 should be made of material that retains its
shape upon use without significant shrinkage or deformation from
heat or pressure of normal use. The strength layer 103 may extend
from heel-to-toe across the entire surface of the insole 100, or
alternatively, may only extend across the heel area, the heel to
mid-foot area, or the forefoot to toe area.
[0055] The forefoot pad 107 and the midfoot/heel support cushion
105 are secured adjacent to one another on the bottom surface of
the base layer 102. In one preferred embodiment, the base bottom
surface has indentations 102A, 102B dimensioned to receive
cushioning pads 105, 107. In an alternative embodiment, the bottom
surface of the base layer 102 has cushions 105 and pads 107 molded
into the base bottom surface. A thin layer of nylon fabric may also
be positioned in the forefoot pad indentation 102B between the
forefoot pad and the material of the base bottom surface to
increase the adhesion of the forefoot pad 107 to the base layer 102
material when the forefoot pad 107 and base layer 102 bottom
surface are made of differing materials. Or, a thin fabric can also
be positioned in a similar manner between the support cushion 105
and the base layer 102 in the support cushion indentation 102A.
[0056] There is a raised separation wall 151 located on the base
layer 102 between the forefoot pad 107 and the midfoot support
cushion 105, which is located laterally across the width of the
insole between the metatarsal and forefoot areas on the insole. The
insole 100 has a top sheet 128 that extends from heel to toe over
the top surface of the base layer 102, or alternatively, over the
strength layer 103 (which may be placed above or below the base
layer 102). There is a metatarsal dome 134 raised on the top
surface of the insole, which respectively improves the cushioning
characteristics of the insole at or near high impact points on the
insole. The forefoot pad 107 has a diamond cube groove pattern 117
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 107 has a
honeycomb-shaped pattern 117. In yet another embodiment, the
forefoot pad 107 has a texturized un-patterned surface 117.
[0057] The midfoot/heel cushion 105 has a raised arch 119A in the
medial arch area and a raised lateral arch 119B on the lateral
mid-foot side on the bottom surface of the insole 100. These raised
arches 119A and 119B support the midfoot arch and lateral areas of
the user's foot, and can assist with preventing and minimizing
pronation or supination conditions.
[0058] Longitudinal curvilinear indentations 132 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 105 also possesses a flattened central midfoot
area 148 on the midfoot area with a square grid pattern and a
metatarsal midfoot tear-drop raised area 134 positioned in a
metatarsal tear-drop aperture of the midfoot-to-heel support
cushion 105. The flattened area 148 on the central midfoot area of
the midfoot/heel cushion 105 is bordered on the medial side by a
medial side longitudinal ridge 143, on the lateral side by a
lateral side longitudinal ridge 142, and around the exterior of the
heel pod opening by a heel ridge 152. The midfoot/heel cushion 105
also has a surrounding heel cup 104 that supports the exterior back
of the user's heel with the heel cup and extends to the raised arch
area 119.
[0059] 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
pod opening 112 is surrounded by opening border grooves 138, which
surrounds the circumference of the heel pod opening 112. The heel
pad 118 is located on the bottom surface of the insole 100 and is
made of a clear TPR gel, blown EVA or other suitable material and
extends through the full depth of the heel pod opening 112 and is
attached to the bottom surface of the base layer 102. The heel pad
118 has a diamond shaped groove pattern 120, but can be have a flat
un-patterned surface 120. FIGS. 1A-1C and 2A-2B show the heel pad
118 with a diamond cube pattern 120, and FIG. 2C shows the same
insole design with a small diamond patter surface 120 on heel pad
118.
[0060] A shoe insole 100 with a base layer 102 made 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 layer 102 material
ranging 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. A raised arch 119 on the support cushion 105 is located in
the medial arch 119 with integrally formed longitudinal curvilinear
indentations 132 situated lengthwise, integrally formed with raised
gripping ridges in the medial arch 119 on the support cushion 105;
and, a teardrop shaped indentation 134 is located in the metatarsal
area of the midfoot which curves upwardly (concave) from the bottom
of the insole 100 (shoe contact) and forms a collapsible metatarsal
support which is convex on the top (foot contact) of the insole
100.
[0061] The forefoot pad 107 can be made of clear TPR gel
(thermoplastic rubber), where said TPR gel has a hardness rating of
10-20 Asker .+-.3. Alternatively, the forefoot pad 107 can be made
of molded pre-blown ethylene vinyl acetate (EVA), polyurethane
(PU), or thermoplastic rubber (TPR) or other suitable material, so
that it extends from the toe end of the insole to the midfoot area
and from the medial side to the lateral side of the forefoot area
with a hardness of approximately 10-30 Asker C .+-.3. If the
forefoot pad 107 has a patterned surface 117, it has a 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 107 can also be molded into the PU insole base distal
to the separation wall 151 on the base layer 102 with a knitted
fabric layer secured between the forefoot pad 107 and the base
layer 102.
[0062] A heel pad 118 on the bottom surface of the insole 100 is
made of clear TPR (thermoplastic rubber) or pre-blown ethylene
vinyl acetate (EVA), molded of EVA, polyurethane (PU), or other
suitable material with a hardness of approximately 10-35 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 100. The heel pad 118 can have 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-shaped
groove pattern 120 molded in the EVA having pattern spacing of
about 1 mm, with groove depth of approximately 1 mm, and a
thickness of the heel pad of about 1.5 mm.+-.0.5 mm. This heel pad
118 surface of the base layer 102. In an alternate embodiment, the
heel pad 118 has a honeycomb-shaped pattern 120. In yet another
embodiment, the heel pad 118 has a small diamond shaped texture,
which are shown in FIG. 2C. Embodiments showing a diamond cube
pattern on the heel pad 118 can be seen in FIGS. 1A, 1B, 1C and
2A-2B.
[0063] A thin layer of nylon fabric may be positioned in the heel
pad indentation 102B between the heel pad 118 and the material of
the base layer 102 to increase the adhesion of the heel pad to the
base material when the heel pad 118 and base layer 102 are made of
differing materials. A supersoft metatarsal dome 134 shaped like a
teardrop is located on the top (foot contact) midfoot surface of
the insole 100 which would normally be located below the foot
metatarsal bones. And, a top sheet 128 of polyester covers the
entire foot contact surface of the insole which is treated with an
antimicrobial agent.
[0064] In a preferred embodiment, the heel pad 118 is surrounded by
a flat midfoot/heel surface 148 and cupped along the back by a heel
cup 104. Nylon fabric can be placed between support cushion 105 or
forefoot pad 107 and the base layer 102 (for adhesion of pads to
PU). A medial arch 119 has raised and indented curvilinear lines
132 extending longitudinally along arch with vent holes, and the
grooves on the flat area 148 of the support cushion 105 have a
groove depth on bottom of approximately 0.50 mm-1.5 mm. The top
sheet 128 can be made of 65% Nylon/35% polyester, and a teardrop
metatarsal dome 134 on the top side of the insole 100 is integrally
formed as an upwardly-curved indentation. The separation wall 151
added between base and forefoot pad is approximately 1 mm in
height.
[0065] The forefoot pad 107 is made of a clear TPR (thermoplastic
rubber) gel 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-shaped groove pattern 117
molded in the gel having pattern spacing of about 1 mm and a depth
of about 1.5 mm. The forefoot pad 107 is preferably made of clear
TPR gel (thermoplastic rubber--hardness 20 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.
[0066] In accordance with principles of the present invention, the
present invention is a shoe insole having 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.
[0067] 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
forefoot pad indentation 102B on the bottom surface and the
midfoot-to-heel support cushion indentation 102A under the
calcaneal (heel) area on the bottom layer 102B; a raised arch 119
in the medial arch area with integrally formed longitudinal
curvilinear indentations 132 situated lengthwise, the curvilinear
indentations 132 integrally forming raised gripping ridges in the
medial arch 119 on the bottom surface of the support cushion 105;
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 layer 102 (shoe contact) surface and forms a
collapsible metatarsal support having a convex dome shape on the
top (foot contact) side of the base layer 102.
[0068] A forefoot pad 107 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-shaped groove pattern 117
having pattern spacing of about 1 mm and a depth of about 1.5 mm.
The forefoot pad 107 can be 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 base layer
102 material. This insole 100 also has: (1) 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 or
diamond-shaped groove 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; (2)
a soft metatarsal dome 134 on the top (foot contact) surface
providing cushioning directly over the metatarsal area of the foot
(shown in FIGS. 3A, 3B, 5A, 5B, 6A and 6B); and, (3) a top sheet
128 of polyester covering the entire foot contact surface of the
insole 100 which is treated with an antimicrobial agent (shown in
FIGS. 1B, 3A, 4A, 5A, 6A and 7A).
[0069] 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 102 extending from heel-to-toe, (2) a
forefoot pad 107 positioned in a forefoot/toe indentation on a
forefoot base area 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. A strength layer 103 is
positioned above the base layer 102, or alternatively, positioned
between the base layer 102 and the forefoot pad 107 and/or support
cushion 105, and it is composed of a woven fabric, a composite
material or a fortified or enhanced fabric is also inserted between
those components to strengthen and enhance the durability of the
insole. Alternatively, this strength layer 103 can be made of
knitted or woven high-strength fabric secured to the top surface of
the EVA base material, but this strength layer 103 should be made
of material that retains its shape upon use without significant
shrinkage or deformation from heat or pressure of normal use. The
strength layer 103 may extend from heel-to-toe across the entire
surface of the insole 100, or alternatively, may only extend across
the heel area, the heel to mid-foot area, or the forefoot to toe
area.
[0070] The combination of the base layer 102, support cushion 105,
strength layer 103, 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.
[0071] The insole 100 also has a forefoot area 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 119A
along the medial arch side, a raised arch support 119B on the
lateral midfoot side, a heel area just forward of the heel cup 104,
and a midfoot area 106 between the heel area and forefoot area. 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.
[0072] In one preferred embodiment, the base layer 102 has
indentations 102A, 102B dimensioned to receive the support cushion
105 and forefoot pad 107, respectively. In an alternative
embodiment, the base layer 102 can have the support cushion 105
and/or the forefoot pad 107 molded directly onto the base layer
102. 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.
[0073] 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 FIGS. 1A-1C and 2A-2C 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 100 will be used to replace an insole that previously was
used in the shoe.
[0074] 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 100. 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.
[0075] 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.
[0076] 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 to the arch on the
medial side, a midfoot area 106 between said arch support 119 and
the lateral midfoot area, and a forefoot area located between the
metatarsal area to the toe end of the insole 100. There is a
metatarsal dome 134 raised on the top surface of insole 100 (shown
in FIGS. 3A, 3B, 5A, 5B, 6A and 6B), which improves the cushioning
characteristics of the insole at or near high impact points on the
insole 100.
[0077] 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 100 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 100 (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
102 may be formed from a gel material (e.g. TPR gel) or made of
polyurethane polyester glycol with a hardness 30 Asker .+-.3, or
alternatively, can be made of any durable nylon fabric.
[0078] 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.
[0079] The top sheet 128 bottom surface is secured to base layer
102 top surface and a top sheet 128 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, CA.).
[0080] In accordance with principles of the present invention and
as shown in FIGS. 1A, 1B, 1C and 2A, 2B and 2C, 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 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.
[0081] 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
hardness of the molded base material ranging from less than 10
Asker .+-.3 to greater than 30 Asker .+-.3; a forefoot pad 107 made
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) (groove
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) (pattern spacing 1.0 mm-1.50 mm) surrounded by a flat
midfoot/heel surface 148 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 medial arch 119A that has raised and
indented curvilinear lines 132 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 raised lateral
side arch 119A in the lateral midfoot area, a teardrop metatarsal
dome 134 on top side is integrally formed as upwardly-curved
indentation from bottom surface, a diamond-shaped groove 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.
[0082] 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 102 extending from heel-to-toe, (2) a
forefoot pad 107 positioned in a forefoot/toe indentation on a
forefoot base area 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. A strength layer 103 is
positioned above the base layer 102, or alternatively, positioned
between the base layer 102 and the forefoot pad 107 and/or support
cushion 105, and it is composed of a woven fabric, a composite
material or a fortified or enhanced fabric is also inserted between
those components to strengthen and enhance the durability of the
insole. Alternatively, this strength layer 103 can be made of
knitted or woven high-strength fabric secured to the top surface of
the EVA base material, but this strength layer 103 should be made
of material that retains its shape upon use without significant
shrinkage or deformation from heat or pressure of normal use. The
strength layer 103 may extend from heel-to-toe across the entire
surface of the insole 100, or alternatively, may only extend across
the heel area, the heel to mid-foot area, or the forefoot to toe
area.
[0083] The metatarsal support 134 is 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 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.
[0084] 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.
[0085] 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.
[0086] 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.
[0087] 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 is secured within a
forefoot pad 107 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.
[0088] 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.
[0089] 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
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.
[0090] 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 shaped groove 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.
[0091] 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 1.sup.st 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.
[0092] The midfoot/heel support cushion 105 has a raised arch 119A
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 direction 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 119A provide
additional rigidity to the raised arch support, which improves
support raised arch 119A 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 in the arch area also allow the arch area to
collapse to fit the shoe thus providing a more accommodative
design.
[0093] 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 has a
square groove pattern and 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. The ridges 143, 142 and heel ridge
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 119A and
the lateral arch 119B, which also improves the support provided to
the user's foot during use.
[0094] 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.
[0095] 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 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.
[0096] 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
permits the first metatarsal to flex more naturally and thereby
encourages loading of the great toe during toe off.
[0097] 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 aperture or opening 112 formed in the
support cushion 105 of the insole, with said heel pad 118 being
secured to the base layer 102. The heel pad opening 112 has a
groove pattern 138 surrounding it periphery, which assists with
durability of the insole 100 and enhances the cushioning
capabilities of the heel pad 118.
[0098] 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.
[0099] 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.
[0100] The heel pad 118 has a diamond shaped groove 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 groove pattern with a width spacing of approximately 1.0
mm-1.50 mm.
[0101] 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.
[0102] Alternatively, the forefoot pad 107 can be molded onto the
bottom surface of the insole base layer 102 from the forefoot pad
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 forefoot pad 107 and the base layer 102 in the forefoot
pad indention 102B. And, the midfoot/heel cushion 105 can be molded
onto the bottom surface of the insole base layer 102 from the
support cushion 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 midfoot-to-heel support cushion 105 and the
base layer 102 in the indentation 102A. 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.
[0103] FIG. 3A illustrates the top (foot side) of an insole 100
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.
FIG. 3B shows the insole 100 without the top sheet 128 in place and
a midfoot to toe area 108 shown in both FIGS. 3A and 3B. 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 FIGS. 3A and 3B.
The teardrop metatarsal pad 134 on top side is integrally formed as
upwardly-curved indentation from bottom surface of the insole.
[0104] On the foot contact surface of the insole 100, the base
layer 102 has a raised metatarsal dome 134. The metatarsal dome 134
is positioned under the heel bone to provide additional cushioning
to the user's heel while walking or standing. 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 metatarsal dome 134 is preferably molded as a cushion
separate from the base layer 102 and is secured to the top side of
the base layer 102. The metatarsal dome 134 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 metatarsal dome 134 is integrally formed in the
material comprising the top side of the base layer 102.
[0105] The metatarsal dome 134 is 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 metatarsal dome 134
material can range from less than 10 Asker .+-.3 to greater than 30
Asker .+-.3.
[0106] A soft metatarsal dome 134 is located on the top (foot
contact) surface providing cushioning directly over the metatarsal
area of the foot. The top sheet 128 is shown in FIG. 3A, and the
exposed top view of the insole 100 is shown in FIG. 3B without the
top sheet 128. 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 extends 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.
[0107] Referring to FIG. 4A, the medial side view of the insole 100
is shown with curvilinear indentations 132 shown in the raised arch
area 119. FIG. 4B shows the insole 100 without the top sheet 128 in
place. 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 119A that extends upwardly along
the medial side of the insole to provide extra cushion and support
to the raised arch 119 of the foot.
[0108] A strength layer 103 is composed of a woven fabric, a
composite material or an enhanced fabric is also inserted between
the base layer 102 and the forefoot pad 107 and/or support cushion
105 to strengthen and enhance the durability of the insole. A
portion of the strength layer 103 can be seen in FIG. 1B.
Alternatively, this strength layer 103 can be made of knitted or
woven high-strength fabric secured to the top surface of the EVA
base material, but this strength layer 103 should be made of
material that retains its shape upon use without significant
shrinkage or deformation from heat or pressure of normal use. The
strength layer 103 may extend from heel-to-toe across the entire
surface of the insole 100, or alternatively, may only extend across
the heel area, the heel to mid-foot area, or the forefoot to toe
area.
[0109] Also referring to FIGS. 5A and 5B, the insole 100 lateral
side view is shown with the raised lateral arch 119B, 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 of
the support cushion 105, and a top sheet 128 (shown in FIG. 5A
only). The top sheet 128 is not shown in FIG. 5B. FIGS. 5A and 5B
shows that 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.
[0110] As shown in FIGS. 5A and 5B, 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.
[0111] 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 groove pattern 117 (shown in FIGS. 1A-1C
and 2A-2C) 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.
[0112] The midfoot/heel support cushion 105 has a raised arch 119A
in the medial arch area and a lateral arch 119B, 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.
There is a raised separation wall 151 shown in FIGS. 5A and 5B
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.
[0113] 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.
[0114] Now referring to FIGS. 6A and 6B, these figures show the
front end view of the insole 100 from the toe end looking toward
the heel end 104, upraised heel area is visible at the heel end
104, raised arch support 119 is seen on the medial side, with the
top sheet 128 shown in FIG. 6A and not shown in FIG. 6B. FIG. 6A
shows forefoot pad 107 in forefoot area 108, base layer 102, raised
arch area 119, and top sheet 128. FIGS. 7A and 7B 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 FIG. 7A and not shown in
FIG. 7B. 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.
[0115] As shown in FIGS. 6A, 6B, 7A and 7B, 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 102B (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 102A (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-1C and 2A-2C).
[0116] Also shown in these figures, a strength layer 103 is
composed of a woven fabric, a composite material or an enhanced
fabric is also inserted between the base layer 102 and the forefoot
pad 107 and/or the support cushion 105 to strengthen and enhance
the durability of the insole. A portion of the strength layer 103
is shown in FIG. 1B. Alternatively, this strength layer 103 can be
made of knitted or woven high-strength fabric secured to the top
surface of the EVA base material, but this strength layer 103
should be made of material that retains its shape upon use without
significant shrinkage or deformation from heat or pressure of
normal use. The strength layer 103 may extend from heel-to-toe
across the entire surface of the insole 100, or alternatively, may
only extend across the heel area, the heel to mid-foot area, or the
forefoot to toe area.
[0117] 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 119A 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, as well as a lateral arch 119A in the midfoot area. A teardrop
metatarsal dome 134 shown in FIGS. 6A and 6B 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-shaped groove pattern 117, 120 is located on the
bottom surface of the forefoot pad 107. A separation wall 151 is
located between cushion 105 and forefoot pad 107 with an
approximate height of 1 mm.
[0118] 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 117
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 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.
[0119] The midfoot/heel cushion 105 has a raised arch 119A 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. 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.
[0120] 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.
[0121] To cushion the impact the components described above to 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.
[0122] 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.
[0123] 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.
* * * * *