U.S. patent application number 16/052268 was filed with the patent office on 2018-12-27 for fitting system and method for customizable footwear.
The applicant listed for this patent is DJO Consumer, LLC, Nano Terra, Inc.. Invention is credited to Austin ARROCO, Jonathan Luis NUNEZ, Dave ORTLEY, Mark SOMERS, Noah TREMBLAY.
Application Number | 20180368512 16/052268 |
Document ID | / |
Family ID | 59626276 |
Filed Date | 2018-12-27 |
United States Patent
Application |
20180368512 |
Kind Code |
A1 |
NUNEZ; Jonathan Luis ; et
al. |
December 27, 2018 |
FITTING SYSTEM AND METHOD FOR CUSTOMIZABLE FOOTWEAR
Abstract
Disclosed embodiments relate to a footwear system. The footwear
system includes a shoe, a first insole, and a second insole. The
first insole is a fitting insole having a first volume. It is
positioned within the shoe during a fitting of a potential wearer
of the shoe. The fitting insole is removed after the fitting is
completed. The second insole has a volume substantially similar to
the first volume. The second insole adapted for positioning within
the shoe if the first insole demonstrates an appropriate fit. The
second insole is self-customizable and further adapted to conform
to the imprint of the sole of the potential wearer.
Inventors: |
NUNEZ; Jonathan Luis; (San
Marcos, CA) ; ORTLEY; Dave; (Encinitas, CA) ;
TREMBLAY; Noah; (Cambridge, MA) ; SOMERS; Mark;
(Cambridge, MA) ; ARROCO; Austin; (Cambridge,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DJO Consumer, LLC
Nano Terra, Inc. |
Vista
Cambridge |
CA
MA |
US
US |
|
|
Family ID: |
59626276 |
Appl. No.: |
16/052268 |
Filed: |
August 1, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/US2017/018006 |
Feb 15, 2017 |
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16052268 |
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62295826 |
Feb 16, 2016 |
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62295863 |
Feb 16, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 7/28 20130101; A43B
13/386 20130101; A43B 17/003 20130101; A43B 7/1465 20130101; B29C
43/021 20130101; A43B 13/187 20130101; A43B 17/14 20130101; B29L
2031/504 20130101 |
International
Class: |
A43B 7/14 20060101
A43B007/14 |
Claims
1. A kit for providing customizable fit for footwear, comprising: a
first imprint insole system comprising an insole affixed to a
cradle; a second imprint insole system comprising a mold-on-demand
insole comprising a first elastomeric layer, a second elastomeric
layer, and a plurality of burstable packets disposed between said
first and second elastomeric layers; wherein said mold-on-demand
insole is affixed to a second cradle; and instructions for
activating the second imprint insole system; wherein said first
imprint insole system is a fitting insole dimensioned to fit within
a shoe; wherein the second imprint insole system is dimensioned
substantially similarly to said first insole and is trimmable to
accommodate a plurality of shoe shapes; and wherein said second
insole comprises a mold-on-demand layer configured to conform to
the shape of a wearer's foot upon the application of pressure.
2. The kit of claim 1, wherein said second imprint insole system
includes a cutting guide.
3. The kit of claim 2, further comprising instructions for trimming
said second imprint insole system along the cutting guide.
4. The kit of claim 1, further comprising thermoformed plastic
packaging of said second insole system.
5. The kit of claim 1, wherein said plurality of burstable packets
comprises a curable fluid.
6. The kit of claim 5, wherein said curable fluid is a silicone
resin.
7. The kit of claim 1, wherein said instructions for activation
comprise: advising the wearer to insert said first insole system
into a shoe; confirming the fit of the shoe by inserting the foot
of the wearer in the shoe having said first insole system; removing
said first insole system and replacing said first insole system
with said second insole system; applying pressure to said second
insole to activate said second imprint insole system; and
instructing said wearer to reinsert said foot into the shoe with
the second insole system such that the second insole can conform to
the shape of said wearer's foot.
8. The kit of claim 1, wherein said first cradle is polyurethane
foam.
9. The kit of claim 4, wherein said packaging further comprises at
least one cut-out window.
10. An item of self-customizing footwear comprising: an upper; an
insole; and an outsole; wherein the insole comprises an upper layer
positioned to contact with the bottom of the foot; an elastomeric
bottom layer coupled to the outsole; and a middle layer enclosed
between the upper layer and the lower layer; said middle layer
comprising a plurality of burstable packets; said burstable packets
comprising a curable fluid material.
11. The item of claim 10, wherein at least some of the burstable
packets are configured to burst when pressure is applied to said
packets.
12. The item of claim 11, wherein upon bursting, the curable fluid
is configured to flow within the enclosed middle layer of the
insole to conform to and solidify in the shape of a foot.
13. The item of claim 11, wherein upon bursting, the curable fluid
is configured to flow within the enclosed middle layer of the
insole to conform to and solidify in the shape of a foot.
14. The item of claim 13, wherein the curable fluid in one of the
plurality of compartments is different than the curable fluid in
another compartment.
15. The item of claim 14, wherein the plurality of compartments are
configured to control flow of curable liquid as pressure is applied
to various portions of the foot.
16. The item of claim 15, wherein said pressure is a weight bearing
action by a user of said footwear.
17. A customizable footbed, comprising: an elastomeric bottom
layer; and a layer of burstable packets coupled to the bottom
layer, wherein at least one of the burstable packets comprises a
curable fluid.
18. The footbed of claim 17, wherein said curable fluid is a
silicone resin.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International
Application No. PCT/US2017/018006, filed Feb. 15, 2017, which
claims the benefit of U.S. Provisional Application No. 62/295,826,
filed Feb. 16, 2016, and U.S. Provisional Application No.
62/295,863, filed on Feb. 16, 2016. Each of the above-referenced
patent applications is incorporated by reference in its
entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] This application relates to a fitting system for
self-customizing footwear. More particularly, this application
relates to insole systems and methods which provide a precision fit
for footwear.
Description of the Related Technology
[0003] Traditionally, fitting footwear required the wearer to test
various sizes of the footwear by trying them on at a point of sale
establishment. In a traditional fitting scenario, a customer
interested in purchasing new shoes would be sized by a sales
associate using a brannock device to determine the length and width
of the customer's feet and a sales person would then bring the
customer one or more sizes of a particular item of interest. The
customer would insert his or her foot into the shoe to determine
whether the shoe provided a snug and comfortable fit. If the shoe
did not provide a snug and comfortable fit, the customer would
typically put it aside and try on another size. This process would
be repeated until the customer found a size that provided the
desired comfort and fit. Still, often times an ideal fit cannot be
realized by way of conventional sizing scales.
[0004] More recently, designers of footwear have attempted to
improve the fit of footwear by providing customized footwear items.
Some customizable footwear has been made using molds taken of the
foot of the customer. Using these molds, customized footwear was
produced which was then delivered to the customer. Of course, there
were certain disadvantages of this approach, including the fact
that the fitting process took quite a bit of time, as the shoe
needed to be designed after the mold was taken of the customer's
foot.
[0005] Another type of customizable footwear approach has been
developed using digital imaging technology. In these types of
customizable footwear, digital scans of the customer's foot are
taken, and using those scans a customer-specific item of footwear
is created to closely conform to the shape and contour of the
customer's feet. As with the use of a mold, this approach suffers
from certain disadvantages. For example, in order to obtain the
digital image of the foot, special equipment is needed. This type
of equipment can tend to be expensive, require special training for
operation of such equipment, and may not always be readily
available in every retail shoe-selling establishment. Moreover,
even though the digital scans can be transmitted digitally to the
manufacturer, there is still lead time and delay between the
fitting and the delivery of the shoe.
[0006] Shoe inserts have long been used to provide better fit, feel
and support for the foot within a shoe. Such inserts range from
simple linings, to contoured paddings, to support orthotics. They
also range from inexpensive standard insoles, to very expensive
custom-fit inserts. Inexpensive insole options, which often fail to
provide sufficient fit and comfort, are currently produced by one
of the following methods: "boil and wear" type solutions, ski-shop
spray or heat form solutions. More custom-fit or personalized shoe
inserts tend to be very expensive and the fitting process sometimes
involves a trip to a physician's office or to a location with
specialized fitting equipment where a scan or mold of the foot can
be made. The customer will often have to wait days or weeks for
delivery of the final insert.
[0007] Accordingly, improvements in the fitting and customization
of footwear are needed which do not suffer from the problems
identified above.
SUMMARY OF THE INVENTION
[0008] Disclosed herein is an optimized shoe footwear fitting
system. More particularly, systems and methods for providing a
self-customized fit for footwear are provided.
[0009] In one aspect, a kit for providing customizable fit for
footwear is disclosed. The kit may include a first imprint insole
system having an insole affixed to a cradle; a second imprint
insole system having a pressure-sensitive insole affixed to a
second cradle; and instructions for activating the customized
insole. Advantageously, the first imprint insole system is a
fitting insole dimensioned to fit within a shoe. The second imprint
insole system may be dimensioned substantially similarly to said
first insole and is trimmable to accommodate a plurality of shoe
shapes. Optionally, the second insole includes a pressure sensitive
layer configured to conform to the shape of a wearer's foot upon
the application of pressure. The first and second cradle may be
constructed from a polyurethane foam material.
[0010] In certain aspects, the imprint insole systems may include a
cutting guide. The kit may likewise include instructions for
trimming the first or second imprint insole systems or both the
first and second imprint insole systems along the cutting guide to
promote a better fit of the insoles in a shoe. In other aspects,
the kit can include thermoformed plastic packaging of the first and
second insole system. Optionally, the packaging may include at
least one cut out window.
[0011] In yet another aspect, the pressure sensitive layer of the
second insole system is a thermoset polymer.
[0012] In still another aspect, the kit for providing customizable
fit for footwear can include instructions for activating the second
pressure sensitive insole. The instructions may include advising
the wearer to insert the first insole system into a shoe. The
wearer may then confirm the fit of the shoe by inserting his or her
foot in the shoe having the first fitting insole. The instructions
may further include a directive to remove the first insole system
and replace the first insole system with said second insole
system.
[0013] The instructions may further instruct the wearer to apply
pressure to the insole to activate the second imprint insole
system. Finally, the instructions may include a directive that the
wearer reinsert his or her foot into the shoe with the second
insole system such that the second insole can conform to the shape
of said wearer's foot. Pressure may be applied by hand activation,
by stepping on insole when it is in a shoe, or by manipulating the
insole to pre-mix the mold-on-demand components prior to placing
the insoles directly on a hard surface. The activation of the
mold-on-demand insert can be performed one insert at a time or both
the left and right insole can be activated substantially
simultaneously.
[0014] In one aspect of the invention, a footwear system is
provided. The system may include a shoe, a first insole system, and
a second insole system. The first insole system may include a
fitting insole having a first volume, and adapted to be positioned
within the shoe during a fitting of a potential wearer of the shoe
and removed after the fitting is completed. The second insole
system may include an insole having a volume substantially similar
to the first volume. Advantageously, the second insole is adapted
to be positioned within the shoe if the first insole demonstrates
an appropriate fit, and wherein the second insole is
self-customizable and further adapted to conform to the imprint of
the sole of the potential wearer. The shoe may include an athletic
shoe, sport shoe and the like, casual shoe, sandal, heel, boot, or
an orthopedic shoe.
[0015] In yet another aspect, the second insole includes a
thermoset polymer. Optionally, the second insole can include an
antibacterial layer.
[0016] Also disclosed is a method of customizing the fit of
footwear. The method may include providing a shoe; wherein the shoe
includes an outsole having a top layer and a bottom layer; a
cushioning element attached to the top layer of said outsole; a
first imprint insole system comprising a fitting insole affixed to
a cradle and removably inserted in the shoe; and an upper shell.
The method further includes confirming fit of the shoe; removing
the first imprint insole system from the shoe; replacing the first
imprint insole system with a mold-on-demand insole system; applying
pressure to the mold-on-demand insole system; and imprinting the
mold-on-demand insole to the shape of a wearer's foot. In some
aspects, the fitting insole comprises a memory foam. In another
aspect, the memory foam is a slow return memory foam.
[0017] In another aspect, a customized footwear system is provided.
The footwear system may include a shoe; a fitting insole; and a
mold-on-demand insole; wherein the fitting insole has a first
volume; wherein the mold-on-demand insole has a volume
substantially similar to the first volume; and wherein the
mold-on-demand insole is configured to conform with the shape of
the wearer's foot upon application of pressure. The mold-on-demand
insole may be a thermoset resin. In yet another aspect, the shoe is
selected from the group consisting of an athletic shoe, a sandal, a
heel, a boot, and an orthopedic shoe.
[0018] This invention relates also to an improved footbed
technology that provides a custom-fit, mold-on-demand footbed which
molds to the contours of the foot, is pliable, and has the feel of
a gel. Please note, the terms "footbed", "insole", and "insert" are
used interchangeably. The mold-on-demand footbeds of the present
invention contain a top layer and bottom layer with packets,
capsules, blister packets, or blisters (hereinafter referred to as
"packets") arranged in between the two layers. The packets are made
of a form and material such that they burst during the custom-fit
molding process, thereby releasing the material or materials
contained within the packet. These packets contain materials which
begin to cure or set when released from the packets, with or
without further reaction or stimuli.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is an example of an item of footwear according to one
or more embodiments disclosed herein.
[0020] FIG. 2 is an exploded view of various components of the item
of footwear shown in FIG. 1.
[0021] FIG. 3 is a more detailed view of the fitting insole
components shown in FIG. 2.
[0022] FIG. 4 is an example of a self-customizing insole according
to one or more embodiments.
[0023] FIG. 5 is a block diagram illustrating components in a shoe
system according to one or more embodiments.
[0024] FIG. 6 is a flow diagram providing an illustration of a
fitting process according to one or more embodiments.
[0025] FIGS. 7A-7C illustrate a schematic of a portion of a
mold-on-demand footbed having burstable packets comprising a curing
fluid.
[0026] FIGS. 8A and 8B depict a portion of a packet array sheet for
use in a mold-on-demand insole system.
DETAILED DESCRIPTION OF CERTAIN INVENTIVE EMBODIMENTS
[0027] Embodiments will be described with respect to the
accompanying figures. Like reference numerals refer to like
elements throughout the detailed description. As used herein, the
term "substantially" includes the meanings of completely, almost
completely, or to any significant degree under some applications as
understood by those skilled in the art. The phrase "imprint insole
system" as used herein refers to an insole permanently affixed to a
cradle. While an insole or cradle may be described separately, it
will be appreciated that the imprint insole system comprises the
combination of an insole and a cradle, wherein the component parts
(namely the insole and cradle) are permanently joined to form the
imprint insole system. The imprint insole system may or may not
include a cushioning element, which will be described in greater
detail below.
[0028] Embodiments of this application relate generally to footwear
fitting systems comprising a fitting insole and a mold-on-demand
insole to provide a customizable fit to a consumer. Advantageously,
the fitting insole is provided in order to prevent activation of
mold-on-demand insoles during a fitting process. As will be
described in greater detail below, kits comprising a fitting insole
and a mold-on-demand insole are specifically contemplated.
Additionally, in certain embodiments, footwear is provided to a
consumer prior to purchase which includes a fitting insole and a
separate mold-on-demand insole. The fitting insole has the same
initial thickness and volume as the mold-on-demand insole, ensuring
a proper fit from heel to toe, tip to tail, and side to side. Once
a proper fit is found and a purchase decision is made, the consumer
may remove the fitting insole from the shoes and replace them with
the mold-on-demand insoles. Once inserted, the consumer puts on the
shoes and secures the shoes to the feet. The consumer then
activates the mold-on-demand technology in the mold-on-demand
insole by application of pressure as will be described in greater
detail below. For example, activation can be accomplished by the
consumer standing up and applying pressure throughout the footbed.
Alternative methods of activation include bursting and kneading the
mold-on demand imprint insole (by hand or with the aid of a tool
such as a roller), placing the imprint insole on a hard surface and
manipulating the insole in a rocking motion to ensure activation
and mixing of component parts, then placing the insole assembly in
a footbed of a shoe, and securing the shoe to a consumer. Once the
shoe is secured, the consumer may stand, thereby applying the
pressure of the consumer's weight load on the insole to activate
and cure the insole as described in the instructions for use. The
material contained in the mold-on-demand insole flows into areas of
the foot where voids exist, and solidifies to form a customized
insole.
[0029] With reference now to the Figures, FIG. 1 is an example of
an item of footwear 100 which may be used to implement various
aspects of the features disclosed herein. The item of footwear may
take various forms. It may be any one of types and/or style of
shoe, including but not limited to, athletic shoes including
specialized athletic shoes such as cleats, ski and snow boots,
roller skates, and the like, comfort orthopedic shoes, orthotic
shoes, ordinary casual wear shoes, boots, dress shoes, high heels,
fashion shoes, slippers, house shoes, sandals, and the like.
Footwear construction types may include but are not limited to flat
lasting, double lasted, string lasted, strobel stitched, and
waterproofing constructs such as full bootie and gasket type. The
shoe 100 may include various constituent parts which are described
in FIG. 2.
[0030] Turning now to FIG. 2, an exploded view of various
components of the shoe from FIG. 1 are shown. The shoe and
constituent parts can be configured for use with either a right or
a left foot. For example, as illustrated in FIG. 2, the shoe and
constituent parts are shaped for use with a left foot. As shown in
FIG. 2, the shoe may include an upper shell 201. The shell may be
of any pattern such as a high leg boot, court shoe, slingback,
mule, sandal, ankle boot, wedge brogue, Derby/Gibson, causal, monk,
tasseled loafer, Chelsea boot, moccasin, or combinations thereof.
As is well-known, the upper comprises the portions of the shoe that
cover the toes, the top of the foot, the sides of the foot, and the
back of the heel. The upper may be constructed from any number of
suitable materials including, for example, leather, textile,
synthetic (nonwoven and microfiber backed), microfiber, spacer
meshes, plastic, rubber, wood, natural fibers such as jute and the
like. The upper shell 201 can be open toed or closed toed.
Similarly, the heel of the upper shell 201 can be open heeled or
closed heeled.
[0031] The shoe 100 may also include an insole 203. The insole 203
may be a mold-on-demand insole or a fitting insole as will be
described in greater detail below with reference to FIGS. 3 and 4.
The insole 203 is permanently affixed to a cradle 205, the insole
203 and cradle 205 together form an imprint insole system 213. The
imprint insole system 213 is removable and when in use, can be
positioned within the enclosure formed by the upper shell 201 and
the outsole 211 of a shoe.
[0032] The imprint insole 213 is preferably constructed from
materials which afford the imprint system 213 the properties of
being substantially lightweight, providing the consumer with
cushioning for comfort and fit, flexibility for ease in inserting
and removing said imprint insole system 213 into a shoe, and
providing a platform as well as support for the foot. Thus, the
cradle 205 is preferably a foam material which offers cushioning,
support, heel stabilization, and acts as a foundation for the shoe.
Suitable foam materials contemplated for use in the manufacturing
of the cradle 205 include, without limitation, EVA foam,
polyethylene foam, polyurethane foam, foam, and blown polyurethane
foam. The cradle 205 may optionally include an antimicrobial
additive to inhibit the growth of odor-causing bacteria. The cradle
205 generally has a shape of the inner base of a shoe and is
designed to fit within the cavity of a shoe. In some embodiments,
the cradle 205 includes markings around the exterior perimeter of
the cradle to delineate to a consumer where the cradle may be
cut/trimmed to accommodate different toe box shapes as will be
described in greater detail below. The cradle 205 may be positioned
within a foam (or foam-like) cushioning element 207 to provide
added comfort and support. The cradle 205 can thus include a single
layer of foam or may include a plurality of layers such as a
plurality of durometer foam layers, die out or injection
stabilization components such as shanks and the like. These
stabilization components may be formed from metal, die out, and
injection plastics or in any other suitable material as will be
appreciated by a person having ordinary skill in the art. The
cradle 205 can be formed in a variety of forming processes such as
but not limited to reaction, rotary, injection, direct pour, and
compression molding. The cradle 205 provides dynamic shock
attenuation and stabilization characteristics. Table 1 sets forth
exemplary characteristics of the cradle 205 when fabricated from a
pour molded polyurethane.
TABLE-US-00001 TABLE 1 Material/Component Specifications for Pour
Molded Polyurethane Cradle CHARACTERISTICS MIN-MAX STANDARD
DUROMETER 32-38 Asker C COMPRESSION SET 0.80% SPECIFIC GRAVITY
.35-.45 g/cc TENSILE 10.0 kgf/cm.sup.2 ELONGATION 190% DIE C TEAR
4.5 kgf/cm - NON MARKING NO MARKS HYDROLYSIS RESISTANCE After 10
days: Tensile Strength: 2.4 kgf Extension at Break: 190%
[0033] In certain embodiments, the midsole cushioning element 207
may provide additional dynamic shock attenuation, stabilization,
comfort and support. The midsole cushioning element 207 is
constructed of a material adapted for shock absorption such as, for
example, EVA, polyurethane, blown polyurethane, and blown rubber.
The midsole cushioning element 207 is fabricated via reaction,
rotary, injection, direct pour, compression molding, injection
molding or any other techniques known by a person having ordinary
skill in the art of foam fabrication. In some embodiments, the
insole imprint system 213 may further include the cushioning
element 207 when the midsole cushioning element 207 is exterior to
the midsole of a shoe. In some embodiments, the cushioning element
is internal to the midsole of a shoe and is thus not part of the
insole imprint system 213.
[0034] Tables 2 and 3 set forth exemplary materials and
characteristics of certain embodiments of the midsole cushioning
element 207. Table 1 sets forth the raw materials and
characteristics including the minimum-maximum standard for a
polyurethane (PU) exposed insole. Table 2 sets forth the raw
materials and characteristics including the min-max standards for
an EVA foam insole:
TABLE-US-00002 TABLE 2 PU Exposed Midsole Cushioning Element
CHARACTERISTICS MIN-MAX STANDARD Durometer 55-60 Asker C
Compression Set 6.40% Specific Gravity .30-.33 g/cc Tensile
16.0-16.5 kgf/cm2 Elongation 175% Die C Tear 12.8 kgf/cm - Stitch
Tear (Dry) 6.4 N/mm min Din Abrasion 345 Ross Flex, Oil#3 125,000
cycles - 4 mm growth Max Discoloration 3.5 u.v class - Volume Swell
(Fuel B@46 Hrs) 7.6 max Non Marking NO MARKS Hydrolysis Resistance
After 10 days: Split Tear Strength: 1.7 kgf Tensile Strength: 2.4
kgf Extension at Break: 175%
TABLE-US-00003 TABLE 3 EVA Exposed Midsole Cushioning Element
MIN-MAX CHARACTERISTICS STANDARD Durometer 52-58 Asker C
Compression Set 20-25% Specific Gravity .19-.24 g/cc Elongation
175% Split Tear Strength 1.7 kgf Tear Strength (Dry) 6 kgf min Din
Abrasion Per Material Specification Discoloration 3.5 u.v class -
Non Marking NO MARKS
[0035] The outsole 211 comprises the exterior bottom portion of a
shoe which is in direct contact with the ground. The outsole may be
constructed from any number of materials including, without
limitation, leather, natural or synthetic rubber, fabric, plastic,
or combinations thereof and may be attached to the bottom of the
cushioning system 207, and it forms the outer boundary between the
shoe and the ground. When the imprint system 213 is integrated into
footwear, the upper shell 201, midsole cushioning element 207, and
outsole 211 may be bound together by any conventional means of
adhesion. As illustrated in FIG. 2, the upper shell 201, midsole
cushioning element 207, and outsole 211 can be bound together at
the midsole using a binder 209. The binder 209 may be a foxing tape
such as crepe foxing tape, or some other binding material known in
the art. It is specifically contemplated, however, that in some
embodiments, no binder 209 is required for connecting the upper
shell 201, midsole cushioning element 207, and the outsole 211. For
example, when the footwear is a sandal or high heel, the upper
shell 201 can be attached/adhered directly to the outsole 211 with
or without a midsole cushioning element 207.
[0036] As discussed above, the footwear fitting system may include
two different insoles--one for trying on the shoe and the other a
mold-on-demand insole which customizes to the anatomical shape of
the wearer's foot. Turning now to FIGS. 3 and 4, examples of a
fitting insole 203A and a mold-on-demand insole 203B are provided.
Though shown as separate components in FIG. 3, the fitting insole
203A is permanently affixed to the top surface of the cradle 205
and adhered by any of a number of fusing techniques such as stock
fitting, direct pour, insert molding, and flame lamination. The
fitting insole 203A may be fabricated from any suitable material
including, without limitation, polyurethanes and ethyl vinyl
acetates (EVA). In one embodiment, the fitting insole 203A is
fabricated from a slow return memory foam. The fitting insole 203A
may be fabricated to achieve a variety of densities or hardness as
will be appreciated by a skilled artisan. For example, by varying
the air, gas, or blowing agent, the imprint insole can be modified.
Likewise, EVAs of different density or hardness can be fabricated
by varying the amount of monomeric units (e.g. ethylene or vinyl
acetate). Other materials such as polyethylenes, foam rubbers,
memory foam, plastazote, dyanofoam, or other foam plastics or
elastomers can be used. Features of preferred insole material
provide durability and comfort while also being substantially light
in weight. In certain embodiments, the fitting imprint insole,
comprising the fitting insole 203A and the cradle 205, includes a
top layer having a substantially soft texture to improve fit and
feel of the shoe. The top layer can be felt or imitation felt and
may include special ventilation features such as air channels,
shock absorption features, anti-bacterial features, antifungal
features, or the like.
[0037] The fitting insole 203A can be manufactured in any suitable
manner known to a person having ordinary skill in the art of insole
manufacturing. The outline of the fitting insole 203A, defined by
its outer edge, may substantially follow the profile of a left or a
right foot. In some embodiments, the outer edge is sized and shaped
to follow the outline of the user's shoe so that the fitting insole
203 can be used within a shoe. The fitting insole 203A permanently
affixed to the cradle 205 has substantially similar dimensions as a
mold-on-demand insole 203B permanently affixed to a cradle 205,
which will be described in greater detail below with reference to
FIG. 4. In general, the fitting insole 203A may have a flexible,
absorbing surface and is dimensioned to have a thickness and volume
that is substantially the same as the thickness and volume of the
mold-on-demand insole 203B and cradle 205. This allows for the
customer to get a sense of how the shoe will fit when the
mold-on-demand insole 203B is activated.
[0038] Now with reference to FIG. 4, after removing the fitting
imprint insole comprising the fitting insole 203A and the cradle
205 (as illustrated in FIG. 3) from a shoe and replacing the
fitting insole 203A with the mold-on-demand imprint insole
comprising a mold-on-demand insole 203B coupled to a cradle 205,
the mold-on-demand insole 203B and cradle 205 are positioned within
a shoe.
[0039] The mold-on-demand imprint insole comprises the
mold-on-demand insole 203B and cradle 205 and provides precision
fit, cradling support, and stability to the user. Additionally, the
mold-on-demand insole serves to unify the foot of a user with the
shoe to improve overall fit of the shoe, propulsion, fatigue
reduction, enhance lateral and arch support, and promote proper
alignment of the foot and ankle of the user. The mold-on-demand
insole 203B may take various forms. In general, the mold-on-demand
insole 203B is configured to provide personalized support in areas
of the foot which need it the most. The mold-on-demand insole 203B
may be configured to provide a form-fit to the contours of the foot
of the consumer, while at the same time providing gel-like
pliability and feel. In addition, the mold-on-demand insole 203B
may be formed using flexible, resilient materials which provide a
fully customized fit. In general, the mold-on-demand insole is
configured to mold to the foot of the wearer without needing any 3D
scan of the foot or any casting whatsoever. Additionally, the
mold-on-demand insole may provide customization in real-time,
generally within a few minutes of activation. As illustrated in
FIG. 4, the mold-on-demand insole 203B is a thermoset formed insole
configured to take on the imprint of the wearer's foot.
[0040] The mold-on-demand insole 203B is fabricated from material
which can take on the ability to mold to a user's foot. In one
embodiment, the mold-on-demand insole 203B is fabricated from a
thermoset polymer such as a thermoset resin. The mold-on-demand
insole may be fabricated from a slow return memory foam. In other
embodiments, the mold-on-demand insole 203B can include a top and
bottom elastomeric layer. In between the top and bottom layers may
be a middle layer having curable fluid stored in pressure sensitive
packets which are pressure activated and may burst to release the
curable fluid. The packets contain components that set or cure upon
release from the activated packets and may combine and react with
contents of adjacent packets to initiate curing. Exemplary curable
fluids suitable for use include, without limitation, polyurethane
resins, silicone resins, and epoxy resins.
[0041] In one aspect, the top and bottom layers of the
mold-on-demand insole are both made of an elastomeric film, and the
packets are arranged in between the two layers are made from a
silicon resin. These packets can contain materials that begin to
set or cure upon release from the packets and mixing/reacting with
contents of adjacent packets. The packets are arranged in arrays
and compartments and can be configured to optimize fit upon cure.
As will be described in greater detail below, during the molding
process, the user places the footbed within the shoe, and places
his or her foot within the shoe on top of the footbed. The user
then presses down on the footbed and rocks the foot back and forth,
causing the packets to burst and the packets' contents to mix and
react. The mixed material cures to the contours of the foot. In
some embodiments, the footbed may be enclosed in a compartment
within the shoe.
[0042] In some embodiments, curable fluid is contained within a
plurality of bladders which are arranged along the length and width
of the insole to optimize fit once the fluid cures. These bladders
or packets are preferably burstable by hand or foot (0.1N/cm2,
<500 psi). The packets may contain liquid or gaseous components
that, when mixed, result in a chemical reaction that cures the
materials to become solid. The mixing or reaction may also produce
an added attribute such as heat, cold, light, or color change.
[0043] The packets can be filled with a range of two-component or
multi-component reactive liquids. Examples of reactive liquids are
two-component resins, such as polyurethane resins, silicone resins,
epoxy resins, melamin resins, and polyurea resins; multi-component
liquid reactants to affect the production of heat, such as in the
dissolution of calcium chloride into water; multi-component liquid
reactants to affect the lowering of the temperature, such as the
dissolution of ammonium chloride into water; and multi-component
liquid reactants to affect the production of light, such as the
mixing of luminol and hydrogen peroxide.
[0044] FIGS. 7A-7C depict a schematic Depicts a schematic of a
portion of footbed of the present invention, with the packet array
and compartments on the bottom layer. FIG. 7(A) shows a top view of
that portion of the footbed, with individual packets (1), and
separate compartments or regions such as the toe region (2). FIG.
7(B) shows a perspective view of the portion of the footbed with
separate compartments or regions such as the toe region (2), arch
region (3) and heel region (4). FIG. 7(C) shows a cross section
view of the portion of the footbed, with individual packets (1)
Also depicted is the border surrounding the footbed area allows the
footbed to be clamped during manufacturing processes.
[0045] The packets may be made in different three-dimensional
structures, aspect ratios, and overall dimensions for different
applications. The three-dimensional structure of the packets can be
any three-dimensional closed solid compromising flat, contoured
and/or curved surfaces; some examples are hemi-spherical, cubic,
hexagonal prism, pentagonal prism, rectangular prism, cone, and
tetragonal pyramid shapes.
[0046] The packets may be arranged two-dimensionally on a flat or
curved surface. The curvature of the two-dimensional array may be
optimized to maximize the ease of packet bursting by the user. The
spacing, distribution, shape, and size of the packets can also be
varied to maximize the ease of bursting by the user.
[0047] The spacing between the packets may vary between a nil
thickness and 100 centimeters. Packets may be all the same size and
shape or comprise a variety of different shapes within the same
footbed.
[0048] Packets may take different shapes, sizes, two-dimensional
positioning, or wall thickness in order to tune the packet's burst
strength. In some applications, it may be important that certain
packets burst before others so a mixture of burst strengths may be
desired.
[0049] The most preferable arrangement of packets is a pattern of
identical shaped and sized close-packed polygonal prisms, such as
cubes, rectangular prisms, or hexagonal prisms. This arrangement
allows the air to be evacuated efficiently from the outside
thermoplastic, elastomeric bag. In this arrangement, a
two-component resin can be distributed in packets such that parts A
and B (i.e., the parts to be mixed) are spaced out in separate
packets an alternating fashion.
[0050] The two plastic sheets that bond together to form the packet
may both be thermoformed, blow molded, or otherwise shaped to
define the packet volume or only one sheet can be shaped. The
preferred embodiment for the moldable footbeds is a singly shaped
low-density polyethylene sheet bonded to a flat low-density
polyethylene sheet. In the preferred embodiment for the moldable
footbed, the polyethylene is thermally welded to the adjacent sheet
to define the seams of each packet.
[0051] Packets may be formed from any materials that can be sealed
to each other by some means. Methods of sealing the packet seams
include thermally welding, sonically welding, mechanically folded
together, using a curable adhesive, or using a hot-melt adhesive or
thermoplastic). For other applications, the packets could be formed
by thermal or sonic welding of thermoplastic sheets or it may be
desirable to use an adhesive or other material to form a
significantly stronger or weaker bond to tune the delamination of
the packet seam. For example, all inner seams of the individual
packets in the array may be tuned to delaminate while the outer
seams are meant to remain laminated such that the packet array
becomes one continuous pouch after bursting. The shaped plastic
sheet could also form packets with hard non-porous surfaces, such
as glass, metal, rock, or a coated surface.
[0052] In a preferred method of making the footbed of the present
invention, the packet arrays are formed by vacuum forming
thermoplastic sheets into bubble sheets. The thermoplastic material
can survive strenuous conditions during manufacturing, shipment and
handling but bursts when body weight pressure is applied. This
prevents premature curing and preserves on-demand molding
functionality. The arrayed packets are filled with resin and a
backing layer is thermally sealed to the open back of the packets
to form an arrayed sheet of packets, which can be seen in FIGS. 8A
and 8B. FIGS. 8A and 8B illustrate a portion of a packet array
sheet 5 where the packets have been filled with silicone resin
prior to sealing within elastomeric top and bottom layers. FIG. 8A
is a side profile of the filled packet array 5. FIG. 8B is a top
view of a portion of the filled packet array 5.
[0053] The arrayed packet spacing and individual packet volume can
be optimized in order to achieve the desired resin volume. When
multiple components are desired, packet characteristics can be
customized in order to contain the required volume. Also, an
arrayed packet design allows for quick mixing by holding components
in close proximity to each other. Upon bursting, each packet of
material can be in close proximity to other packets. The preferred
embodiment has an array of packets optimized for the desired volume
and with curing components in close proximity.
[0054] The upper and lower elastomeric layers are preferably made
from a breathable, anti-bacterial and/or anti-odor material.
[0055] Once activated, fluid from the packets may pool to areas of
the foot where voids exist, and a curing process takes place. After
a short period of time, the fluid may solidify, surrounding and
defining the perimeter of the foot, and also flowing in between the
toes and across the metatarsal area. In some embodiments, curing
can be achieved in less than five minutes. In another aspect,
curing can be achieved in approximately three minutes. In addition,
the curing material may also flow under the midfoot or arch area,
ultimately leaving a cured, soft, flexible and lasting impression
of the foot. In some embodiments, the curable fluid may be
compartmentalized to control the flow of the material to different
areas of the foot. For example, the toe area may include one
compartment of curing material, the ball and arch area another, and
the heel yet another to ensure proper support in those areas.
[0056] In one embodiment, the mold-on-demand insole 203B may
include memory foam infused with a pressure-activated resin. In
use, when a consumer applies pressure to the insole 203B by, for
example, stepping on the insole 203B, the memory foam takes the
shape of the consumer's foot and the insole molds to that shape.
The application of pressure also activates a resin. The resin is
released and sets the memory foam in the shape of the consumer's
foot imprint.
[0057] As detailed above, the mold-on-demand insole 203B is
permanently affixed to the cradle 205. The cradle 205 can include
markings (not illustrated) around the exterior perimeter of the
cradle to delineate to a consumer where the cradle may be
cut/trimmed to accommodate different toe box shapes as well as
different shoe sizes.
[0058] In certain inventive embodiments self-customizing footwear
may be provided as a footwear system which includes both a fitting
imprint insole and a mold-on-demand imprint insole. Turning now to
FIG. 5, a block diagram provides an example of contents and
configuration of a footwear system 500 as delivered to a consumer.
As shown, the footwear system 500 includes left and right shoes
502A and 502B. Inside the shoes 502A and 502B are the left fitting
insole 504A and right fitting insole 504B, respectively. The
fitting insoles are provided within the shoe so that the consumer
may try on the shoe without activating the mold-on-demand
technology provided in the customizable insoles 506A and 506B. The
customizable insoles 506A and 506B are positioned outside of the
shoe so that they can replace the fitting insoles 504A and 504B
after a purchase has been made.
[0059] Turning now to FIG. 6, an example of a fitting process for
according to one or more embodiments is provided. The process
begins at block 601, where a pair of shoes is prepared with the
fitting insole (such as fitting insole 502A and 502B) inserted into
each shoe. Next, the mold-on-demand insoles (such as insoles 504A
and 504B) are provided in the shoe packaging, but not within the
upper. The process next moves to block 605. There, the customer
selects a pair of shoes and tries on the pair of shoes using the
fitting insole. As discussed above, the fitting insoles and the
mold-on-demand insoles (in a pre-activated state) will generally
have substantially the same initial thickness from heel to insuring
a proper fit from heel to toe, tip to tail, and front to back.
Next, the process moves to decision block 607, where the customer
decides whether the shoes are a good fit. If not, the process
returns to block 605, and the customer selects a new pair of shoes
and tries them on with the fitting insole.
[0060] If at decision block 607 the customer determines that the
shoes are a good fit, the process moves ahead to block 609. There,
the fitting insoles are removed from the shoes. Once the fitting
insoles are removed, the process moves to block 611, where the
mold-on-demand insoles are inserted to replace the fitting insoles.
Once the mold-on-demand insoles have been placed within the shoes,
the process moves to block 613. There, the customer secures the
shoes to their feet. The process then moves to block 615, where the
customer, now wearing the shoes, activates the mold-on-demand
insole. Activation is generally accomplished by the application of
pressure. In practice, the application of pressure can be achieved
in any number of ways. For example, activation can be achieved by
stepping into a shoe with the mold-on-demand insert, applying a
force to the sole of the shoe having the mold-on-demand insole
inside the shoe, standing up with the shoe and insole on the
consumer's foot such that the weight of the customer applies
sufficient pressure throughout the footbed to activate the
mold-on-demand technology. Additionally, pressure may be applied by
hand activation or by manipulating the insole to pre-mix the
mold-on-demand components prior to placing the insoles directly on
a hard surface. The activation of the mold-on-demand insert can be
performed one insert at a time or both the left and right insole
can be activated substantially simultaneously.
[0061] Once the mold-on-demand technology has been activated the
customer may stand with his or her feet shoulder width apart as the
molding process begins. Depending upon the configuration of the
mold-on-demand insole, the customer may stand for one or two
minutes, or possibly more. Next, the process moves to block 617
where the customer stands with their feet shoulder width apart, and
the material in the footbed flows. The curing material may flow
into those areas of the foot where a void exists and the
pre-existing shape of the mold-on-demand insole fails to provide
adequate support. In particular, material will surround and define
the perimeter of the foot, flow in between the toes and across the
metatarsal area, and under the midfoot or arch area leaving a
cured, soft, flexible and lasting impression of the foot in
intricate detail. Generally, curing occurs within around five
minutes of activation.
[0062] In some embodiments, a kit for promoting fit and customized
footwear is disclosed. The kit comprises an insole/imprint system
having at least one mold-on-demand insole adhered to a cradle. The
kit can include a left footed mold on demand insole/imprint system,
a right footed insole/imprint system, or both. In some embodiments,
the kit further comprises a fitting insole permanently affixed to a
cradle. The fitting insole/imprint system can include a left footed
fitting insole/imprint system, a right footed fitting
insole/imprint system, or a combination thereof. The insole/imprint
system is provided in various sizes for use with different sized
feet. In some embodiments, the sizes correspond to typical men's,
women's and children's shoe sizes. Advantageously, the sizes of
insole/imprint systems disclosed herein are all purpose and can
include wide, narrow, children's sizes, as well as sizes and shapes
suitable for use in any number of shoe types including heels,
athletic shoes, orthopedic footwear, sandals, etc. In some
embodiments, sizes can range from size 3-14.
[0063] The insole/imprint system may include a marking/cutting
guide along the perimeter of the cradle. In some embodiments, the
marking/cutting guide appears on the top surface of the insole. The
cutting guide designates the boundaries for which further
customization of fit can be achieved by trimming the edges of the
insole/imprint system to accommodate sizing as well as different
toe box shapes in various shoe designs. The cutting guide can be
printed, etched, engraved, or molded onto the surface of the
insole/imprint system. In operation, the user will be instructed
that if further sizing optimization is necessary to promote better
fit of the insole/imprint system in a shoe, the insole/imprint
system may be trimmed by the user provided such trimming is
restricted to the exterior boundaries of the insole/imprint system
and should not exceed beyond the area of the insole/imprint system
indicated by the cutting guide. Thus, the kit can further include
instructions for guiding the consumer to further customize the fit
of an insole/imprint system by trimming the edges of the insoles
relative to the cutting guide on the top surface of the
imprint/insole system. Instructions also include a directive not to
cut beyond the cutting guide to avoid activation of the
mold-on-demand.
[0064] In another embodiment, the kit can optionally include
instructions to size the insole/imprint system by removing the
manufacturer's insole from a shoe and using said manufacture insole
as a template for trimming the insole/imprint system to optimize
fit. Instructions can include directions to remove the manufacture
insole, trace the outline of the manufacturer insole onto the
insole/imprint system, and trim the insole/imprint system along the
trace lines to fit. Instructions would further include directions
to insert the trimmed insole/imprint system into the shoe prior to
activation.
[0065] In some embodiments, the kit includes packaging to prevent
unintentional activation of the mold-on-demand insole. The
packaging may be a thermoformed clamshell. In some embodiments, the
packaging comprises a cut-away window to provide visualization of
the insole as well as an opportunity for the consumer to tactilely
interact with the insole.
[0066] A method of forming mold-on-demand imprint insole systems is
likewise contemplated. The steps for producing such footbeds can
include the following: materials are prepared by cutting LDPE, TPU,
fabric, and transfer adhesive to the proper size required. With the
LDPE sheeting, custom bubble arrays are formed by vacuum
thermoforming of the film. The LDPE sheeting is brought into close
proximity of a high temperature heat source, kept at 275.degree. C.
Once the material begins to soften and exhibits characteristics of
melting, the sheeting is then brought into contact with a custom
mold that is arranged on a vacuum plate, allowing the softened
material to form a net shape of the custom mold. Once this custom
bubble arrangement is formed, the piece is then placed into a
custom holder with rigid channels between the formed bubbles,
allowing the bubbles to hang freely. In this holder, silicone
components are then loaded into the bubbles in an alternating
fashion. Once the bubbles are filled, a sheet of LDPE is then laid
across the loaded bubbles. Using a high temperature and high
pressure pneumatic thermal press, this film is pressed into the
custom bubble arrays, forcing a high pressure gradient where the
rigid channel below lies, allowing the LDPE to seal to itself
through the silicone contamination. This completes the formation of
the silicone loaded bubble arrays.
[0067] Using the prepared TPU sheeting, two films are placed
substantially directly on top of one another and a desired fabric
top cover is applied to the top surface using a double sided
transfer tape adhesive. With the fabric in place, the silicone
loaded bubble array is aligned in proper position in between the
two TPU sheets. With this array in place, three sides of the film
stack are heat sealed, creating TPU-TPU bonds around the outer
edge. With these seals completed, the final open side is then used
to evacuate the excess air held within the films, creating a vacuum
tight seal of the TPU sheeting around the custom bubble arrays.
Once the air has been evacuated, the TPU sheets are then heat
sealed using a custom sealing plate kept at high temperature and
pressure, forming the overall shape of an insole complete with
sealed partitions in specific areas of the insole to separate
bubbles in certain regions of the foot. Once this seal has been
created, the net shape desired for further manufacturing is then
cut and the custom moldable layer of the mold-on-demand insole is
finalized.
[0068] Certain preferred materials for use in the manufacture of a
mold-on-demand imprint insole can include: [0069] a. Silicone
filler material is Andisil 204-37 Parts C&D, supplied by AB
Specialty Silicones [0070] b. Bubble films formed from LDPE, 10 mil
film thickness, supplied by SC Johnson. Film with no slip additive
preferred [0071] c. TPU sheeting is product DT-7101, 8 mil film
thickness, supplied by American Polyfilms Inc. [0072] d. Fabrics
provided by Cosmo Fabrics
[0073] While certain embodiments are described herein in detail, it
is to be understood that this disclosure is illustrative and
exemplary, and is made merely for the purposes of providing a full
and enabling disclosure. The detailed disclosure herein of one or
more embodiments is not intended, nor is to be construed, to limit
the scope of patent protection, for which scope is to be defined by
the claims and the equivalents thereof. It is not intended that the
scope of patent protection be defined by reading into any claim a
limitation found herein that does not explicitly appear in the
claim itself.
* * * * *