Note: Descriptions are shown in the official language in which they were submitted.
2 ~ 2~`24~7
The present invention relates to a cushioning pad
and more particularly relates to a cushioning pad which may
be incorporated into a shoe insole and for similar applica-
i tions to relieve pressure on adjacent portions of the user'sanatomy.
~ianv professions and occupations require that the
~] , inaivid~al wor~;er stand for long periods of time. Typical
12 ¦ occupations that require an extended or protracted periods
~3 ¦ of standing and walking are factory workers such as machin-
14 ists or assembiers, food service personnel, postal workers,~5 I barbers, beauticians and many others. Long periods of
~G ¦ standing, particularl~ on hard floors or surfaces, often
~_ ~ results in fatigue, tired legs, sore hips and back. In
~8 fact, it is estimated that some seventy-five percent of the
~¦l hmerican public has back pain or back fatigue. Standing or
(~l working for eight hours or so causes a pooling of the blood
2] ¦i and body fluids in the lower extremity resulting in edema,
2~1~ fatigue, tired feet, sore arches, knee pains, circulation
23 I problems, varicose veins and the like. Quite simply, humans
24 are not adapted to stand for extended periods on hard sur-
2~ ¦ faces. ~.an as we know him has been on this planet for about
2G four million years. During that time man evolved on grassy
27 plains, forest floors and sandy beaches. However, in the
28 last one hundred fi-fty years, as a result of industrializa-
29 tion, man spends much of his time walking, working and play-
ing on hard, paved surfaces. As mentioned above, the pre-
3] velance of hard, nonresilient surfaces has taken its toll.
32
G2~
I - 2
] I ~s a result of the problems encountered or imposed
2 bv prolonged periods o' standing or walking on such harà
3 I surfaces, fatigue mats have come into use. Generally a
4 I fatiaue mat consists of carpeting with some sort of foam or
shock-absorbar,t bac~ing which is placed around work areas
6 such as machines, barber chairs, and duty stations of food
_ service wor};ers. These mats serve to somewhat cushion the
S effects of hard surfaces. ~lanufacturing facilities use such
~J mats extensively, particularly in machine shop and assembly
~() areas. The arGhbac~ with such mats is that their use is
~11 limited since such matS cannot be usea in areas where eauip-
]2 ment is being movea. Such standard fatigue mats have other
~ disadvantages:
]911 1. Oil, water or chemicals that may spill upon
¦ them and make them sl ippery and therefore unsafe;
]~ ¦ 2. Debris and metal filings and machine metal
]/ ¦ curls may get imbedded in these mats, making them difficult
to use or causing them to deteriorate over prolonged use;
3. Such mats pose a problem for janitorial ser-
vices because the mats must be lifted for cleaning and the
mats themselves must be cleaned which imposes additional
~ ¦~ work on the cleaning personnel.
231 4. The most important deficiency of such conven-
2~ tional fatigue mats are that they are stationary and do not
2~ travel with the worker when the worker leaves the duty sta-
2G tion or work area.
2/
2~ There are various foot cushioning devices in the
29 prior art which are insertable in footwear such as foam
rubber insoles. These insoles serve to some extent to les-
3] sen the detrimental effects of hard surgaces but generally
32 these pads are of limited effectiveness and deteriorate
- 3 -
quickly o~ :c,rnr,a~t so that tlle.ir cu~h:ioning effe~tivene~s is
quickly sacr:ific~dO One particularly effective foot cushioning
device is shown in my prior patent, u.s. E~ate~t No. 4,179,826
issued December 25, 1979 for "I`oot Cll~hi.oning Device". This
device i8 a novel and un:ique heel cup but is designed more
specifically .for individuals engaged in athle-tic and activ~
endeavours .such as joggers, runners, hikers, football and soccer
players and the like. Whi.le thi~ device is highly efEecti.ve and
ha~ achieved a high degree of commercial succe~, the device i~
primarily aimed at cushioning the effects of heel strike and not
de~igned to reduce the effects of prolonged period~ of standing.
Accordingly, there exist~ a need for an effective and portable or
tran~ient cu~hioning pad or mat.
By one broad aspect of thi3 invention, a cushioning mat i~
provided, comprising: ta3 an upper laminate of material having
moi~ture-absorbant characteri~tics; (b) an intermediate laminate
having an upper and lower surEace, the upper ~urface being bonded
to the lower surface of the upper laminate, the intermediate
l~minate being xesilient and permanently deformable over
prolonged application of pre~sure; ~c~ a lower cushioning pad
having a base layer having an upper and lower surface, the upper
surface of the ba~e layer being bonded to the lower surface of
the intermediate layer; (d) a plurality of generally spaced-apart
longitudinally and transversely extending ribs extending from the
,... . .
, , ,
lower ~urfac* of the base defining a plurality of cell~, the xib~
having memory to ~eturn to the original shape upon remoYal of
deformati.on force~ and being resi.lient to flex and deform under
application o.f pre~ure to cllshion shock; and (e) the rihs
defining first air passageways placing the ce.lls in communication
with one another; wherein the laminate and the pad define second
air passageways at selected locations, whereby air flow is
induced through the mat and between the cel.ls as -the mat is
flexed.
The upper laminat:e i~ preferably nylon, and the intermediate
layer preferably is neoprene rubber. The lower cushioning pad
preferably i~ molded as a unitary structure of natural latex
rubber. The laminate preferably has a peripheral configuration
generally conforming to the ~hape of a human foot~
The present invention in one embodirnent thus provides a new
comfort product for reducing fatigue in the foot, leg, and back
imposed by prolonged periods of bodily contact with hard
surfaces. The present invention may be be~t termed a portable,
personal fatigue mat. The fatigue mat in one embodiment consi~ts
of multi-layered cushion structure which, in the preferred
embodiment, is configured a~ an insole to be worn in footwear.
The bottom of the three layers consists of a cushion made of a
very soft natural latex rubber having a cellular design which
provides permanent "memory" and absorbs shock due to compression
and deformation of the cells. The intermediate layer is of
neoprene foam rubber which molds to an individual's particular
foot contour and shape as it is used. These layers are bonded to
a -top cover of strong nylon. Air channels are provided through
the layers and through the individual cells at spaced-apart
locations to provide good ventilation and Eor hygienic reasons.
The cushioning material may also be configured in other product~,
e.g. knee pads, helmet liners and the like.
J~4~7
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In the accompanying drawings,
91 Figure l is a bottom view of a preferred embodi-
]~¦ ment of the cushior,ing pad of the present invention partl
¦1 bro}en a~ay;
]"1 .
_ .
¦ Fi~ure 2 is a top view of the pad of Figure l
~4 partly broken away to illustrate the various layers;
]''li
~ ¦ Figure 3 is a detail view of a portion of the pad
]/ ¦ as indicated in Figure l;
]~
; Figure 4 is a transverse sectional view of the
~()n cushioning pad taken along lines 4-4 of Figure l;
~,~. Figure 5 is a bot.om perspective vie~ of another
j embodiment in the form of a stationary pad or mat construct-
I
24 ¦ ec according to the present invention;and
2~ l
2G ¦ Figure 6 is a perspective view of a knee pad in-
2/ ¦ corporating the cushioning structure illustrated in Figures
2~ l to 4.
2~1
Turning now to the drawings, Figures l through 4
31 show a preferred embodiment of the cushioning pad of the
32 present invention which is generally designated by the num-
:3L 2~ , d
] eral 10. Embodlment 10 is a cushion in the form of an insole
2 and is shown adapted for use with the left foot of the wear-
3 er insertable in footwear. The cushioning pad 10 is a lam-
9 inated structure comprising an upper or top laminate or
~ layer 12, an in.ermeaiate layer :L~ and bottom layer 16. The
G ~ pad is, as mentioned above, in the form of an insole adapted
_ , for insertion in ~ shoe or other footwear and has a curved
X , toe portion 20, curved heel portion 22, and opposite sides
24 and 26. Sides 2~ and 26 are config~red to conform to the
~nl shape of the foot having, for example, a long indentation 25
1] I which correspon~s to the long medial arch of the foot.
]2 I
]3 ¦ As best seen in Figures 3 and 4, the bottom layer
]g 16 of the cushioning mat or pad is formed from a resilient
~5 material, preferably a very soft natural latex rubber, hav-
~G ing the characteristic of permanent "memory". That is, the
1/ material is deformable and resilient upon application of
1~ ¦ force and when force is removed, the material will return to
~) ' its oriainal shape. Other materials including synthetic
20¦l rubbers and plastics having these characterics will become
2~¦i apparent to those skilled in the art.
2~ i
23 i The bottom layer 16 is preferably molded having
2g I longitudinally extending ribs 28 and transversely extending
2~ ~ ribs 30 which intersect to form a plurality of individual,
2G ¦ gener~lly rectangular cells 32. The individual ribs 28 and
2/ 30 project downwardly from the base 34 approximately 1/8
28 inches. The individual cells may vary in size but are typi-
2~ cally approximately one-quarter inch square. The cellular
design closely duplicates the method of absorbing shock in
3~ the heel pad of the human foot as the individual cells pro-
32 vide columns of air which will deflect and cornpress to ab-
2~7
]¦ sorb shoc~:. The longitudinal ribs define transversely
2~ arranged notches 36. Similarly, the transversely extending
ribs 30 define longitudinally arranged notches 40. The
notchec r~av be in alternatelv spaced rows with the result
, that both transverse and longitudinal air channels are pro-
61 vided communicating with a substantial number of the indivi-
-ll dual cells 32.
Intermediate layer 14 is typically one-sixteenth
tc three-eighths inch thic}: and preferably of a resilient
m,tericl such as neoprene foarl rubber which has the charcc-
2I teristic of molding or shaping under continued application
~31~ f pressure. Thus, as the insole is worn by the user, the
4¦l intermeaiate layer tends to conform to the particular footcontour and irregularities of the individual wearer provid-
~G I ing a comfortable and personalized "feel". The intermediatelayer 14 and the lower layer 16 are bonded together by
application of heat and/or adhesive as is well known to
()l, those in the arts. The particular method of bonding may
~)l vary but bonding techniques similar to those used in the
"~ll manufacture of conventional swimmer's and diver's wetsuits
~2,i is preferreo.
~3l
24 ¦ The upper layer or cover 12 is primarily for mois-
~.~ ¦ ture absorption and consists of a suitable moisture-absorb-
2G I ing material such-as nylon. The nylon, again, is bonded to
2J ¦ the upper surface of the intermediate layer 14 by conven-
28 tional bonding techniques known to those skilled in the art.
29
In use, the cushioning mats or pads may be provid-
3~ ed to the user in various sizes and shapes for insertion in
~ shoes or may be provided in blank form and trimmed to the
Il _ 9 _
]~ desired shape by the ~ser. The unique construction provides
2 ¦ substantial advantages. The upper layer serves to provide
3 ¦ comfort anc absorbs moisture. The intermediate layer 1~
conforms to the contours of the foot of the user. The lower
or botto~, layer consisting of the individual cellular shock
G absorbers c~shions the wearer's foot to relieve fatigue to
_ the feet, };nees, legs and back. A significant advantage is
~ that th~ indi~iaual cells or grids 32 permit air circulation
9 across the pad to the foot of the wearer via notches 36 and
~0 ~ 40 arranaec with the ribs defining ~he cell walls. In
]I ~ addition, a plurality of air holes ~ are provioed at multi-
~2 I ple spaced-apart locations in vario~s channels extending
~3 I through the base layer 34, intermeciate layer 14 and upper
~4 I layer 12. The location and spacing of the holes may vary
]~ ¦ but is preferred that the holes be located on approximatelya
~G ¦ 1/2" grid spacing. This allows air transfer in, around and
~7 ! under the c~shioning pad. These individual cells which are
1~ ' in communication with the air passageways or notches, serve
~) ¦ as small bellows or air pumps to assist in air circulation.
20l
21 I A further advantage is that the individual cells
2~¦¦ 32 serve to assist in circulating blood through the body.
23 The muscles in the lower extremities of the body act as an
24 auxilliary pump. The heart in the human pumps blood
2~ throughout the body system and is pressed back into the
2G atriums of the héart and reci~culated again. However, when
27 blood is pumped down to the feet, the peripheral venus pump
28 mechanism made up of muscles in the leg squeezes the veins
29 and forcec blood back to the heart. The flexing and defor-
mation of the individual cells against the foot assists the
31 peripheral venus pump mechanisms to force blood back to the
32 heart. In addition, shock on the foot and remainder of the
- 10- ~ 7
I ~,oay of t:he wearer is re~uced as shock is dissipated in the
2 ~ aeformc,tion of the individ~al cells. Accordingly, fatigue
3 is reduced and less strain is placed on the skeletal struc-
g I ture o~ the user. ~
)
In Fig~re 5, which is a bottom perspective vie~,
/ the fatigue mat of the present invention is designated by
8 the numeral 5G ana again constructed as a laminated struc-
9 I ture having the ,nols.ure absorbing top cover 12h, interme-
~0 ¦ dia~e layer 1~. whic~ c~nforms to the foot and bottom c~sh-
~] I ionins st~~c~re 16~. corsis.ing of the gric-like or egg
I crate cells aer~ned by intersecting ribs. The cushioning
]2 I !
~3 ¦ pac 50 OL .his embodiment is shown as being generally rec-
]4 I tangular, however~ any geometric shape could be utilized
]5 I consistent with the requirements of the user. The mat is a
]~ ~ stationarv mat positioned in the work area and as long as
I the worker is standing on it, provides the benefits desribed
¦, above. The disadvantage of the permanent mat is that these
benefits are achieved only as long as the worker is standing
on the mat, whereas with the previous embodiment the cush-
~nl, I
¦l ioning device is considered a "personal" cushioning device
1 that remains with the user.
2~, In addition to the foregoing, the unique cushion-
ing structure described above may be incorporated in other
2~ - :
2G ob~ects and devices. In Flgure 6, a knee pad 60 is shown
again constr~cted of the laminate structure with a cover
2/
28 12B, intermediate layer 14C and cushioning layer 16C. The
29 knee pad is shown as generally rectangular and is curved in
both the later~l and longitudinal directions so as to cover
3] the patella and knee area of the user. A strap 62 extends
from one side of the knee pad so that the ~ad can be secured
_,. !
6zg,a7
1,
to the knee o. t'-e user with the strap extending about the
2 back of the leg of the uscr and secured at tab 63 by cooper-
3 ating hoo~ and pile members 64 and 65. Knee pads of this
~ I type can be used by athletes as a protective measure and as
well as use by construction workers, gardeners, and others
who find it necessary to remain on their knees for a long
/ ¦ period of time. ~g2in, the cushioning layer 16C tends to
S ~ absorb shoc~; w~, le providing the pumping and massage action
g ¦ to the ad~acent bod~ area of the user.
10 l
]~ I rrO:r~ .ne ~oregoing, it will be apparent that the
present invention provioes a unique cushioning device having
substantial applications. The particular peripheral config-
13
14 uration of the pad may vary in accordance with the particu-
lar application, 2S for exam?le, the cushioning device may
be an insole, knee pad, helmet liner or the like.
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