Note: Descriptions are shown in the official language in which they were submitted.
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HEATED INSOLE WITH REMOVABLE HEATING ASSEMBLY
Related Applications
This application claims priority to and benefit of U.S. Non-Provisional
Application No.
14/568,516, filed December 12, 2014.
Technical Field
This application relates to insoles such as heated insoles.
Background
Several occupations require employees to endure harsh weather conditions
during the
winter months. To name a few, soldiers, construction workers, agricultural
workers, and law
enforcement officers must routinely spend several hours outdoors despite cold,
snowy or icy
conditions. Others happily brave cold weather in order to enjoy activities
such as skiing, hiking,
snowshoeing, and sledding. Further, many must bear freezing temperatures after
a snowstorm to
shovel their car out and to clear accumulated snow from their driveway and/or
sidewalk.
Regardless of whether one is exposed to cold weather conditions for work, fun,
or chores,
most accessorize with coats, boots, hats, and gloves to make the cold weather
bearable. In
addition to those accessories, heated insoles for shoes have recently been
introduced in order to
provide heat directly to a wearer's feet. Known heated insoles include
electronics located
between an insole's layers. The heated insoles include an internal heating pad
coupled to an
internal battery. The internal battery, due its size, has a limited battery
life (e.g., 3-4 hours). In
order to charge the electronics, one must connect the heated insole to an
electrical power source.
This requirement is a hassle for those who desire warmth in excess of the
battery life. One must
remove the heated insole from the shoe, plug in the insole to recharge its
internal battery, wait
for the insole's internal battery to recharge, and then re-introduce the
insole into the shoe prior to
continuing with their activity.
Summary
A heated insole, according to aspects of the invention, allows a user to
easily remove and
replace a battery-powered heating assembly without removing the insole from
the shoe and
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waiting for the insole to recharge. According to the present invention, a
charged heating
assembly may be introduced in its place, thereby allowing essentially
undisrupted use of the
heated insoles. Another benefit of the present invention is that the removable
heating assembly
may be used as a personal heating unit when not used in conjunction with the
insole. For
example, the removed heating assembly may be placed in a user's clothing
pocket for warmth or
may be held by a user to warm the user's hands.
According to certain aspects, an insole of the invention includes an insole
body and a
heating element for generating heat. The heating element is removeable from
and insertable into
a recess of the insole body. The recess may be located anywhere in the insole,
including at the
heel portion, the mid-foot portion, or combination thereof. In particular
embodiments, the recess
and heating element are configured such that the heating element is removable
from and
insertable into the recess while the insole is disposed within the shoe. The
heating element is
typically a component of a heating assembly, in which the heating assembly is
removeable from
and insertable into the insole as a single unit. The removable heating
assembly may further
include a battery for transferring energy to the heating member. The battery
may be
rechargeable. Alternatively or in addition to the battery, the removable
heating assembly may
further include a control circuit for adjusting a level of energy transmitted
to or from the heating
element. The control circuit may be operated by a remote control.
Aspects of the invention further include heating assemblies for inclusion in
insoles. A
heating assembly for inclusion in an insole may include a heating member. The
heating
assembly may be incorporated into an insole to form a heated insole. The
heating assembly may
further include a battery for transferring energy to the heating member. The
battery may be
charged while disposed within the heating assembly or the battery may be
removed from the
heating assembly for charging. Additionally, the heating assembly may include
a control circuit
for adjusting the level of energy transferred to or from the heating member.
The circuit may be
operated by a remote control. In certain embodiments, the assembly, when
included in an insole,
may be directly removeable from a surface of the insole. In addition, the
assembly, when
included in an insole, preferably allows one to remove the heating assembly
from the insole
when the insole is disposed within a shoe.
A benefit of the present invention is that the heating member or assembly may
be easily
inserted into and removed from the insole. The removable and insertable
heating member or
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assembly is preferably designed to mate-fit with the recess of the insole. The
recess may be a
frame formed within the insole. In certain embodiments, the heating member,
when placed
within the recess, forms a portion of a top surface of the insole. In such
instances, a surface of the
heating member, when the heating member is disposed within the frame, is
substantially flush
with a surface of the frame and/or insole. The flush surfaces of the heating
member, frame,
and/or insole form an undisruptive surface for receiving a user's foot,
thereby preventing the
removeable heating member from being uncomfortable to the user wearing the
insole. In
embodiments where the heating member is part of a heating assembly, the
heating assembly,
when placed within the recess, forms a portion of a top surface of the insole.
That is, a surface of
the heating assembly, when the heating assembly is disposed within the frame,
is substantially
flush with a surface of the frame or the insole.
Insoles of the invention may be an independent item that is separate from a
shoe that the
insole is being used with. In such case, the insole is insertable and
removable from the shoe.
Alternatively, the insole of the invention can be built within or incorporated
into the shoe itself
(i.e. not designed for easy removal). Thus, the invention also includes a shoe
having an insole
that is configured to receive a removable heating member or assembly such that
the heating
member or assembly may be inserted into and removed from the insole while the
insole is
disposed within the shoe.
The heating member or assembly may include a base portion and the cushion
portion
coupled to the base portion. The cushion portion may form the exposed surface
of the heating
member or assembly that is configured to receive the user's foot. Ideally, the
cushion portion is
substantially flush with a surface of the insole. When the heating member or
assembly is
installed in the insole, the cushion portion forms a surface of the insole,
and provides comfort to
a user wearing a shoe with the insole disposed therein. The base portion is
typically a container
that encloses the components of the heating member or assembly. The base
portion of the
heating member or assembly fits within the recess or frame of the insole. The
base portion or the
cushion portion may include a finger tab for assisting direct removal of the
heating member or
assembly from the surface of the insole.
Other aspects of the invention involve insoles having a removable and
rechargeable
battery. According to such aspects, an insole of the invention includes an
insole body having a
battery-receiving portion and a battery. The battery-receiving portion is
configured such that the
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battery is removable from and insertable into the insole body while the insole
is disposed within
a shoe. In certain embodiments, the battery-receiving portion of the insole is
a frame. The frame
may be part of a heating assembly that provides heat to a wearer's foot when
powered by the
battery. The heating assembly is typically located within the insole and
delivers heat to at least
the forefoot portion of the shoe. The heating assembly may include a heating
member and a
connector, in addition to the frame. The connector of the heating assembly may
be operably
coupled to the frame, and functions to transfer energy from the battery to the
heating member.
The heating member may include a heater panel and a conductive ribbon that
transfers energy
along a length of the insole to the heater panel. The heating assembly may
further include a
circuit coupled to the connector. The circuit allows one to adjust the level
of energy being
transferred from the battery to the heating member. In certain embodiments,
the circuit is
adjustable from a remote control.
Brief Description of the Drawings
FIG. lA illustrates a perspective view of an insole of the invention,
according to certain
aspects.
FIG. 1B illustrates a top view of the insole of FIG. 1A.
FIG. 1C illustrates a bottom view of the insole of FIG. 1A.
FIG. 2A illustrates a perspective view of a frame of an insole of the
invention, according
to certain aspects.
FIG. 2B illustrates a top view of a frame of the insole of FIG. 2A.
FIG. 3A illustrates a perspective view of a battery of the invention,
according to certain
aspects.
FIG. 3B illustrates a side view of the battery of FIG. 3A.
FIG. 3C illustrates a front view of the battery of FIG. 3A.
FIG. 3D illustrates a top view of a battery of the invention, according to
another
embodiment.
FIG. 3E illustrates a rear view of the battery of FIG. 3D.
FIG. 3F illustrates a side view of the battery of FIG. 3D.
FIGS. 4A and 4B illustrate an insole of the invention, according to certain
aspects,
disposed within a shoe.
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FIG. 5 provides a partially transparent view of a heated insole 300 according
to certain
embodiments.
FIG. 6 illustrates an exploded view of a heated insole according to certain
embodiments.
FIG. 7 illustrates an insulation layer of an insole of the invention.
FIG. 8 illustrates a water-proofing layer of an insole of the invention.
FIGS. 9A, 9B and 9C illustrate a configuration that allows bending of a
heating
assembly.
FIG. 10 illustrates a layout of a heating assembly according to certain
embodiments.
FIG. 11 illustrates a frame of a heating assembly according to certain
embodiments.
FIG. 12 depicts a rivet used to connect a circuit to the frame of FIG. 11.
FIGS. 13A and 13B illustrate a connector of the invention.
FIG. 14 illustrates a transparent side view of the connector of FIGS. 13A and
13B.
FIG. 15 illustrates an exploded view of a battery of the invention.
FIG. 16 illustrates the coupling between a battery and a connector of the
frame.
FIG. 17 illustrates a battery magazine of the invention.
FIG. 18 illustrates enlarged prospective view of a heel portion of an insole
of the
invention, and shows a connector positioned at an incline.
FIG. 19A illustrates an insole with a removable heating assembly.
FIG. 19B illustrates another insole with a removeable heating assembly.
FIG. 20A illustrates the insole of FIG. 19A with the heating assembly removed.
FIG. 20B illustrates the insole of FIG. 19B with the heating assembly removed.
FIG. 21 is a schematic illustration of a removable heating assembly.
FIG. 22A provides a side-view of a removable heating assembly with a single
compartment.
FIG. 22B provides a side-view of a removable heating assembly with multiple
compartments.
FIGS. 23A-23B illustrates various configurations of the components disposed
within a
multi-compartment heating assembly.
FIG. 24 illustrates a heating element according to certain embodiments.
FIG. 25 illustrates a control circuit according to certain embodiments.
FIG. 26 illustrates a battery according to certain embodiments.
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FIG. 27 illustrates an insole with a removable heating assembly and conductive
elements.
FIG. 28 illustrates the insole frame with a conductive contact.
FIG. 29 illustrates a removable heating assembly with a conductive contact.
Detailed Description
While the invention is described herein as pertaining to heated insoles,
concepts of the
present invention are also applicable to other insoles that may require
battery power. For
example, the structure and configuration of the present insoles with removable
and insertable
batteries can be applied in insoles having a vibrating mechanism (e.g.
massaging insoles). In the
case of a removable and insertable assembly, the assembly may include a
battery, control circuit,
and the vibrating mechanism. In addition, the invention is described in
reference to one insole
and shows a left-footed insole, but it is understood that the invention could
be used to form right-
footed insoles or a pair of insoles (right-footed and left-footed insoles)
FIGS. 1A-1C illustrate views of an exemplary insole 100 with a removeable
battery
according to the invention. As shown in FIGS. 1A-1C, the insole 100 includes a
body 28 that
has a distal end 24 and a proximal end 26, and can be divided up into separate
sections: a heel
portion 2, a midfoot portion 4, and a forefoot portion 6. The heel portion 2
is typically thicker
than the midfoot portion and forefoot portion 6 due to additional cushioning.
The midfoot
portion 4 may be designed to support the arch of one's foot and provides a
transition between the
heel portion 2 and the forefoot portion 6. The forefoot portion 6 corresponds
to the ball of one's
foot and toes. Preferably, the insole body 28 is shaped to conform to a foot
(left or right) of a
user. In addition, the insole body 28 may be shaped to fit within any type of
shoes, including
boots, tennis shoes, ski boots, sandals, slip-ons, etc. Ideally, the insole
body 28 is flexible such
that it flexes with the motion of one's foot while they walk.
The insole body 28 includes a top surface 10, a bottom surface 22, a side
surface 8. The
top surface 10 receives the foot of a wearer, and the bottom surface 22 rests
against the sole
(bottom frame) of the shoe. The top surface 10 or bottom surface 22 may be
specially formed to
conform to different types of feet and different types of shoes. In addition,
the bottom surface 22
may rest or be designed to rest against another insole (i.e. for when the shoe
has built-in insoles).
The insole body 10 may be formed, at least in part, by a cushioned material to
provide comfort to
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the user. Furthermore, the insole body 28 may be formed as part of the sole of
a shoe. For
instance, when the shoe, due to its structure, does not have an insole
separate from the sole itself,
which is often the case in slip-on shoes.
The insole body 28 of the insole 100 includes a frame 12 that is configured to
receive a
battery 14 disposed therein. Preferably, the frame 12 is positioned in the
heel portion 2 of the
insole 100, or in the arch segment of the insole 100. The top surface 20 of
the frame is
substantially flush or flush with a top surface 10 of the insole body 28. As
shown in FIGS. lA
and 1B, the battery 14 is shown inserted in the frame 20. The top surface 30
of the battery 14 is
substantially flush or flush with the top surfaces 10, 20 of the insole body
28 and frame 12,
respectively. This flushness advantageously allows a user to comfortably rest
his/her foot
against the insole 100 without feeling differences among the multiple
components. As such, the
frame and the battery (when placed in the frame) may be said to form a portion
of the top surface
of the insole. In addition, top surfaces 20, 30 of the frame 12 and battery 14
may be cushioned
in the same manner as the insole body 28 to further prevent a wearer from
feeling or being
disrupted by the multiple components. For example, each component may be
formed from a
polymer or polymer foam. A preferred polymer or polymer foam is polyurethane.
Alternatively,
the components may be formed from different materials.
The frame 12 optionally includes a grasping region 18 that is shaped to allow
a user to
directly remove the battery 14 from the top surface 10 of the insole body 28.
That is, one does
not have to remove the battery 14 from an enclosed battery compartment (i.e.
with a lid for
example), but can access the battery from the outer surface of the insole. As
shown, the grasping
region 18 is a recess within the frame 12 next to the battery 14. Preferably,
the grasping region
18 is shaped to allow a wearer to partially insert one or more fingertips
therein so that the wearer
can use their fingertips to easily remove the battery 14. The grasping region
18 may be
positioned anywhere within the frame 12, and is shown on a distal portion of
the frame 12.
According to certain aspects, insoles 100 of the invention may be inserted and
removed
into one's shoes when one desires. In such aspect, the insole is a separate
from the shoe. For
removable insoles, the insole 100 may include a tab 16 that a user can pull to
remove the insole
100 from the inside of a shoe. Alternatively, insoles 100 of the invention may
be built into one's
shoes (e.g. not designed for easy removal).
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FIGS. 2A and 2B provide a close-up view of the frame 12 without a battery
inserted
therein. The frame 12 defines a recess 40 that is surrounding by sides 42 and
bottom 44. The
recess 40 of the frame 14 is sized and shaped to receive the battery 14.
Preferably, the frame 12
snuggly receives the battery 14 within the recess 40 to prevent unintended
movement or removal
of battery 14. The frame 12 further includes a connector 46. The connector 46
couples to the
battery 14, and places the battery 14 in communication with a heating member
(discussed
hereinafter). In certain embodiments, the coupling between the connector 46
and the battery 14
is a mate-fit coupling (the particulars of which are described in more detail
hereinafter). The
connector 46 is preferably constructed out of an elastomeric material, which
provides the ability
to absorb deflection and stress. The connector 46 may pivot to assist in
battery 14 insertion and
removal (this function is described in more detail hereinafter). The pivoting
capability and
flexibility of the connector 46 allow it to maintain its mechanical integrity
even when deflecting
while bearing weight and other stresses.
In certain embodiments and as shown in FIG. 2A, the frame 12 may include a
rigid
portion 52 and a cushion portion 50. The cushion portion 50 provides comfort
to the user, and
the rigid portion 52 provides the needed structural support for the connector
46 and associated
circuitry. The cushion portion 50 may be a polymeric foam.
In certain embodiments, the frame 12 of the insole 100 includes a battery
indicator. The
battery indicator may include light emitting diode (LED) that is associated
with circuitry (such as
circuit 210 shown in FIGS. 5 and 6) disposed within the insole. In one
embodiment, the battery
indicator emits a light when the battery 14 is inserted into the insole 100.
The emitted light my
indicate that the battery 14 is fully connected and may appear as a single
flash, a series of flashes
over time, or the light may constantly be emitted while the battery is in
place. Optionally, the
battery indicator also emits a light to illustrate that the battery 14 is
running low on charge. The
low-battery light may appear as a single flash, a series of flashes over time,
or constantly emitted
light. Preferably, the light emitted to indicate that the battery is properly
inserted or connected is
different from the light emitted to indicate the battery is low on charge. For
example, a green
light may indicate the battery is properly inserted, and a red light may
indicate the battery needs
to be recharged. In addition, the battery indicator may also emit a light to
illustrate that the
battery 14 is defective, and should be discarded.
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The battery indicator may be positioned anywhere on the insole 100. According
to some
embodiments, the battery indicator is positioned on the frame so that it is
easily visible to a user
while the insole is disposed within a shoe. FIG. 2B shows a battery indicator
27 positioned in
the grasping region 18 of the frame 12. In this particular embodiment, the
battery indicator 27
includes an LED in close proximity with an opening of the grasping region 18
of the frame 12.
The frame 12 near the battery indicator 27 may include a reflective surface to
further enhance the
light emitted from the LED. The opening allows light emitted from an LED,
which is associated
with the internal circuitry of the insole, to be seen therethrough.
The battery 14 may be the battery itself (i.e. one or more battery cells) or a
battery pack,
which is a body that encloses one or more battery cells. Any suitable battery
may be used for the
battery or battery cell. Types of batteries include, for example, nickel
cadmium, nickel-metal
hydride, lead acid, lithium ion, lithium ion polymer batteries. The battery
chosen ideally holds
charge for more than 2, 3, 4 or 5 hours, and is rechargeable. In one aspect,
the battery 14 is a
battery pack, and such aspect is described hereinafter and shown in FIGS. 3A-
3C. The battery
can be inserted and removed from the insole (or sole) at the user's
convenience.
FIGS. 3A-3D illustrate battery 14 as a battery pack according to certain
embodiments.
Preferably, the battery 14 is shaped to fit within the frame 12 such that the
top surface of the
battery 14 is substantially flush or flush with top surfaces of the frame 12
and insole body 28. In
some embodiments, the battery 14 includes a lower body portion 62 and an upper
body portion
64. The lower body portion 62 may be formed from a polymeric material, and the
upper body
portion 64 may be a polymeric form. The lower body portion 62 is designed to
mate fit with the
rigid portion 52 of the insole frame 12. The lower body portion 62 also
includes a connector
portion 66 that is designed to couple (i.e. mate-fit) to the connector 46 of
the frame 12. In certain
embodiments, the lower body portion 62 is also rigid to protect the battery
cell disposed therein
and to protect the coupling between the battery connector 66 and the frame
connector 46. The
lower body portion 62 may include a door or latch that allows one to remove
the battery cell(s)
disposed therein. The upper body portion 64 is coupled to the lower body
portion 62.
Preferably, the upper body portion 64 is cushioned to provide comfort to a
user.
According to certain embodiments, the battery 14 includes a finger tab 67 that
one can
leverage with his/her finger to assist in removing the battery 14 from the
frame 12. The finger
tab 67 can extend from the lower body portion 62, and may be positioned on any
side of the
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battery 14. Preferably, the finger tab 67 is on a side of the battery 14 that
mates with the
grasping region 18 of the frame 12. As shown in FIG. 3B, the finger tab 67 is
positioned at the
distal end of the lower body portion 62, which is opposite to the connector
66, and is level with
the top of the lower body portion 62.
In preferred embodiments, the lower body portion 62 and the upper body portion
64 are
designed to accommodate a raised finger tab 69, as shown in FIGS. 3D- 3E. In
such
embodiment, one side (such as the distal end) of the lower body portion 62 may
include a raised
portion 70 from which the raised finger tab 69 extends. In addition, one side
(such as the distal
end) of the upper body portion 64 may include a cut-out 71 to accommodate the
raised portion
70. The raised finger tab 69 further eases one's ability to remove the battery
14 with his/her
fingertip.
A benefit of insoles of the invention is that the battery 14 may be removed
from the
insole 100 while the insole is disposed within a shoe. FIGS. 4A and 4B
graphically illustrate an
insole 100 of an invention disposed within a shoe 200. The insole 100 is
placed within a shoe
200 such that the bottom surface of the insole rests against, for example, a
sole of the shoe 200.
The battery 14 of the insole 100 is positioned at the heel portion of the
insole such that the
battery 14 is accessible from the shoe opening 202. The battery 14 may be
conveniently inserted
into and removed from the shoe 200, while the insole 100 is disposed within
the shoe, by simply
reaching one's hand into the shoe opening 202 and grabbing the battery 14.
This allows one to
quickly replace a used battery for a charged battery, without having to remove
the insole or wait
for an internal battery of the insole to charge. In addition, the used battery
may be recharged
while the charged battery is being used. For example, the used battery may be
charged in the
charging magazine shown in FIG. 17.
As discussed above, insoles of the invention with removable batteries are
particularly
well-suited for use as heated insoles. FIG. 5 provides a partially transparent
view of a heated
insole 300 according to certain embodiments. The heated insole 300 (like
insole 100) includes
an insole body 28, a frame 12 disposed in the heel portion of the insole, and
a battery 14 placed
within the frame 12. The surfaces of the battery 14, frame 12, and insole body
28 may be
substantially flush with each other. The battery 14 may be removed directly
from the surface of
the insole body 28. In addition, the battery 14 may be removed from the insole
300 while the
insole 300 is disposed within a shoe. The heated insole 300 further includes a
heating assembly
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220, which is described in more detail hereinafter. The heating assembly 220
is coupled to the
battery 14 via the connector 46 (not shown in FIG. 5) of the frame 12.
Optionally, the heating
assembly 220 includes a circuit 210. The heating assembly 220 extends from the
heel portion to
the forefoot portion of the insole body 28. The heating assembly 220, when
powered by the
battery 14, provides heat to a wearer of shoe having the insole 300 disposed
therein. In addition,
the heating assembly 220 may be flexible such that it flexes in response to a
wearer's movement.
FIG. 6 illustrates an exploded view of the components of the heated insole
300. The
main components of the insole body 28 include a top layer 302, a heel cushion
306, and a bottom
layer 304. The top layer 302 and the heel cushion 306 include openings 308,
310 (respectively).
The openings 308, 310 are designed to receive the frame 12. The frame 12 is
designed to receive
the battery 14. The battery 14 includes a lower body portion 62 (e.g. a rigid
body that encases a
battery cell) and an upper body portion 64 (e.g. cushioned body).
The heated insole 300 further includes a heating assembly 220. As shown in
FIG. 6, the
heating assembly 220 includes the frame 12, a ribbon cable 312, and a heater
panel 314. As
discussed above, the insole layers (top layer 302 and heel cushion 306)
include openings 308,
310 (respectively) that are shaped to receive the frame 12. The frame 12
includes a connector 46
that electrically couples to a connector of the battery 14, when the battery
14 is placed within the
frame 12. The heater panel 314 may be any desirable shape. As shown, the
heater panel 314 is a
flat, substantially rectangular shape designed to fit within the forefoot
portion of the insole. The
ribbon cable 312 (or other conductive material) delivers electric current from
the battery 14,
when coupled to the connector 46, to the heater panel 314. Preferably and as
shown, the ribbon
cable 312 is coupled to a circuit 210. In a preferred embodiment, the ribbon
cable 312 has a first
end that is soldered or otherwise electrically connected to circuit board 210
and a second end that
is connected to the heater panel 314. The circuit 210 is configured to adjust
the level of energy
transferred from the battery 14 to the heater panel 314. For example, the
circuit 210 may be
programmed to provide certain heating levels, e.g., low, medium, and high. In
some
embodiments, the circuit 210 may be operably associated with a temperature
sensor, and the
circuit 210 delivers energy to maintain a certain threshold temperature level
(such as body
temperature) in response to readings transmitted from the temperature sensor.
In certain
embodiments, the circuit 210 may be controlled by a remote control (not
shown). In such an
embodiment, the circuit 210 includes a receiver that receives signal from a
remote, decodes the
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signal, and then the circuit 210 executes the operation based on the signal.
In embodiments that
include a battery indicator 27, the circuit 210 controls an LED of the battery
indicator. For
example, the circuit 210 may cause the LED to emit light as discussed in more
detail above. In
addition, the circuit 210 may cause the LED to emit light upon receipt of a
signal from the
remote control.
Remote control technology is generally known, and relies on sending a signal,
such as
light, Bluetooth (i.e. ultra-high frequency waves), and radiofrequency, to
operate a device or
circuit. Dominant remote control technologies rely on either infrared or
radiofrequency
transmissions. A radiofrequency remote transmits radio waves that correspond
to the binary
command for the button you're pushing. As applicable to the present insoles,
the command may
include high heat, low heat, medium heat, on, or off. A radio receiver on the
controlled device
(e.g. circuit 210 of heating assembly 220) receives the signal and decodes it.
The receiver then
transmits the decoded signal to the circuitry, and the circuitry executes the
command. The
above-described concepts for radiofrequency remote controls are applicable for
light and
Bluetooth remote controls.
According to certain aspects, all electrical and electronic components (i.e.
connector 46,
circuit 210, ribbon cable 312, and heater panel 314) are completely coated or
sealed with water
proofing sealants, coatings, and water tight encapsulating means coating to
enable the circuit to
function well when exposed to moisture and water.
According to certain embodiments, the heated insole 300 further includes
insulation and
water-proofing. For example, the ribbon cable 312 and heater panel 314 may be
sandwiched
between an insulation layer 316 below (also shown in Fig 7) and a water-
proofing layer 318
above (also shown in Fig. 8). Water proofing layer 318 may be made of any of
various woven or
non-woven materials, which allow heat to pass there through. Insulation layer
316 supports the
heater panel 314, ribbon cable 312 and the circuit board 210 ¨ all of which
are placed on the top
face of insulation layer 316. The insulation layer 316 has a contact region
320 which abuts the
frame 12. The ribbon cable 312, heater panel 314, insulation layer 316 and
water proofing layer
318 are aligned with the circuit board 210. The circuit board 210 is attached
to the frame 12 with
a rivet that connects the circuit board 210 to the battery frame 12. See, for
example, FIGS. 11-12.
The rivet allows variation in the angle between the frame 12 and ribbon cable
312/circuit board
210/heater panel 314.
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According to certain aspects, the design of the heating assembly 220 is
flexible in order
to allow the heating assembly 220 to withstand the stress and pressure
accompanied by
movement of a wearer. In some embodiments, the underlying insulation layer 316
includes an
opening 326 that allows the ribbon cable 312 to release an amount of
longitudinal stress by
protruding excess length thereof into the opening 326. For example and as
shown in FIG. 9A,
the opening 326 is a substantially rectangular slot or groove that is slightly
wider than ribbon
cable 312. When the insole 300 is in its flat state, the ribbon cable 312 is
laid flat in straight line
between the heater 314 and the circuit board 210 without any excess length in
the cable. When
the insole 300 bends, the ribbon cable 312 and insulation 316 also bend (as
shown in FIGS. 9B
and 9C). Due to the ribbon cable's 312 fixed length, it needs room to move
during bending or
else buckling occurs. The slot 326 receives the excess ribbon cable 312,
thereby eliminating
stress on the ribbon cable's 312 electrical connections due to the bending of
the insole 300. This
helps to protect the ribbon cable 312 and its electrical connections from
being torn or
compromised by bending and sheering stresses. In certain embodiments, the
heater panel 314 is
attached to insulation layer 316 in a manner that allows slight movement of
the heater panel 314
as the insole 300 bends. This relieves bending stress on the heater panel 314
caused by the
bending of the insole 300. For example, in one embodiment, the heater panel
314 is glued,
riveted or otherwise connected at one end thereof to the underlying insulation
layer 316. The
insulation layer 316 is preferably formed from a soft, pliable material, which
allows some "give"
when the heater panel 314 is pulled by ribbon cable 312 during bending.
Referring now to FIG. 7, the insulation portion 316 has a contact region 320
that abuts
the frame 12. The contact region 320 is designed to be used interchangeably in
right and left
shoes. To that end, and as best shown in FIG. 7, the terminal end 350 of
contact region 320
angles outwardly to create two different attachment ends. As shown, wall 350a
emanates from a
first corner 354a of the contact region 320 and angles outwardly. Wall 350b
similarly emanates
for a second corner 354b and angles outwardly. Walls 350a and 350b meet at
apex 352. This
geometry enables the insulation layer 316 and the heater 314 to be assembled
in a range of
angles so the same assembly would fit into left and right shoes with varying
sizes. This geometry
is described further in reference to FIG. 10.
FIG. 10 shows a bottom transparent view of an insole 300 according to an
embodiment of
the invention. As shown, an insole 300 is slightly angled from heel (proximal
end 26) to toe
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(distal end 24). In order to substantially center the heater panel 314 in the
forefoot portion 6 of
the insole 300, the heater panel 314 must be somewhat offset with respect to
the heel portion 2.
As illustrated by the dotted line 44 in FIG. 10, if the ribbon cable 312 and
heating element 314
would emanate from the frame 12 in a substantially linear manner ¨ the heating
element 314
would not be substantially centered in the forefoot portion 6, but rather it
would be skewed to
one side of the forefoot portion 6. However because, as shown, wall 350a abuts
the frame 12
and because wall 350a is angled, the trajectory of the ribbon cable 312 and
heating element 314
is slightly angled so as to position the heating element 314 in the general
center of forefoot
portion 6. As shown in FIG. 10, wall 350a is used as a contact surface in a
left shoe. Wall 350b
may be used as a contact surface of a right shoe. The angled terminal end 350
of the contact
region 320, thus, allows the ribbon cable 312 and heating panel 314 to be used
in any shoe.
The above-described features of the heating assembly 220 (e.g. flexibility and
angled
nature due to contact region) beneficially allow the heating assembly 220 to
be incorporated in
an insole or sole of a wide variety of shoes, including worker boots, tennis
shoes, hiking boots,
skiing shoes, snow shoes, etc. In addition, the above-described features allow
one to use the
same manufacturing process to produce heating assemblies for both right and
left insoles.
FIG. 11 illustrates a close up view of the frame 12 that may be used in
insoles of the
invention. The frame 12 includes connector 46 and defines a recess 40 that is
surrounding by
sides 42. The recess 40 of the frame 14 is sized and shaped to receive the
battery 14. The frame
further includes extension member 370. The extension member 370 includes a
rivet opening
462. A rivet associated with the circuit 210 (as shown in FIG. 6) may couple
to the frame 12 via
rivet opening 462. FIG. 12 illustrates a rivet 372 suitable for coupling the
circuit 210 to the
frame 12. Preferably, the rivet 372 is flexible such that it can deflect
without breaking. A
flexible rivet maintains the integrity of the connection between the frame 12
and the circuit board
210 despite bending of the insole 300. In certain embodiments, the rivet 372
is made from a
technical grade elastomeric material.
As discussed above, the connector 46 of the frame 12 may, according to certain
embodiments, pivot or rotate in order to connect to the battery as it is
placed directly into the
frame 12. This pivoting motion allows the battery 14 to snuggly fit within the
recess of the
frame 12. Without the pivoting motion, the frame 12 and its recess may have to
be larger than
the battery in order to accommodate the lateral motion required to connect the
battery 14 to the
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connector 26. FIG. 18 illustrates an enlarged view of the heel portion of an
insole with the
connector 46 positioned at an incline. The angle of the incline can vary
depending on
applications and the amount of pivot one desires. In certain embodiments, the
connector may be
configured to rotate, for example, 100, 200, 30 ,..., 800, 90
FIGS. 13A and 13B illustrate an exemplary design of the connector 46. The
connector
46 includes one or more hinges 510. The hinges mate with indents in the frame
12 (not shown).
The hinge 510 allows the connector 46 to pivot/rotate upwardly in order to
align with a battery
14 to be inserted. The connector may be formed from a polymer, plastic,
rubber, and/or
thermoplastic elastomeric material. The connector 46 is preferably constructed
out of elastomeric
material giving it the ability to absorb deflection and stress. The above-
mentioned features of the
connector 46 allow the connector 46 to maintain its mechanical integrity even
while deflecting
and being subjected to external stresses (e.g. pressure from a wearer's
movement).
According to certain embodiments and as shown in FIG. 13A, the connector 46
includes
one or more electrical contact housing members 512. Electrical contacts (best
shown in FIG. 16)
are housed inside of the housing members 512, and are accessible through
openings 502. The
electrical contact housing members 512 mate fit with a connector portion 66 of
the battery 14. In
particular embodiments, the connector portion 66 of the battery 14 defines a
recess 19 that
includes an internal separator 17. See, for example, FIG. 3C. When the battery
14 is coupled to
the connector 46, the internal separator 17 is positioned between the
electrical contact housing
members 512. Thus, the internal separator 17 acts to guide the housing members
512 into place
as the battery 14 coupled to the connector 46. Electrical contacts (as shown
in FIG. 16) within
the housing members 512 are then coupled to battery pins 21 that are
positioned in the battery
recess 19. When the contact points are coupled to the battery pins 21, energy
from the battery 14
can be transferred to the heater panel 314 via the connector 46.
As further shown in FIG. 13A, the outer walls of the connector 46, which face
the
battery, may have angled geometry 504 to help guide the electrical contact
housing members 512
into the battery recess 19. In certain embodiments, the connector 46 further
includes one or more
ridges 508 for water proofing. When the battery 14 is fully engaged with the
connector 46, the
ridges 508 prevent water from entering the battery recess 19 and disrupting
the electrical
connection.
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FIG. 13B illustrates a back side of the connector 46, which is in
communication with the
heating assembly 220. The back side of the connector 46 may include one or
more openings 520
or similar cutouts for allowing wires or similar conductors to pass out of the
connector 46.
Those conductors/wires are in electrical communication with the electrical
contacts 537 (as
shown in FIGS. 15 and 16) of the connector 46 and may be coupled to the
circuit 210, ribbon
cable 312, or both. The openings 520 are sealed with a water proof sealant to
protect the wires
from water or other elements. The back side of the connector 46 may also
include a lip 522,
which is used as a height gauge for the wires and sealant compound during the
assembly of the
connector 46. Lip 522 presents a physical barrier which limits the amount of
sealant compound
that may be introduced into the area there below. This prevents excessive
build-up of sealant
materials ¨ which may prevent or limit movement of the connector 46.
FIG. 14 shows a side, transparent view of a connector 46. As shown, a
structural recessed
round cavity 518 inside of the connector 46 is filled with the sealant and
keeps the sealant in
place to help maintain any sealant that is introduced through openings 520
from loosening and
compromising the water tight seal.
As discussed above, the insoles of the invention are designed to receive a
battery 14.
See, for example, FIGS. 3A-3C. In certain embodiments, the battery 14 may be a
battery pack.
A battery pack includes a body enclosing a battery cell. The body may be the
lower body
portion 62, as shown in FIGS. 3A-3C. FIG. 15 illustrates an exploded view of
the lower body
portion 62. As shown in FIG. 15, the lower body portion 62 of the battery pack
includes a boxed
portion 602. The boxed portion 602 defines a recess to receive the battery
cell 604 and includes
the connector portion 66 (which couples to the connector 46 of the frame 12).
A battery cell 604
may be placed in the recess. The boxed portion 602 may include a locking ridge
608 or tab on
the side opposite of the connector portion 66. Optionally, the locking ridge
608 meets with an
indent in the frame 12, when the battery 14 is placed in the frame, in order
to prevent undesirable
movement of the battery 14 while still allowing the battery 14 to be removed
from the frame
upon application of upward force (e.g., manual removal). The battery cell 604
is enclosed in the
boxed portion 602 via lid 606. The lid 606 may be permanently attached to the
battery box 602
or the lid 606 may be removable to allow one to swap the battery cell 604. The
lid 606 includes
a finger tab 67 that one can leverage with his/her finger to assist in
removing the battery 14 from
the frame 12. When the lid 606 is removable, the finger tab 67 may also be
used to remove the
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lid 606 from the boxed portion 602. When assembled, the pins 21 of the
connector portion 66 are
in electrical communication with the battery cell 604.
FIG. 16 provides a transparent view of the battery 14 coupled to the connector
46 of the
frame, according to certain embodiments. As shown in FIG. 16, the pins 21 of
the battery 14
enter the electrical contact housing members 512 of the connector 46, which
places the pins 21 in
electrical communication with the electrical contacts 537. Ideally and as
shown, the inners walls
of the recess 19 of the connector portion 66 include one or more slanted
segments 540. The
slanted segments press on the edges of the connector 46 when the battery is
inserted all the way
into the connector, this pressure forces the electrical contacts 537 to press
against the pins 21,
and maintain such contact.
FIG. 17 shows a battery magazine for charging and transporting batteries,
according to
certain embodiments. As shown in FIG. 17, the battery magazine is a frame 700
forming one or
more recesses 702, each configured to receive a battery. The frame 700 of the
magazine is
configured to hold one or more connectors 746 (which are ideally the same as
pivoting connector
46 of frame 12). The connectors 746 may be coupled to electrical cord that
allows the
connectors 746 to charge one or more batteries when the electrical wiring is
plugged into an
electrical outlet. In alternative embodiments, the battery magazine may
include a USB socket
that is coupled to the connectors 746. In such embodiments, a USB adaptor may
be used to
charge the batteries. The battery magazine may also include a circuit, such as
a printed circuit
board, disposed within the magazine and operably associated with the
connectors 746. A
function of the circuit includes monitoring charging of the battery to prevent
under- or over-
charging of the batteries. The circuit may be operably associated with one or
more LEDs. In
one embodiment, the battery magazine includes LEDs for each battery that the
magazine is
designed to receive. In this embodiment, the circuit can be configured to
cause each LED to
emit light in order to convey one or more functions with respect to one or
more batteries in the
magazine. The one or more functions may include, for example, showing the
following: battery
is connected, battery is charging, battery is malfunctioning, and battery is
fully charged. The
light emitted from the LED may be same or different for each function. For
example, the light
may be a different color for the one or more functions, or the light may be
emitted in the same or
different manner (single pulse, series of pulses, or constant light) for the
one or more functions.
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In addition to insoles with removable batteries, aspects of the invention also
involve
insoles with a removeable heating member or assembly. Such aspects are
described in more
detail hereinafter.
FIGS. 19A and 19B illustrate views of exemplary insoles 200 having a removable
heating
element. The insoles of FIGS. 19A and 19B have the same basic insole
construction (top surface,
bottom surface, heel portion, midfoot portion, forefoot portion, materials,
tab, etc.) as the insoles
of FIGS. 1A-1C.
The insoles 200 of FIGS. 19A and 19B include a removable heating element 802.
As
shown in FIGS. 19A and 19B, the removeable heating element 802 is a component
of a
removable heating assembly 804. The removeable heating assembly may include
the heating
element and optionally a control circuit and a battery. The components of the
removable heating
assembly are discussed in more detail hereinafter. The removable heating
assembly 804 may be
centralized across the insole (as shown in FIG. 19A) or may be abutted against
an edge of the
insole 200 (as shown in FIGS. 19B).
The body 808 of the insole 200 may include a recess or frame 810 configured to
receive
the removable heating assembly 804. The frames 810 for insoles of FIGS. 19A
and 19B are
shown in FIGS. 20A and 20B, respectively. Preferably, the heating assembly 804
and frame 810
have complementary designs to achieve a snug fit, which prevents unintended
movement or
removal of the heating assembly 804. The frame 810 may be positioned in the
heel section,
midfoot section, or span across both sections of the insoles. The frame may be
a cut-out portion
of the insole body 808 or may be a separate reinforced insert disposed within
the insole body
808. When the heating assembly 804 is inserted into the frame, a top surface
of the heating
assembly is substantially flush with the top surface of the insole body 808
and, in some
instances, a top surface of the frame 810. The flushness advantageously allows
a user to rest
his/her foot against the insole 200 without feeling differences between the
multiple components.
In this manner, the heating assembly and/or frame may be said to form a
portion of the top
surface of the insole. In addition, top surfaces of the heating assembly 804
and/or frame 810
may be cushioned in the same manner as the insole body 808 to further prevent
a wearer from
feeling or being disrupted by the multiple components. For example, each
component may be
formed from a polymer or polymer foam. A preferred polymer or polymer foam is
polyurethane.
Alternatively, the components may be formed from different materials.
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The frame 810 optionally includes a grasping region 812 that is shaped to
allow a user to
directly remove the assembly 804 from the frame 810. The grasping region may
be a cut-out to
receive one or more fingertips of a user for removal of the assembly 804.
Alternatively, the
assembly 804 may include a pull tab 814 that allows a user to directly remove
the assembly 804
from the frame 810. In either case, a user does not have to remove heating
member 802 or
heating assembly 804 from an enclosed compartment (i.e. with a lid), but can
access the heating
member 802 or heating assembly 804 directly from the external surface of the
insole body 808.
A benefit of insoles having removable heating assemblies is that the heating
assembly may be
directly removed from the insole while the insole remains within a shoe.
The heating assembly 804 includes a heating element 802. The heating member
802 is
designed transfer heat to a user. When the heating assembly 804 is disposed
within the insole
200, the heating assembly 804 delivers heat to a foot of the user. When the
heating assembly
804 is removed from the insole 200, the heating assembly 804 can be used a
personal heating
device. For example, the heating assembly 804 may be placed in a clothing
pocket for additional
warmth, or the heating assembly 804 may be held by the user for personal
heating (e.g. hand
warmer, neck warmer, etc.). As such, the removeable heating assemblies of the
invention
perform several functions, e.g., 1) heat warmers when used in conjunction with
an insole; 2)
personal heating device when removed from the insole.
The heating assembly 804, in addition to a heating member 802, may also
include a
control circuit, one or more batteries, or a combination thereof. FIG. 21 is a
schematic
illustration of a preferred heating assembly, which includes the following
interconnected
components: a battery, a control circuit, and a heating element. As shown in
FIGS. 22A-22B, the
heating assembly 804 may be formed from a lower body portion 820 and a top
body portion 822.
According to certain embodiments, the lower body portion 820 acts as a base
and is a container
that encloses the components of the heating assembly, such as the battery,
control circuit and
heating element. The top body portion 822 may be a cushion to provide comfort
to the user.
The top body portion 822 also forms the top surface of the assembly 804, which
is configured to
be flush with top surface of the insole 200. In certain embodiments, the lower
body portion 820
is of sufficient rigidity to protect the internal components from damaging
pressure, while
retaining sufficient flexibility to accommodate bending of the insole during
use. In other
embodiments, the lower body portion 820 may have variable flexibility/rigidity
across the length
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of the lower body portion 820. For example, it may be advantageous for the
part of the lower
body portion 820, which corresponds to the midfoot of the insole when the
assembly is placed
within the insole, to have greater flexibility because the midfoot experiences
more bending
during use. The lower body portion 820 may be formed from a polymeric material
and the top
body portion 822 may be formed from a polymeric foam 820.
FIGS. 22A and 22B depict side profiles of heating assemblies 804. The heating
assembly
804 of FIG. 22A has a lower body portion 820 formed from a single compartment,
which may
encompass the heating element, control circuit, and/or battery. The heating
assembly 804 of
FIG. 22B has a lower body portion 820 with two or more compartments (shown
with two
compartments), in which the heating element, control circuit, or battery may
be placed in the
same or separate compartments 830. FIGS. 23A and 23B illustrate various
combinations of the
components of the assembly placed in separate compartments 830. For multi-
compartment
lower body portions 820, the divider 832 between the compartments 830 may be
flexible or
hinged to allow slight bending of the lower body portion 820.
FIGS. 24-26 depict the various components of the heating assembly 804. FIG. 24
depicts
a heating element suitable for use in the heating assembly 804.
As shown in FIG. 24, the heating element 802 includes a panel 840 with a
plurality of
interconnected resistors 840. Energy is transferred from the battery to the
panel 804 with the
interconnected resistors 840, which then generates uniform heat. The panel 840
may formed
from a flexible (such as a copper film) or a rigid material.
FIG. 25 illustrates a control circuit 844 suitable for use in the heating
assembly 804. The
control circuit 844 (like circuit 210) configured to adjust the level of
energy transferred from the
battery to the heating element 802. For example, the circuit 844 may be
programmed to provide
certain heating levels, e.g., low, medium, and high. In some embodiments, the
circuit 844 may
be operably associated with a temperature sensor, and the circuit 844 delivers
energy to maintain
a certain threshold temperature level (such as body temperature) in response
to readings
transmitted from the temperature sensor. In certain embodiments, the circuit
844 may be
controlled by a remote control (not shown). In such an embodiment, the circuit
844 includes a
receiver that receives signal from a remote, decodes the signal, and then the
circuit 844 executes
the operation based on the signal. In certain embodiments, the heating
assembly 804 may
include an external battery indicator, which alerts the user to a charge
status of the battery. In
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such embodiments, the circuit 844 controls an LED of the battery indicator.
For example, the
circuit 844 may cause the LED to emit certain types of light as discussed in
more detail above.
In addition, the circuit 844 may cause the LED to emit light upon receipt of a
signal from the
remote control.
FIG. 26 illustrates a battery 846 suitable for use with the heating assembly
804. Any
suitable battery may be used for the battery 846. Types of batteries include,
for example, nickel
cadmium, nickel-metal hydride, lead acid, lithium ion, lithium ion polymer
batteries. The battery
846 chosen ideally holds charge for more than 2, 3, 4 or 5 hours, and is
rechargeable. The
battery 846 may be charged while disposed in the heating assembly 804 by a
plug-in charger.
Alternatively, the battery 846 may be removed from the heating assembly 804
and recharged
while removed or replaced by another fully-charged battery. As further shown
in FIG. 26, the
battery 846 may optionally be physically attached to the control circuit 844.
FIG. 27 illustrates an additional embodiment of the heated insoles with the
removable
heating assembly. As shown in FIG. 27, the insole body 808 may include one or
more heat
spreading or conductive elements 860. The conductive elements 860 facilitate
the transfer of
heat generated by the heating member 802 or assembly 804 to other portions of
the insole (such
as the toe portion of the insole body 808). Ideally, the conductive elements
860 are formed from
a material that transfers thermal or electrical energy. In some embodiments,
the conductive
elements 860 are formed from a flexible metal (e.g., copper, silver, graphite,
etc.). The
conductive elements 860 may be positioned within an insole layer or between
insole layers. The
conductive elements 860 may be placed in an array-configuration (as shown in
FIG. 27), but
other configurations may also be used.
In some embodiments, the conductive elements 860 may transfer heat indirectly
received
from the heating assembly 804 (e.g. due to close proximity to the thermal
energy outputted by
the heating assembly). In other embodiments, the conductive elements 860 may
electrically
connect to the heating assembly 804 to further facility heat transfer. FIGS.
28 and 29 illustrate
an electrical connection between the heating assembly 804 and conductive
elements 860. As
shown in FIG. 28, the conductive elements 860 terminate at a connective
contact 862A. The
connective contact 862A may be positioned within the frame 810 of the insole
body 808. The
connective contact 862A is configured to mate/connect with a connective
contact 862B of the
heating assembly 804 (See FIG. 29). The connective contact 862B is coupled to
the heating
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member 802 and/or battery 846 for transmission of energy when connected to the
connective
contact 862A. When the heating assembly 804 is inserted into the frame 810,
the heating
assembly 804 is electrically coupled to conductive elements 860 of the insole
body 808. The
electrical connection allows energy to be directly transferred from the
heating assembly 804 to
the conductive elements 860, thereby causing the conductive elements to
transmit heat.
Portions of the insole (such as the frame), assembly (such as the lower body
portion) and
the battery (such as the lower body portion) may be formed from any suitable
plastic, polymer,
or polymeric blend. Any components and portions thereof may be formed from a
flexible
material, rigid material, or a material of variable rigidity (e.g. transition
from rigid to flexible).
Suitable materials may include Polyethylene terephthalate (PET), Polyethylene
(PE), High-
density polyethylene (HDPE), Polyvinyl chloride (PVC), Polyvinylidene chloride
(PVDC) ,
Low-density polyethylene (LDPE), Polypropylene (PP), Polystyrene (PS), High
impact
polystyrene (HIPS), etc. The material of the frame and the battery may be the
same or different.
In addition, the material of the insole body and the layers of the insole may
depend on the need
of the insole (e.g. what activity will the insole be used for). These insole
materials may be
plastic, polymer, rubber, thermoplastic elastomeric material, leather, cotton,
and polymer foams.
Preferred polymer foams include polyurethane foams.
The invention may be embodied in other specific forms without departing from
the spirit
or essential characteristics thereof. The foregoing embodiments are therefore
to be considered in
all respects illustrative rather than limiting on the invention.
22
