Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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CUSTOMIZABLE ORTHOTIC WITH RESILIENT, DYNAMIC SUPPORT
AND
SIMPLIFIED ADJUSTABLE FOOT CUSHIONING AND SUPPORT SHOE INSERT
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Applications No.
60/135,300 filed 21 May 1999, and No. 60/159,842 filed 15 October 1999.
REFERENCE REGARDING FEDERAL SPONSORSHIP
Not Applicable
REFERENCE TO MICROFICHE APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to insoles for shoes and, in particular, to
customizable orthotics with resilient, dynamic support and simplified
adjustable
foot cushioning and support.
2. Description of Related Art and Other Considerations
Inasmuch as the present invention relates to concepts which are based
upon those described in related Keflerman patents 5,154,682, 5,799,414 and
6,000,147 and in Kellerman patent application Serial No. 09/118,401 and
which constitute improvements and other advances in the art over these
patents and patent application, the concepts described and illustrated therein
are incorporated in this application entirely as if set forth in haec verbs.
Orthotics or shoe inserts, also called insoles, make standing, walking,
running and sports activities more comfortable for individuals who suffer
discomfort resulting from various foot, joint, leg, hip, back and other
problems
and injuries. Some of these problems may be congenital, caused by overuse,
improper shoes, sports, workplace injury or other causes.
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Traditionally custom-made orthotics fitted by a foot care professional
have been used to care for these problems and have had some success in
correction but generally very limited success in alleviating discomfort. In
addition, these orthotics are very expensive and are not easily adjustable.
The
above-noted Kellerman U.S. Patents 5,154,682 and 5,799,414 describe
adjustable orthotic devices, generally comprising a foot-contacting layer,
with
various cushion pads adjustably adhering to the underside. Such devices
require the user to engage in "mirror thinking" in which the underside of the
insole, where the pads are to be adjusted, is the mirror image of the user's
foot.
Additionally, such prior art units may employ a hook-and-loop fastening
or attachment system, such as marketed under the trademark Velcro°
(trademark of Velcro USA Inc.> and described, for example, as prior art in
U.S.
Patent 5,953,797 and similar literature. Such a hook-and-loop fastening or
attachment system tends to be somewhat harder than the soft cushion pads
that are designed for comfort. Thus, when the user steps on the
foot-contacting surface, which deforms downwards around the pad profiles,
the edges of the pads, where the Velcro° hook member is present, may be
harder and the user may feel this as a hard protrusion and experience
discomfort on the underside of his/her feet. Furthermore, friction between the
rough foot-bed of the shoe and the loop member surface of both the insole and
pads tends to wear down the loop member surface over time. In addition, the
loop member surface tends to become soiled from the particulate dirt that
typically accumulates at the bottom of the wearer's shoes.
SUMMARY OF THE INVENTION
These and other problems are successfully addressed and overcome by
the present invention in which an orthotic of differing components is disposed
to be inserted into a shoe and onto its footbed. In general, the orthotic
comprises a top section, a pad section and, if desired, a bottom section. The
top section has a surface which is disposed to contact a user's foot. The pad
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section is disposed to rest directly on the footbed or through the
intermediary
of a bottom section on the footbed. The pad section includes at least one pad
positioned between the top section and bottom section or between the top
section and the flatbed of the shoe. A hook-and-loop fastening system includes
one or more hook members and loop members that releasably secure the pad
or pads to at least one of the top section, the bottom section and releasable
attachment material that is secured to the footbed. Hook members are formed
from a sufficiently thin sheet stock to provide molding capability and freedom
from the feel of hard edges; a thickness of less than 0.03 inched (0.08 cm)
has
been found to work well.
The top section is formed from a component whose material is of a
compressible resilient material, such as that marketed under the trademark
Poron° (trademark of the Rogers Corporation) and, if desired, a
conformable
non-compressible component of a material such as HDPE (high density
polyethylene). In the absence of the conformable non-compressible
component, the hook member or the loop member is directly adhered to the
compressible resilient material enabled, in particular, by the use of thin
hook-
and-loop fastening system members. In addition, in one embodiment, the hook
material serves the dual function both of being an element of the hook-and-
loop
fastening system and of acting as the conformable, non-compressible
component.
For enhanced mobility, cushioning and impact absorption, a layer of a
resin foam material, such as marketed under the mark Evazote°
(trademark of
BXL Plastics, Ltd.) may be added as a further component to the
Poron°
component. The Evazote° material causes enhanced cushioning and
molding.
Other cushioning materials may be used for other purposes to alter the energy
absorption or returning characteristics of the insole. The conformable, non-
compressible materials help the wearer experience more continuous contouring
sensations, as opposed to experiencing the sensation of individual underlying
cushioning elements, i.e., to avoid any uncomfortably uneven feeling. These
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additional resin foam materials can also add a firmer supporting and molding
capability.
The pads of the pad section are configured variously in combinations
of cushioning material and hook and loop members in both two-section and
three-section orthotic assemblies. Such combinations include a loop member
cushioning material combination, a hook member-cushioning material
combination, a loop member-cushioning material-loop member combination, a
loop member-cushioning material-hook member combination and a hook
member-cushioning material-hook member combination. The reason for the
extra hook and loop members to enable additional cushions to be added to the
assembly, such as to raise the heel or arch portions for obtaining resilience,
molding contour and various heights.
The bottom section is configured to provide a plurality of different
functions. The hook member alone can function as a conformable non
compressible component for fastening to the top section to protect the
orthotic
assembly for dirt and wear. A separate conformable non compressible
component is fastened to the top section by either hook or loop members. To
provide a stiffening capability to the assembly, a hook member alone, or a
vinyl
component with a hook or a loop member, are used. Such a stiffening
capability prevents the assembly from bunching up and facilitates the
insertion
of the assembly into a shoe. A gripping material, such as latex and neoprene
alone, can be adhered to the orthotic assembly solely for gripping purposes.
When additional cushioning is desired, such compressible resilient material as
Poron° and latex and neoprene gripping material can be added to any
of the
stiffening elements.
The conformable non-compressible component may be provided with
perforations, slits or round or rectangular cutouts that provide aeration,
wicking
for passage of perspiration, and comfort.
The shoe footbed may be recessed to form a cavity into which the
orthotic is placed, to provide the shoe with a slim-line fashionable
appearance.
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Several advantages are derived from this arrangement. Standing,
walking, running and sports activities are made more comfortable for
individuals
who suffer discomfort from various foot, joint, leg, hip, back and other
problems and injuries. The orthotics are easily adjustable. Their cost is
lower
5 as compared to custom-made orthotics. Pad inserts are quickly and easily
positioned and removed by use of a hook-and-loop fastening system. Frictional
and soiling problems are significantly reduced.
Other aims and advantages, as well as a more complete understanding
of the present invention, will appear from the following explanation of
exemplary embodiments and the accompanying drawings thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an embodiment in generalized form illustrating an
adjustable foot comfort system in top planar view in which any of the
inventive
embodiments may be housed, including an top section in FIG. 1 (a) and middle
and bottom sections in FIG. 1 (b1. The middle section includes cushion pads of
various shapes, sizes, thicknesses and physical characteristics which are
attached, for example and in accordance with one attachment system, by a
hook-and-loop fastening system to the bottom section. Other attachments
systems are further described and depicted herein.
FIG. 2 is an exploded view in cross-section of a portion of a first more
specifically depicted embodiment of the present invention comprising a three-
section insole or orthotic.
FIG. 3 shows a variation of a portion of the bottom section employable
in the first embodiment depicted in FIG. 2.
FIG. 4 is an exploded view in cross-section of a portion of a second
embodiment of the present invention comprising a three-section insole or
orthotic similar to that shown in FIG. 3.
FIG. 5 is an exploded view in cross-section of a portion of a third
embodiment of the present invention comprising a two-section insole or
orthotic.
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FIG. 6 is a cross-sectional view of a portion of a fourth embodiment of
the top section of the present invention in which the hook member or portion
of the hook-and-loop fastening system is secured directly to the foot-
contacting
layer, rather than through the intermediary of a supporting material such as
comprising high density polyethylene (HDPE). This is enabled by using a very
thin hook member.
FIG. 7 is a cross-sectional view of a variation of a portion of the fourth
embodiment of the top section of the present invention depicted in FIG. 6 in
which the loop member or portion of the hook-and-loop fastening system is
likewise secured directly to the foot-contacting layer, rather than through
the
intermediary of a supporting material such as comprising high density
polyethylene (HDPE). This is enabled by using a very thin loop member.
FIG. 8 shows the use of a portion of a finishing surface, such as of
leather or athletic top cover material, secured to the top section for
purposes
of presenting the orthotic in a fashionable manner.
FIGS. 9-12 respectively illustrate a cross-sectional view of a portion of
an top section of a fifth embodiment of the present invention, a perforated
component part thereof in plan, and detail views of portions of differently
configured perforations in one (e.g., the conformable non-compressible
component) of the components of the top section.
FIGS. 13-15 depict top planar views of three variations actualized as
slit areas and differently configured cut outs in one (e.g., the Conformable
non-
compressible component) of the components of the top section.
FIGS. 16-19 illustrate another aspect of the present invention in which
a cavity is formed in the shoe itself for reception of an orthotic for
purposes,
for example, of fashionably reducing the shoe size.
FIG. 20 shows a further embodiment wherein an top or bottom section
may be reduced in length to constitute only the heel and arch sections for
use,
for example, where height in the front of the shoe is limited.
FIG. 21 illustrates another embodiment including the use of cushioning
pads secured by a hook-and-loop fastening system directly onto the footbed of
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a shoe, also for such purposes as to enable the shoe size to be reduced for
reasons of fashion and to prevent inside slipping against the footbed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Because the preferred fastening or attachment system employed in the
present invention is a hook-and-Loop system, as a preliminary matter, it will
be
useful to describe this hook-and-loop system at this point of exposition.
Reference is made, for example, to U.S. Patent 5,953,797 and related
literature, not only to the specific product as marketed by the proprietor
thereof, but also to all relevant literature relating to such hook-and-loop
technology. It is to understood that, although specific reference is made to
this
patent, other systems similar thereto and to competing systems are equally
employable in the present invention and, therefore, no conclusion should be
inferred that a particular manufacturer's system is critical to the use and
working of the present invention.
In general, hook-and-loop fasteners comprise two mating components:
a hook member that has upstanding, hook-type fastener elements, and a loop
member that has a surface that provides fibers or fiber loops with which the
hook member elements become engaged.
As used herein, a "hook member" means a member having fastener
elements whose hooks extend substantially in a given plane. When of molded
form, the stems of these elements are significantly broader in the direction
of
their plane of extent than in the thickness direction at a right angle
thereto.
Also, while hook fasteners have performed successfully, other types of
fasteners, e.g., those having mushroom-like form, may be employed should
their configurations provide equivalent success in the present invention. For
purposes of the present invention, however, reference to the term "hook
member" will be used as a matter of convenience; but its use is not to be
construed in any limiting manner. Thus, the term "hook member" is intended
to include equivalent elements in all fastening systems, including those
having
a mushroom-like form.
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Loop members for hook-and-loop fastening have been formed from
knitted, woven and non-woven textiles. A common example of a non-woven
textile is known by the term "spun bonded," which is made by spinning fine
filaments of plastic resin, e.g., nylon and polypropylene, and distributing
them
in superposed layers. The fibers are bonded to each other in random
orientation, with a fine, low-lying, nappy component of looped and arched
fibers exposed at the surface of the fabric. The use of the term "loop member"
herein is intended to incorporate the forgoing description and those elements
which cooperate to form a fastening system with the "hook member."
In the following discussion, it is to be understood that the hook and
loop members may be exchanged, one for the other, as desired.
Accordingly, with reference to FIG. 1, an adjustable foot comfort
system 30 includes an top section 32, a middle section 34 and a bottom
section 36 to form an assembly thereof. Any of the inventive embodiments
disclosed hereafter may be housed within system 30. Middle section 34
includes cushion pads 38 of various shapes, sizes, thicknesses and physical
characteristics which are attached, for example, by a hook-and-loop fastening
system to bottom section 36. This and other examples of attachments systems
are further described, referenced by indicia and depicted in greater detail in
the
ensuing description of the several inventive embodiments.
Reference is now made to the assembly shown in FIG. 2. A three-
section insole or orthotic 40 includes a foot-contacting top section 42, a
middle
section 44 and a bottom section 46. Middle section 44 is composed of one or
more cushioning pads 48. Although two pads are depicted, as many pads as
are needed are used. Cushion pads 48 are defined by various shapes, sizes,
thicknesses and physical characteristics which, in this embodiment, are
attached by hook and loop members 50 and 52 to bottom section 46. As
illustrated, bottom section 46 has a top component which comprise a loop
member but a hook member can also be used and, if so, a loop member would
be secured to pads 48. A component 54 of vinyl or any other suitable sheet
material is bonded to the underside of this loop member for support thereof.
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Top section 42 includes a foot-contacting component or portion 56 of
a compressible resilient material, such as a material marketed under the
trademark Poron° (trademark of the Rogers Corporationl. A conformable
non-
compressible component 58 of a material such as HDPE (high density
polyethylene) is bonded by a laminating adhesive 60. it is preferred that
Poron° component 56 also be sewed around the perimeter of top
section 42
approximately 0.25 inches (0.64 cm) from the edge to ensure a durable
attachment.
As stated above, middle section 44 of the present invention comprises
one or more cushion pads 48 generally spaced apart with hook members 50.
The pads are made from a compressible soft material, generally formed from
the same type Poron° material used in top foot-contacting component 56
of top
section 42. Hook members, preferably formed as strips, are secured to the
undersides of the pads. Preferably, loop members 50 and Poron°
components
48 of this section are bonded together with a laminating adhesive. In
addition,
it is preferred that two to four lines of stitches be sewn across the width of
the
pads across the areas where the hook members of the hook-and-loop system
is attached to ensure a durable attachment. Hook and loop members may be
added to both sides of the pads to allow stacking of two or more pads
together.
Pads 48 may be produced from any number of compressible, generally
soft, resilient materials. However, Poron° has been found to work well
in the
preferred embodiment. The pads generally are die cut from flat sheet material
or can be molded or extruded from suitable materials to provide angular slopes
and shapes to enhance foot-weight shaping of the top section as described, for
example, in above-referenced patent 5,799,414.
Bottom section component 54 of vinyl or other material component can
have a textured or coated surface on its underside to provide a frictional
engagement to prevent bunching up, slippage and the like, as well as to be
durable and protective of the more fragile component of loop member 52
bonded to it and, therefore, to mitigate any wear resulting from the often
rough
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surface of the shoe foot bed upon which it rests. This bottom component of
the bottom section may be glued, sewn, or otherwise attached to the footbed
of the shoe.
As shown in FIG. 3, bottom section 44 can optionally have a
5 component of compressible material 62, such as Poron° or other
compressible
material, laminated and bonded or otherwise adhered between the underside
of loop member 52 and the top surface of bottom section component 46. The
placement of this extra cushioning in the bottom section enables this
embodiment or assembly to be well-suited for thicker cushioning, greater
10 impact absorption and/or greater support for uses involving high impact
activities, such as differing sports, hard surfaces, long use, and particular
foot
conditions. In addition, it is preferable to sew the bottom section around its
perimeter approximately 0.25 inches (0.64 cm) from the edge in order to
ensure a durable attachment.
An optional grip-like material, such as a neoprene or latex, may be
bonded to the underside of the bottom section to counteract the shear force
of the motion of the foot which would otherwise cause the insole assembly to
slide away from the footbed of the shoe as the user exerts step force on the
insole.
Reference is now made to FIG 3(a) which differs from the embodiment
of FIG. 3 solely in that no under supporting vinyl component is used. Here, a
bottom section 46a consists of a component 62' of different elements, such
as comprising a hook member alone, gripping material such as neoprene and
latex, and a compressible material such as Poron° and/or
Evazote°. As stated
above, these elements comprising bottom section 46a a plurality of different
functions. The hook member alone functions as a conformable non-
compressible component for fastening to the top section to protect the
orthotic
assembly for dirt and wear, as well as a conformable non-compressible
component. As a conformable non-compressible component, the hook member
provides a stiffening capability to prevent the assembly from bunching up and
to facilitate the insertion of the assembly into a shoe. The gripping
material,
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e.g., of latex and neoprene, can be adhered to the orthotic assembly solely
for
gripping purposes or as a conformable non-compressible component. When
additional cushioning is desired, such compressible resilient material as
Poron°
and latex and neoprene gripping material can be added to any of the stiffening
elements. The placement of the cushioning in the bottom section enables this
embodiment or assembly to be well-suited for thicker cushioning, greater
impact absorption and/or greater support for uses involving high impact
activities, such as differing sports, hard surfaces, long use, and particular
foot
conditions.
The embodiment depicted in FIG. 4 provides a response to a matter
deriving from the arrangement of the attachment means illustrated in FIG. 2,
viz., bottom section 44 of FIG. 2 has unused loop member areas, e.g., those
designated by indicium 64, not covered by the cushioning pads. The unused
bottom section areas, which are not covered by cushion pads, such as in the
toe or forefoot areas and adjoining the medial arch pad areas can be employed
to attach the bottom section to the upper section. In the FIG. 4 embodiment,
the hook and loop members are reordered amongst the three sections
designated as top section 42a, middle section 44a and bottom section 46a.
The top section includes Poron~ and conformable non-compressible
components 56a and 58a secured together by an adhesive 60a. In this
embodiment, however, a loop member 66 is secured to the underside of the
conformable non-compressible components and a hook member 68 is secured
to bottom layer 46a. Although both loop and hook members 66 and 68 are
each shown as a single piece, either can be formed as a plurality of discrete
segments. This results in an attachment of the top section to the bottom
section and, thus, to effect a sandwich assembly including the middle pad
section.
In operation, the foot care professional or end user first inserts insole
or orthotic 40 into the user's shoes and then removes and scissor-cuts the
edges of the insole, if necessary, to fit it properly in the shoe.
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Next the user or foot care professional selects pads 48 from among
various standard pre-cut pad or, if that shape and/or size is not available,
to cut
a non-standard pad from pad sheet stock and places the pads on the top side
of bottom section 46 to create the desired support areas, e.g., for the arch
or
other foot areas needing support, and/or valleys defined by areas that are
partially or completely surrounded by elevated areas. Pressure relief of
sensitive areas can be achieved by attaching cushioning material adjacent or
surrounding the sensitive area to transfer pressure away from the sensitive
area. In such a manner, parts of the foot which need support, or are sensitive
or painful due to injury, overuse, anatomical problems, disease or other
causes,
are shielded from the full impact of the user's weight against the shoe and
the
step shock of the surface below.
The user then inserts the insole with Poron° component 56 of top
section 42 side up and steps into the shoe. The user's weight causes the top
section to mold around the pads to provide the optimal orthotic shape for the
user's foot. In one embodiment, the top section utilizes a component of a
conformable, non-compressible material, such as HDPE, which conforms to the
underlying shapes of the pads below, flexibly supports and conforms to the
unique contours of the foot.
As the foot moves and with the pressure of each step, each of these
layers modulates and undulates differently due to differing density,
thickness,
softness, compression and resiliency characteristics. This special combination
of material properties creates simultaneous and continuous actions of molding,
massaging, cushioning and support, with the ameliorative effect of exercising
the foot, and providing pressure relief and flexible dynamic support.
When the pads are moved, the top section will be re-molded to the
existing underlying shapes of the pads below. The pads may also be optionally
stacked one on top of the other or staggered (see FIG. 9 of U.S. Patent
5,799,414), to vary the amount of lift and pressure relief and to
topographically
adapt the assembly to the contours of the foot, thereby enabling the
individual
needs of the wearer for his/her best comfort. These end results are achieved
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by attaching the hook member surface at the bottom of one pad to the loop
member at the top of another pad below it to achieve a desired topography of
the conforming sections above. For stacking purposes, small hook member
circles or strips thereof can be used as attachments to stacked or nested
pads,
and may take the form of double-sided hooks or loops, respectively to fasten
facing loop member-loop member and hook member-hook member
arrangements. Similar double-sided fastening members are. positionable
between facing like fastening members on the top and bottom sections. They
can be attached within the loop member areas which will then form an
attachment to the loop member of the top section.
As disclosed in FIG. 5, a two-section orthotic 70 comprises a top or
first section 72 and a second pad section 74. Top section 72 includes a
Poron~ component 76 and an Conformable non-compressible component 78
bonded thereto by an adhesive 80. A hook member 82 is attached to the
bottom side of Conformable non-compressible component 78 by bonding,
sewing, glueing, etc. Second section 74 includes one or more .pads 84 with
a loop member 86 positioned on top of the pads, to enable the pads to be
affixed to the hook member on the underside of top section 76. If desired, the
two-section orthotic assembly may be converted into a three-section assembly
by adding a bottom section comprising a component of vinyl or similar material
to top section 70 by an appropriate hook-and-loop system to enclose pads 74
and thus to reduce friction and wear, and to inhibit dirt from entering the
shoe
foot bed.
Further embodiments of the present invention are shown in FIGS. 6 and
7, and rnay be used with either of the above described three-section orthotic
or two-section orthotic designs. These assemblies relate to alternative top
section configurations, viz., an top section 88 (FIG. 6) and an top section 88
(FIG. 7). Both include top components 92 and 94 of Poronp or like material
with good resiliency and shock absorbing properties, which are respectively
attached to bottom components respectively configured as a hook member 96
and a loop member 98 by bonding, sewing, gluing, etc., without inclusion of
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an intervening component of non-compressible (HDPE) material between them
and their respective Poron~ components 92 and 94. In this variation, loop
materials having a thickness of less than 0.03 inches (0.08 cm) are used any
molding that occurs is instantaneous without residual memory. Nevertheless,
the benefits described above of cushioning and massaging remain, due to the
conformation of the top cushioning section to the variable hills and valleys
created by the underlying cushioned pads with its attendant ability to vary
shape, resiliency, cushioning and size of these created hills and valleys.
This
design is useful for one whose primary foot treatment needs are for the unique
combination afforded by the present invention of cushioning, massaging,
exercising, pressure relief and soft support capabilities where firmer support
is
not necessarily needed.
In particular, it has been found that, when various shaped pads having
a hook or loop members on their top surfaces which are then attached to the
bottom surface of the insole, a greatly improved feel of comfort is achieved.
The general thickness of the hook member of about 0.024 inches (0.06 cm) is
available in other thickness ranges and formed from polyethylene, nylon and
other materials.
The embodiments illustrated in FIGS. 6 and 7 provide thinner orthotic
assemblies for use in low profile footwear. Where fashion or other
requirements so dictate, these thinner innersoles, which include an top
section
100 having a Poron~ component 102 of previously described construction, can
further utilize a leather or other decorative component overlayed onto and
suitable laminated or otherwise adhered to component 104. The lamination of
leather and like, to cover the Poron~ component of the top section, is
employed
for various reasons, such as to create a certain aesthetic appearance or to
add
a non-slip capability to the insole. For aesthetic purposes, a leather or
leather-
like component may be used in a dress shoe model. To prevent foot slippage,
an athletic-type top cover may be added to the top layer for an athletic model
to be used for such athletic activities as running and jumping or for wicking
away and absorbing perspiration.
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Still another embodiment 116 of the present invention is disclosed in
FIGS. 9-12. Assembly 116 includes a component 108, for example of
Poron°,
to which a perforated Conformable non-compressible component 1 10 is bonded
by an adhesive 112. Component 110 includes a plurality of perforations or
5 openings 114 of different sizes. Such differently sized openings are
illustrated
in FIGS. 11 and 12 as openings 114a and 114b disposed in their respective
components 110a and 110b. In prior art products employing perforated, such
perforation has extended entirely to the foot-contacting top surface,
rendering
the device somewhat uncomfortable for individuals with sensitive feet. In the
10 present invention, however, the perforation is located only in the hook
member
and conformable non-compressible component. The foot thus contacts only
the smooth Poron° component, consequently avoiding such discomfort.
By adjusting the number of holes, the size of the holes, and the spacing
therebetween, the support, in terms of rigidity, flexibility and
compressibility,
15 can be adjusted to meet particular needs. This additional means of
adjustability
is effected, not by the ultimate user, but by the insole fabricator who can,
by
the perforation means, provide a range of insole models with grades of light
to
heavier duty use and variations of foot sense of "just right comfort" with a
certain style.
Additionally, by restricting the perforation to the Conformable non-
compressible component, aeration is enabled due in part to the open cell
structure of the Poron° material without the discomfort often caused by
prior
art units whose perforations extend to the foot-contacting surface. The
perforations also assist in the wicking away of foot perspiration achieved in
the
open cell construction of the Poron°, migrating downwards through the
perforations. Thus, the bottom side of the Poron° component will be
essentially drier than the foot-contacting top side thereof.
The variations in component thickness vis-a-vis opening size, as shown
in FIGS. 11 and 12, also provide different patterns of perspiration. For
walking
and standing activity, the Conformable non-compressible component in
thickness will range from about 0.01 inches to 0.14 inches (0.03 - 0.36 cm)
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and in open area from about 10% to 30%. For active sports, the Conformable
non-compressible component in thickness will range from about 0.015 inches
to 0.03 inches 10.04 - 0.08 cm) with a perforation range of about 25% to
50%. Representative hole sizes range from about '/a to %< inch (0.33 - 0.64
cm).
The Conformable non-compressible components in the top sections can
also be adapted in other manner, as depicted in FIGS. 13-1 5, for use in other
orthotic assemblies. FIG. 13 shows a component 1 16 with slits or slit areas
118 for increased softness and give. FIG. 14 shows a component 120 with
circular or otherwise rounded cutouts 122. FIG. 15 shows a component 124
with rectangular cutouts 126. The round or rectangular cutouts including slits
can be used for all embodiments and serve to provide variations in Conformable
non-compressible component flexibility and resultant molding to the plantar
aspect of the feet.
Special styles, which can be machine or hand laminated, can combine
the Conformable non-compressible components disclosed in FIGS. 13-15 with
ether components. e.g., those of Poron~, and with hook and loop members.
For example, the loop members can utilize selective area cutouts to provide a
softer or firmer resilience, support, shock protection or other
characteristics.
This will enable the areas beneath the heel and metatarsal bones of the feet
to
benefit from elliptical and other special cut out or slit shapes.
The art of pairing perforations and slits of varying shapes and degree,
combined with the ratio of open to closed Conformable non-compressible areas
and to the thickness range of the Conformable non-compressible material used,
provides a plethora of styles for all footwear needs.
The manufacturer using the present invention can provide styles to suit
lighter and heavier weight individuals, younger, more active and elderly
individuals. People requiring special support after trauma, surgery, or
diabetic
care can have standard or custom styles. Also, all the above styles are
further
enhanced by the adjustability feature of the hook and loop member feature of
attachment of resilient pads to the insole.
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A further, differently constructed assembled embodiment of the present
invention is disclosed in FIGS. 16-19, comprising a specially constructed shoe
130. FIG. 16 depicts a shoe 130 which is provided with a space or cavity 132
in its footbed 134 for an orthotic 136, either by creating an indentation in
the
footbed into which the orthotic fits, or by surrounding the orthotic with a
berm
or lip. The berm or lip holds the orthotic and foot in place for sideways
support. Additionally, it enables the orthotic to be better adapted for use in
dress or other shoes which, for reasons of style, do not or may not have a
particularly high toe box. This embodiment is adaptable also for use with any
other type of shoe or foot covering, such as sandals, slippers and boots. A
shoe thus constructed effects a slim-line appearance.
In FIGS. 17 and 18, the cutaway shoe is viewed looking through its toe
box in which insole 136 is not flat, as evidenced by protuberance 138. Due
to the molding of the lamination with the cushion pads beneath the top
Poron°
and Conformable non-compressible components and the loop/hook member, the
foot plantar irregular aspect shapes around pad shapes. Here, the orthotic is
shaped by the weight of the foot. The FIG. 19 embodiment depicts a shoe
130a, similar to that shown in FIG. 16, but without orthotic 138, to provide
more toe box height.
The assembly of FIG. 20 illustrates an orthotic 140 which shows a
further embodiment wherein an top and/or bottom section may be reduced in
length to constitute only the heel and arch sections for use, for example, in
small shoe interiors where height in the front of the shoe is limited.
FIG. 21 illustrates another embodiment where pads are secured to the
shoe through an intermediary structure, e.g., a hook member or a loop member.
A shoe 142, represented by its footbed 144, has cushioning pads 146 secured
by a hook-and-loop fastening system directly to a top section 150, in any
convenient manner, such as previously described. This embodiment may be
used for such purposes as to enable the shoe size to be reduced for reasons
of fashion or to prevent slippage of the foot on the footbed. Pads 146 may be
fashioned in any manner so as to provide the necessary support for the foot.
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Although the invention has been described with respect to particular
embodiments thereof, it should be realized that various changes and
modifications may be made therein without departing from the spirit and scope
of the invention.
