ORTHOPEDIC INSOLES FOR USE IN OPEN FOOTWEAR

Abstract

A multi-layered orthopedic insole has at least four layers. The first layer is leather, the second layer is molded high-density recycled latex foam, the third layer is a molded, rigid density cork-EVA (Ethylene-Vinyl Acetate) footbed, and the fourth or bottom layer is moleskin or moleskin coated to provide a natural grip for gripping a shoe insole. The different layers are fused to form the orthopedic insole of the present invention. The third layer of the multi-layered insole is generally thicker than the other layers and includes sidewalls covered in a leather wrap. The multi-layered orthopedic insole is specifically designed to provide comfort and support to a user's foot using the specified materials, shapes, and contours.

Claims

1. A multilayered shoe insole, comprising: a top layer comprising leather; a first intermediate layer comprising molded high-density recycled latex foam; a second intermediate layer comprising a molded, rigid density cork-EVA (Ethylene-Vinyl Acetate) footbed; and a bottom layer coated in moleskin to provide a natural grip on a shoe insole; wherein, the layers are fused together to form the orthopedic shoe insole.

2. The multilayered shoe insole as recited in claim 1, wherein the second intermediate layer includes sidewalls covered in a leather wrap.

3. The multilayered shoe insole of claim 2, wherein the leather wrap is a tanned leather.

4. The multilayered shoe insole of claim 1, wherein the top layer leather is a tanned, chrome-free, goat, or calf leather.

5. The multilayered shoe insole of claim 1, further comprising: a heel cup configured to cradle a heel of a user's foot.

6. The multilayered shoe insole of claim 5, further comprising: a heel pad disposed centrally in the heel cup.

7. The multilayered shoe insole of claim 6, further comprising: a lateral side and a medial side, wherein the lateral and medial sides rise bilaterally from a midsection of the multilayered shoe insole thereby defining a cupped region for a user's foot.

8. The multilayered orthopedic shoe insole of claim 7, further comprising: a raised ball pad support disposed at a front portion of the multilayered shoe insole.

9. The multilayered orthopedic shoe insole of claim 8, wherein the raised ball pad is reniform in shape.

10. The multilayered orthopedic insole of claim 1, wherein the cork-EVA mold of the second intermediate layer tapers to about 2 mm in thickness at a front edge of the insole.

11. The multilayered orthopedic insole of claim 1, wherein the cork-EVA mold of the second intermediate layer tapers to about 2 mm in thickness at a front edge of the insole.

12. The multilayered orthopedic insole of claim 1, wherein the bottom of the insole has a slightly curved surface through the arch area.

13. The multilayered orthopedic insole of claim 1, further comprising beveled sidewalls extending from the bottom of the insole at an angle of 30-40 degrees.

14. A method of manufacturing a multilayered orthopedic insole, the method comprising: fusing together a top layer, a bottom layer, a first intermediate layer, and a second intermediate layer, wherein the top layer comprises leather; the first intermediate layer comprises molded high-density recycled latex foam; the second intermediate layer comprises a molded, rigid density cork-EVA (Ethylene-Vinyl Acetate) footbed; and coating the bottom layer with moleskin to provide a natural grip on a shoe insole; wherein, the layers are fused together to form the orthopedic insole.

15. The method of claim 14, further comprising: molding a heel cup into a heel portion of the orthopedic insole.

16. The method of claim 15, further comprising: molding a heel pad disposed centrally in the heel cup.

17. The method of claim 16, further comprising: molding a raised ball pad support into a front portion of the multilayered orthopedic insole.

18. The method of claim 17, wherein the raised ball pad support is reniform.

19. The method of claim 18, wherein lateral and medial sides of the multilayered orthopedic insole rise bilaterally from a midsection of the multilayered orthopedic insole thereby defining a cupped region for a user's foot.

20. The method of claim 14, wherein the second intermediate layer includes sidewalls.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0024] FIG. 1 shows a perspective view of an orthopedic shoe insole, according to an embodiment of the present invention.

[0025] FIG. 2 shows a top view of an orthopedic shoe insole, according to an embodiment of the present invention.

[0026] FIG. 3 shows a bottom view of an orthopedic shoe insole, according to an embodiment of the present invention.

[0027] FIG. 4 shows a left-side view of an orthopedic shoe insole, according to an embodiment of the present invention.

[0028] FIG. 5 shows a right-side view of an orthopedic shoe insole, according to an embodiment of the present invention.

[0029] FIG. 6 shows a front view of an orthopedic shoe insole, according to an embodiment of the present invention.

[0030] FIG. 7 shows a rear view of an orthopedic shoe insole, according to an embodiment of the present invention.

[0031] FIG. 8 shows an exploded view of an orthopedic shoe insole, according to an embodiment of the present invention.

[0032] FIGS. 9-10 show material visualizations of an orthopedic shoe insole, according to embodiments of the present invention.

[0033] FIG. 11 shows an exploded view of an orthopedic shoe insole, according to another embodiment of the present invention.

[0034] FIG. 12A shows a perspective view of the orthopedic shoe insole of FIG. 11, according to an embodiment of the present invention.

[0035] FIG. 12B shows a perspective rear view of the orthopedic shoe insole of FIG. 12A, according to an embodiment of the present invention.

[0036] FIG. 12C shows a perspective front view of the orthopedic shoe insole of FIG. 12A, according to an embodiment of the present invention.

[0037] FIG. 13A shows a top plan view of the orthopedic shoe insole of FIG. 12A, according to an embodiment of the present invention.

[0038] FIG. 13B shows a lateral side view of the orthopedic shoe insole of FIG. 12A, according to an embodiment of the present invention.

[0039] FIG. 13C shows a bottom plan view of the orthopedic shoe insole of FIG. 12A, according to an embodiment of the present invention.

[0040] FIG. 13D shows a medial side view of the orthopedic shoe insole of FIG. 12A, according to an embodiment of the present invention.

[0041] FIG. 13E shows a rear elevation view of the orthopedic shoe insole of FIG. 12A, according to an embodiment of the present invention.

[0042] FIG. 13F shows a front elevation view of the orthopedic shoe insole of FIG. 12A, according to an embodiment of the present invention.

[0043] FIG. 14 shows an enlarged view of some of the layers of FIG. 11, according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0044] The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals.

[0045] Reference will now be made in detail to each embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto.

[0046] For purposes of this continuation-in-part (CIP) application, the embodiment(s) reflected in FIGS. 11-14 is the preferred embodiment. Nevertheless, FIGS. 1-10 are still presented herein since the concept(s) embodied in FIGS. 1-10 represent the original or earlier concept upon which this application claims priority. The embodiment(s) reflected in FIGS. 11-14 represent an evolution or update of the original concept and thus should be considered the main or preferred embodiment(s).

[0047] Referring now to FIGS. 1-8, a perspective view (FIG. 1), top view (FIG. 2), bottom view (FIG. 3), left side view (FIG. 4), right side view (FIG. 5), front view (FIG. 6), rear view (FIG. 7), and exploded view (FIG. 8) of an orthopedic shoe insole 100 are illustratively depicted, in accordance with embodiments of the present invention.

[0048] As shown in FIGS. 1-7, the orthopedic shoe insole 100 is configured to provide support to the user, reducing and/or removing pain and/or aiding in posture and/or providing support to treat one or more of a number of foot-related medical issues such as, e.g., plantar fasciitis.

[0049] According to an embodiment, the shape of the orthopedic shoe insole 100 is configured to fit in most flat sandals. It may be small enough to be discreet but molded for support. According to an embodiment, the orthopedic shoe insole 100 comes in various sizes, for left and/or right feet. According to an embodiment, the orthopedic shoe insole 100 is customized to form to a specific user's foot.

[0050] As shown in FIG. 8, the orthopedic shoe insole 100 includes a plurality of materials. According to an embodiment, the orthopedic shoe insole 100 includes a finished top layer 105 and/or a finished sidewall layer 120. According to an embodiment, the finished top layer 105 and finished sidewall layer 120 are configured such that the orthopedic shoe insole 100 has a finished appearance and/or are configured to blend in with the footwear with which the orthopedic shoe insole 100 is intended to be used. According to an embodiment, the top layer 105 and/or the sidewall layer 120 include leather, faux leather, and/or any other suitable material or materials. According to an embodiment, the top layer 105 is perforated. According to an embodiment, the top layer 105 and the sidewall layer 120 are separate components. According to an embodiment, the top layer 105 and the sidewall layer 120 are a singular component. According to an embodiment, the top layer 105 may encompass the entire insole 100.

[0051] The finished appearance of the orthopedic shoe insole 100 due to the top layer 105 and the sidewall layer 120 enables the shoe to be used with open footwear, such as sandals, while still giving the footwear a finished look, as opposed to the look of other forms of orthopedic shoe insoles, which typically only have fabric or plastic exteriors.

[0052] According to an embodiment, below the top layer 105 is a thermoplastic polyurethane (TPU) molded layer 110. According to an embodiment, the TPU layer 110 is thicker in the center of the orthopedic shoe insole 100 and tapers thin around the edges of the orthopedic shoe insole 100. According to an embodiment, the thickest portion of the TPU layer 110 is approximately 2 mm. It is noted, however, that any suitable thickness may be used, while maintaining the spirit of the present invention. According to an embodiment, other types of hardenable material in addition to TPU or instead of TPU may also be used for layer 110, while maintaining the spirit of the present invention.

[0053] According to an embodiment, below the TPU molded layer 110 is a cork layer 115. According to an embodiment, the cork layer 115 is molded into shape. According to an embodiment, the cork layer 115 tapers in the toe region of the orthopedic shoe insole 100. The TPU molding layer 110 and the cork layer 115 provide support, structure, and absorption for the user of the orthopedic shoe insole 100. According to an embodiment, the sidewall layer 120 wraps around the TPU layer 110 and the cork layer 115.

[0054] According to various embodiments of the present invention, the insole 100 may solely have a TPU layer 110, may solely have a cork layer 115, and/or may have both a TPU layer 110 and a cork layer 115. According to various embodiments, the order of the TPU layer 110 and the cork layer 115 may be reversible.

[0055] According to an embodiment, a bottom layer 125 is located below the cork layer 115. According to an embodiment, the bottom layer 125 is relatively flat and covers the entire bottom surface area of the orthopedic shoe insole 100. According to an embodiment, the bottom layer is printed, although it is noted that any suitable method for forming the bottom layer 125 may be used while maintaining the spirit of the present invention. According to an embodiment, the bottom layer 125 includes silicone. It is noted, however, that any suitable material or materials may be used in the formation of the bottom layer 125, while maintaining the spirit of the present invention.

[0056] Sectional views of the layers of an embodiment of the orthopedic shoe insole 100 can further be seen in the material visualizations shown in FIGS. 9-10.

[0057] According to an embodiment, the orthopedic shoe insole 100 may include an adhesive layer 130 on the underside of the orthopedic shoe insole 100. According to an embodiment, the adhesive layer 130 may cover all or a portion of the bottom layer 125 of the orthopedic shoe insole 100. According to an embodiment, the adhesive layer 130 covers a heel portion of the orthopedic shoe insole 100. The adhesive layer 130 is configured to secure the orthopedic shoe insole 100 to the footwear with which the orthopedic shoe insole 100 is intended for use. For open footwear, the adhesive layer 130 prevents the orthopedic shoe insole 100 from falling out of place or falling off of the open footwear. According to an embodiment, the adhesive layer 130 may be a double-sided adhesive layer. It is noted, however, that any suitable form of adhesive layer 130 may be used while maintaining the spirit of the present invention.

[0058] According to a new embodiment illustrated in FIG. 11, the orthopedic shoe insole 100 is a multi-layered cohesive shoe insole. According to FIG. 11, the multi-layered insole includes four distinct layers fused together to form the insole, but one of ordinary skill in the art will appreciate that more or less than four layers may be used to form the multi-layered insole. Layer A (also referred to as the first or top layer; i.e., the layer that comes in direct contact with the bottom of a user's foot) is made of leather. This layer is preferably 0.8-1.0 mm in thickness and is preferably vegetable tanned and chrome-free goat or calf leather. However, other ranges of thickness may be used, as well as other or no tanning processes, and other sources of leather besides goat or calf.

[0059] Layer B (also referred to as the second layer or first intermediate layer) is an ADETEX high-density recycled molded latex foam layer and is preferably 1.5-2 mm in thickness. However, the thickness is not limited to this range.

[0060] Layer C (also referred to as the third layer or second intermediate layer) is a molded cork and EVA (Ethylene-Vinyl Acetate) hybrid footbed with built-in medial and lateral arch support as well as support for the ball of the foot. Layer C includes a contoured heel cup (for cradling the heel) with center support in the form of a heel pad, disposed centrally in the heel cup, for shock absorption and high rigidity. Layer D (also referred to as the fourth layer or bottom layer) is moleskin or moleskin coated for slip resistance and is preferably 1.8-2 mm in thickness. However, the thickness is not limited to this range.

[0061] Referring back to Layer C, this layer includes sidewalls E which are preferably covered by a leather wrap. The leather wrap is preferably 0.8-1.0 mm in thickness and is vegetable tanned and chrome-free goat or calf leather. However, the wrap and layers described herein are not limited to a particular thickness, tanning process, or source.

[0062] Together, the four layers A, B, C, and D are combined to form a multilayered orthopedic shoe insole for closed and open toe footwear offering a fused combination of vegetable tanned leather and molded HD (high-density) recycled latex foam over a molded, rigid density cork-EVA footbed with custom designed arch, ball, and heel support for optimal foot alignment and foot pain relief. The insole side walls are also wrapped in vegetable tanned leather for a fashion element and the moleskin coated bottom layer provides a natural grip for gripping the insole of a shoe.

[0063] FIGS. 12A-C show different perspective views of the multilayered orthopedic insole of FIG. 11 in its fused form. FIG. 12A is a perspective view of the multilayered orthopedic insole, FIG. 12B is a front perspective view of the multilayered orthopedic insole and FIG. 12C is a rear perspective view of the multilayered orthopedic insole. The multilayered insole includes a heel portion 224, a mid-section 226, and a front portion 228. As shown in FIGS. 12B and 12C, a heel cup area 220 is defined by a depression in the heel portion 224 and/or raised lateral and medial sides (310 and 312, respectively) of the insole, which flanks the heel portion. The heel cup 220 is configured to cradle a user's heel, thus providing stability and comfort to the user while standing, sitting, or walking.

[0064] FIGS. 13A and 13E show a top view and rear view, respectively, of the orthopedic insole of FIG. 12A. As can be seen, the insole includes a raised heel pad 212 protruding from the heel cup area 220. The heel pad is preferably about 50×35 mm with a maximum height of about 3 mm. The heel pad tapers off into the surrounding heel cup area. The heel pad 212 provides a rigid support to the user's heel while the heel is seated in the heel cup. The width of the heel section of the insole is preferably about 75 mm.

[0065] Turning to the mid-section of the multilayered insole illustrated in FIG. 13A, the insole is dimensioned as a contoured cup for cradling a user's foot. A waist of mid-section 226 is about 72 mm wide and rises from a central depression to raised medial and lateral sides, respectively. The lateral side 310 and medial side 312 include built-in arch support, i.e., each is configured to provide arch support on their respective sides.

[0066] FIG. 13B is a side perspective view of the insole of FIG. 12A. As illustrated in FIG. 13B, the insole mid-section has a thickness of about 14.5 mm and the bottom side of the insole (i.e., the side in contact with the insole of the shoe) is not entirely flat. Rather, it maintains a slight curve along the arch area for firm support.

[0067] According to FIG. 13A, the front portion 228 of the multi-layered orthopedic insole includes a raised ball pad support 214. The raised ball pad support may have an irregular reniform shape and has a length of about 55 mm and a variable width. The width of one side of the ball pad support is preferably about 12 mm, with the width increasing around the middle of the ball pad to about 15 mm and increasing further at an opposite side to about 25 mm. The ball pad support has a maximum height relative to the surrounding surface of about 3 mm and tapers down into the surrounding surface. The ball pad 214 provides support and cushioning to the ball of a user's foot. Specifically, the reniform shape of the ball pad provides maximum comfort and support to the front portion of the foot. However, the ball pad is not limited to this shape and other shapes may be used to provide cushioning and support for the ball of the user's foot.

[0068] The width of the insole at the front is about 77 mm. The length of the entire insole is about 176 mm.

[0069] FIG. 13B shows a lateral side view of the multilayered insole. The thickness of the insole is about 14.5 mm around its midline (i.e., a transverse line bisecting the insole). However, as stated elsewhere, the specified thickness and other dimensions should be considered non-limiting. FIG. 13B also illustrates the sloping contours of the insole which is designed to provide comfort and relieve pressure from the user's foot while standing or walking.

[0070] FIG. 13C shows a bottom view of the multilayered insole of FIG. 12A. As can be seen, the sidewalls are angled at about a 30-40-degree beveled angle. FIG. 13D shows a medial side view of the multilayered insole and its sloping contours.

[0071] FIGS. 13E and 13F are rear and front views, respectively, of the multilayered orthopedic insole. As shown in FIG. 13E the thickness of the orthopedic insole at the rear is about 18 mm. The cork-EVA mold used for layer C tapers to about 2 mm in thickness at a front edge of the orthopedic insole shown in FIG. 13F. FIGS. 13E and 13F also show the sloping contours of the insole.

[0072] FIG. 14 shows an enlarged view of some of the layers illustrated in FIG. 11. Layer A and sidewalls E both include vegetable tanned leather insock. Specifically, layer A is a vegetable tanned leather insock with medial arch ventilation and is about 0.8-1 mm in thickness. The shaded area 402 shown in layer A represents a protruding area of medial arch support. Sidewalls E may be covered or wrapped in vegetable tanned leather for aesthetic appeal. Layer B is preferably made from ADETEX high-density recycled latex foam with a density rating of (D-80) and is about 1.5-2 mm in total thickness throughout. The edges are tapered for even skiving. The shape and contours of Layer B mirror and conform to the shape of Layer A. Layer D is a moleskin backer having a thickness of about 1.8-2 mm. A logo may be printed or embossed on the top layer (i.e., layer A) such as on the heel section of the insole.

[0073] As can be seen, the contoured slopes, heel cup, heel pad, ball pad, raised medial and lateral sides, and midsection are configured to relieve pressure points of the foot, and provide cushioned support, while also providing proper weight distribution for the foot when the user is standing or walking. In addition, the specified dimensions and overall shape of the multi-layered insole create an inconspicuous profile for the insole when it gets inserted into a shoe so that it does not detract from the style and aesthetic aspects of the shoe.

[0074] Although the different layers of the multilayered orthopedic insole are described as having preferred dimensions, materials, and shapes to achieve maximum comfort, support, and alignment for the user's foot, other dimensions, materials, or shapes may be used. Therefore, the specified dimensions and materials should be considered non-limiting.

[0075] When introducing elements of the present disclosure or the embodiment(s) thereof, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements.

[0076] Similarly, the adjective “another,” when used to introduce an element, is intended to mean one or more elements. The terms “including” and “having” are intended to be inclusive such that there may be additional elements other than the listed elements.

[0077] Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention.