ORTHOTIC SOLE AND INSOLE DEVICES, SYSTEMS, METHODS, AND COMPUTER READABLE MEDIA FOR USE WITH HIGH HEEL FOOTWEAR

Abstract

Orthotic sole devices, systems, methods, and computer readable media are for use with footwear. Three-dimensional scans are used to shape the devices to match the user's feet with the footwear. Each of the devices includes a sunken heel portion, a stopper portion, an arch portion, metatarsal pads, a bunion-cut out shape, and a built-in toe crest portion, all to help redistribute the user's weight away from their forefoot. The devices are infused with eucalyptus oils and silver ions. The devices are automatically manufactured via computer numerical control (CNC) software on a computer readable medium. Milling machines and 3D printers can be used in association with the systems, methods, and computer readable media.

Claims

1. A method and computer-readable medium for manufacturing a custom orthotic sole device for a user, customized to the user's feet and footwear, the method comprising steps of: (a) performing a three-dimensional (3D) foot scan of unique anatomical features of the user's feet; (b) performing a 3D footwear scan of the footwear, wherein the 3D footwear scan comprises a slope line and pitch of the footwear; and (c) shaping the custom orthotic sole device, in dependent relation based on the three-dimensional (3D) foot scan and the 3D footwear scan, to match the unique anatomical features of the user's feet with the slope line and pitch of the footwear; wherein the custom orthotic sole device is further shaped to define one or more of the following orthotic sole features: (i) a sunken heel portion (alternately referred to herein as a heel cup portion) to help counter-shift a weight of the user backwards and to help realign a heel of the user; (ii) a stopper portion, substantially adjacent to and after the heel cup portion, to engage and support a calcaneus of the user and to help stop the calcaneus from sliding downward in the footwear; (iii) an arch portion, which is raised to a predetermined degree, to help stabilize a posture of the user's feet in the footwear and to help reinforce and stop the user's foot from sliding downward in the footwear; (iv) metatarsal pads, which are shaped to a predetermined height and with a predetermined durometer and hardness, to help support the weight of the user, to help with a predetermined shift of metatarsal heads of the user's feet, and to help with a predetermined splay of toes of the user's feet; (v) a bunion cut out shape to help to offload a bunion area of the user, and to help reduce pressure on a forefoot of the user; and (vi) a built-in toe crest portion to help space and divide the toes of the user, to help keep the toes inside the footwear, and to help prevent the toes from becoming squished, overlapping, or falling out from the footwear; wherein the method and the custom orthotic sole device are adapted to help provide for redistribution of the weight of the user away from the forefoot of the user by combination of at least two of said orthotic sole features; wherein step (c) is performed in dependent relation based on at least one of the following medical assessment components: a total body alignment of the user; a posture of the user; a gait of the user; any leg length discrepancy of the user; any limited range of motion of the user; any pelvic tilt of the user; and a substantially precise measured degree of any misalignment of the user; wherein, in step (c), the custom orthotic sole device is automatically 3D printed or milled via computer numerical control (CNC) software on a computer readable medium operatively connected to a 3D printer or a milling machine; wherein the method and the custom orthotic sole device are adapted for use with, and to fit, a wide range of feet and footwear; wherein the method and the custom orthotic sole device are adapted to help avoid toe crush and toe spilling of the toes of the user at a toe box area of the footwear; and wherein the custom orthotic sole device is infused with a blend of eucalyptus oils and/or silver ions, to lend substantial antifungal, antibacterial, sweat-proof, and/or stink-proof characteristics.

2. A method and computer-readable medium for manufacturing a custom orthotic sole device for a user, customized to the user's feet and footwear, the method comprising steps of: (a) performing a three-dimensional (3D) foot scan of unique anatomical features of the user's feet; and (b) shaping the custom orthotic sole device, in dependent relation based on the three-dimensional (3D) foot scan, to match the unique anatomical features of the user's feet; and wherein the custom orthotic sole device is further shaped to define one or more orthotic sole features.

3. The method of claim 2 further comprising the step of (a.1) performing a 3D footwear scan of the footwear, wherein the 3D footwear scan comprises a slope line and pitch of the footwear; and wherein, in step (b), the custom orthotic sole device is also shaped in dependent relation based on the 3D footwear scan, and the unique anatomical features of the user's feet are matched with the slope line and pitch of the footwear.

4. The method of claim 3, wherein the orthotic sole features comprise at least one of the following: (i) a sunken heel portion (alternately referred to herein as a heel cup portion) to help counter-shift a weight of the user backwards and/or to help realign a heel of the user; (ii) a stopper portion, substantially adjacent to and after the heel cup portion, to engage and/or support a calcaneus of the user and/or to help stop the calcaneus from sliding downward in the footwear; (iii) an arch portion, which is raised to a predetermined degree, to help stabilize a posture of the user's feet in the footwear and to help reinforce and stop the user's foot from sliding downward in the footwear; (iv) metatarsal pads, which are shaped to a predetermined height and with a predetermined durometer and hardness, to help support the weight of the user, to help with a predetermined shift of metatarsal heads of the user's feet, and/or to help with a predetermined splay of toes of the user's feet; (v) a bunion cut out shape to help to offload a bunion area of the user, and/or to help reduce pressure on a forefoot of the user; and (vi) a built-in toe crest portion to help space and divide the toes of the user, to help keep the toes inside the footwear, and/or to help prevent the toes from becoming squished, overlapping, or falling out from the footwear.

5. The method of claim 4, wherein a combination of the orthotic sole features is adapted to help provide for redistribution of the weight of the user away from the forefoot of the user.

6. The method of claim 5, wherein step (b) is performed in dependent relation based on at least one of the following medical assessment components: a total body alignment of the user; a posture of the user; a gait of the user; any leg length discrepancy of the user; any limited range of motion of the user; any pelvic tilt of the user; and a substantially precise measured degree of any misalignment of the user.

7. The method of claim 6 wherein, in step (b), the custom orthotic sole device is automatically 3D printed via computer numerical control (CNC) software on a computer readable medium operatively connected to a 3D printer.

8. The method of claim 6 wherein, in step (b), the custom orthotic sole device is automatically milled via computer numerical control (CNC) software on a computer readable medium operatively connected to a milling machine.

9. The method of claim 8, wherein the method and the custom orthotic sole device are adapted for use with, and/or to fit, a wide range of feet and footwear.

10. The method of claim 9, wherein the method and the custom orthotic sole device are adapted to help avoid toe crush and/or toe spilling of the toes of the user at a toe box area of the footwear.

11. The method of claim 10, wherein the custom orthotic sole device is infused with a blend of eucalyptus oils and/or silver ions, to lend substantial antifungal, antibacterial, sweat-proof, and/or stink-proof characteristics.

12. A custom orthotic sole device for a user, customized to the user's feet and footwear, wherein the device is manufactured using a three-dimensional (3D) foot scan of unique anatomical features of the user's feet; wherein the device is shaped, in dependent relation based on the three-dimensional (3D) foot scan, to match the unique anatomical features of the user's feet; and wherein the custom orthotic sole device is further shaped to define one or more orthotic sole features.

13. The device of claim 12, wherein the device is also manufactured using a 3D footwear scan of the footwear that comprises a slope line and pitch of the footwear; and wherein the device is also shaped: in dependent relation based on the 3D footwear scan; and such that the unique anatomical features of the user's feet are matched with the slope line and pitch of the footwear.

14. The device of claim 13, wherein the orthotic sole features comprise: (i) a sunken heel portion (alternately referred to herein as a heel cup portion) to help counter-shift a weight of the user backwards and to help realign a heel of the user.

15. The device of claim 14, wherein the orthotic sole features further comprise: (ii) a stopper portion, substantially adjacent to and after the heel cup portion, to engage and support a calcaneus of the user and to help stop the calcaneus from sliding downward in the footwear.

16. The device of claim 15, wherein the orthotic sole features further comprise: (iii) an arch portion, which is raised to a predetermined degree, to help stabilize a posture of the user's feet in the footwear and to help reinforce and stop the user's foot from sliding downward in the footwear; and (iv) metatarsal pads, which are shaped to a predetermined height and with a predetermined durometer and hardness, to help support the weight of the user, to help achieve any predetermined shift of metatarsal heads of the user's feet, and to help achieve any predetermined splay of toes of the user's feet.

17. The device of claim 16, wherein the orthotic sole features further comprise: (v) a bunion cut out shape to help to offload a bunion area of the user, and to help reduce pressure on a forefoot of the user; and (vi) a built-in toe crest portion to help space and divide the toes of the user, to help keep the toes inside the footwear, and to help prevent the toes from becoming squished, overlapping, or falling out from the footwear.

18. The device of claim 17, wherein a combination of the orthotic sole features is adapted to help provide for redistribution of the weight of the user away from the forefoot of the user.

19. The device of claim 18 further adapted to help avoid toe crush and/or toe spilling of the toes of the user at a toe box area of the footwear.

20. The device of claim 19 infused with a blend of eucalyptus oils and/or silver ions, to lend substantial antifungal, antibacterial, sweat-proof, and/or stink-proof characteristics.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The novel features which are believed to be characteristic of the present invention, and related devices, systems, methods, and/or computer readable media according to the present invention, as to their structure, organization, use, and/or methods of manufacture and/or operation, together with further objectives and advantages thereof, may be better understood from the figures which accompany this application, in which presently preferred embodiments of the invention have been illustrated by way of example. It is expressly understood, however, that such figures have been provided for the purpose of illustration and/or description only, and not intended as a definition of the limits of the invention. In the accompanying figures:

[0039] FIG. 1 is a side perspective view a prior art orthotic insole;

[0040] FIG. 2 is a side perspective view of a foot, showing a number of foot conditions to be prevented and/or corrected;

[0041] FIG. 3 is a side perspective view of a prior art high heel shoe;

[0042] FIG. 4 is a top side perspective view of an orthotic insole device according to a preferred embodiment of the invention;

[0043] FIG. 5 is a top plan view of the orthotic insole device of FIG. 4;

[0044] FIG. 6 is a bottom plan view of the orthotic insole device of FIG. 4; and

[0045] FIG. 7 is a side perspective view of the orthotic insole device of FIG. 4, shown with both a user's foot and high heel footwear in phantom outline.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0046] This disclosure, including the accompanying drawings, may include one or more numbers, words, phrases, sentences, arrangements, and/or configurations which may be included by way of example. It may bear repeating, in this respect specifically, that such drawings and/or this disclosure are for the purpose of illustration and description only, and not intended as a definition of the limits of the invention.

[0047] The accompanying drawings illustrate aspects of one or more orthotic insole devices according to preferred embodiments of the invention.

[0048] FIG. 1 depicts a prior art orthotic insole with a heel cup for rear foot alignment and posture, an arch support for midfoot correction, a metatarsal support for balance and forefoot alignment, and additional cushioning for improved shock absorption.

[0049] FIG. 2 depicts a foot and a number of foot conditions which may desirably be biomechanically prevented and/or corrected, including shin splints, hammer toes, bunions, plantar fasciitis, heel spurs, and achilles tendonitis.

[0050] FIG. 3 depicts a high heel shoe having the following structural features: a heel counter portion to help control a heel's strike position, a stiff shank portion to help provide a suitable base of support for an orthotic insole, a toe spring portion to help offload a bunion area, and a toe box depth portion for an enhanced fit.

[0051] FIGS. 4 to 7 depict an orthotic insole device according to a preferred embodiment of the invention. (The orthotic insole device shown in FIGS. 4 to 7 is for a left foot. Naturally it will be understood that the invention also encompasses orthotic insole devices for right feet, and persons having ordinary skill in the art may readily appreciate that they may be a mirror image of the orthotic insole device shown in FIGS. 4 to 7.) FIG. 4 is a top right perspective view, FIG. 5 is a top view, and FIG. 6 is a bottom view of the orthotic insole device according to a preferred embodiment of the invention.

[0052] As shown in FIGS. 4 to 6, the orthotic insole device according to the invention is preferably shaped with: [0053] (1) A countersink or sunken area on the heel portion of the insole. It is preferably displaced with a padding material which is preferably formed from a microporous plastic material (e.g., a Poron material as may be offered by Rogers Corporation of Chandler, Ariz.) that affords thermal insulation characteristics. The countersink area preferably enables a user's heel to sink into a cupped position therein. It preferably helps with rear foot alignment and posture or helps to redistribute the user's weight to a back portion of the heel. [0054] (2) A built-in heel stopper portion, which preferably (in a new and ingenious way) helps to prevent the ball of the user's heel from sliding forward. [0055] (3) A built-up arch profile portion, which preferably helps raise and fully support the arch of the user's foot, preferably by foot position and body weight. It preferably helps to redistribute the foot's weight and position in the shoe. [0056] (4) A built-up metatarsal head pad portion, which preferably helps to lift the bones of the user's foot and to splay its toes. It preferably also helps with balance and forefoot alignment. [0057] (5) A bunion cut-out portion, which preferably helps displace weight distribution of a user's bunion. The bunion cutout portion is preferably for the user's first metatarsal-phalangeal joint and effectively assists in mechanical loading through the forefoot. And, [0058] (6) A toe crest portion, which preferably helps to neatly position and space the toes of the user's foot.

[0059] Also, as shown in FIGS. 4 to 6, the orthotic insole device includes: [0060] (7) A base portion, which is preferably formed from a closed cell ethylene-vinyl acetate (EVA) copolymer foam material, or from a renewable source used in additive manufacturing. The base portion is preferably shaped with features (1) to (6) above and with feature (9) below. The EVA base portion is preferably CNC milled (or 3D printed) using digital computer-aided design/computer-aided manufacturing (CAD/CAM) computer systems, which may preferably be used to design and/or control manufacture processes for the EVA base portion. (As an aside, it may be worthwhile to specifically note here that preferred embodiments of the invention need not necessarily be limited to CNC milling and/or 3D printing manufacturing processes.) And, [0061] (8) A top-cover portion, which is preferably glued to the EVA base portion. the top-cover portion is preferably infused with one or more eucalyptus oils and silver ions preferably to afford antifungal and antibacterial properties, and to help make the top-cover thermoregulated and substantially odour free. The top-cover portion preferably also provides enhanced grip for a user's barefoot, and further improves the device's ability to prevent the user's foot from sliding forward.

[0062] As best seen in FIGS. 4 and 5, the orthotic insole device is preferably also shaped with: [0063] (9) An additional cushioning portion, which preferably affords improved shock absorption.

[0064] According to preferred embodiments of the invention, the devices, systems, methods, and/or computer readable media are preferably adapted for use in combination with assessment of related medical factors and the user's weight and height. The systems, methods, and/or computer readable media according to preferred embodiments of the invention involve and/or provide for precise measurement (e.g., sub-millimeter dimensions and measurements) of the user's feet and high heel footwear which are preferably taken by 3D scan or photogrammetry. The orthotic insoles according to the invention are preferably medically designed to change biomechanical weight distribution and position, and total body alignment.

[0065] FIG. 7 shows the orthotic insole device according to a preferred embodiment of the invention, with a user's foot, inside high heel footwear. In use, the invention preferably helps to eliminate shin splints, achilles tendonitis, heel spurs, and plantar fasciitis, helps to align the bones of the user's foot and the user's rear foot, and helps provide foot comfort, shock absorption, improved gait, bunion safety and support, and a corrected and supported arch and midfoot. Additionally, use of the invention preferably helps provide better posture and total body alignment, and more comfort in the user's legs, knees, hips, back, and shoulders.

[0066] Substantially precise and/or exact dimensions, measurements, specs, and/or other informationincluding 3D scans of the user's feet in weight-bearing and/or neutrally corrected (calcaneal vertical, sub-talar neutral, with rearfoot and forefoot neutrally positioned to the user's anatomical alignment) non-weight bearing configurationsare preferably transferred digitally for manufacture of the insoles according to the invention. In manufacturing methods, according to the invention, this information is preferably imported to CAD/CAM software on computer readable media to prepare it for output to a CNC milling machine, additive manufacturing/3D printing, and/or other system.

[0067] The insole base portion is preferably milled, from an EVA block, using a CNC milling machine, or from a renewable source used in additive manufacturing, and/or other system according to the invention. According to the invention, the EVA blocks may preferably have standard dimensions of about 5.5 inches, by about 1.25 inches, by about 13.25 inches. The EVA blocks preferably have a Shore Type A or Type OO durometer hardness in the range of between about 30 and about 50. (The scope of the present invention extends to encompass, instead or in addition, 3D printing of the base portion from EVA or another material.)

[0068] After milling, the blocks are preferably shaped as insoles and/or hand-finished with a top-cover portion that is preferably applied and secured thereto by a manual gluing process. (The scope of the present invention extends to encompass, instead or in addition, applying the top-cover to the base portion by an automated gluing process.)

[0069] The top-cover portion for each insole is preferably formed from pre-cut pieces and/or a roll of top-cover material. One or more logos may be pre-printed (e.g., in a zinc-coloured ink) on the top-cover material. The top-cover material preferably has antibacterial properties. It is preferably embedded with silver ions, and is preferably breathable, with an absorption capacity of preferably about 8 times its weight in water. The top-cover material preferably affords comfort and dryness properties with its thermo-regulating effect as aforesaid. It is preferably substantially abrasion, tear, and/or rip resistant under both dry and humid (or wet) conditions. The top-cover material may preferably be embedded with a natural Eucalyptus aroma, and preferably keeps its aroma when washed in temperatures of up to about 30 C. It is preferably anti-allergic and does not generate odors. The top-cover material preferably has a thickness of about 0.75 millimeters. It is preferably relatively light, flexible, and comfortable (as compared, for example, with pigskin). The top-cover material is grindable and can be readily worked with. It is similar to real leather but with increased strength.

[0070] The top cover portion preferably, in addition to helping the foot breathe, provides a high grip surface that may help keep the foot from sliding forward inside the user's high heel footwear.

[0071] After manufacture, finished orthotic insole devices according to the invention may preferably be fit on the user's foot and in specific footwear, and minor adjustments may be performed if necessary.

[0072] Accordingly, some features, elements, parts and/or steps that preferably work together according to (or in association with) the invention may include a medical assessment of the user's needs, 3D scans, correct and/or appropriate footwear, digital design and manufacture of an orthotic insole device, and a professional fitting. Some of the invention's features, elements, parts, steps, and/or sub-combinations thereof may be altogether new, including the built-in heel stopper, the sunken heel cup, and one or more combinations of features, including the EVA base portion and the top cover portion, along with a medical assessment, digital design and manufacture, and dispensing.

[0073] In use, some advantages of the invention, over the prior art, may include one or more of the following: (a) its utility in obviating or mitigating one or more disadvantages or shortcomings associated with the prior art, in meeting or providing for one or more desires, benefits, needs or advantages, or in achieving one or more objects of the invention; (b) its customization and tailoring to each particular user, preferably being moulded to the unique shape of their foot; (c) its custom fit to specific footwear; (d) its compliance and adherence to medically sound principles of design and use; (e) its coverage of the entire foot; and/or (f) its ability for transfer to other (similar structure) high heel footwear.

[0074] The EVA and Poron materials, according to the invention, preferably afford significant comfort advantages for the user's foot and substantially/readily conform to the shape of the user's shoe pitch and slope line, with an ability to accommodate minor nuances.

[0075] The 3D scans, according to the invention, are preferably highly accurate.

[0076] One or more features and functionalities of the invention are preferably offered under or in association with the applicant's distinctive PITCH PERFECT trademark.

[0077] The invention is contemplated for use by or in association with insoles, soles, and footwear. The invention, however, is not so limited. Other embodiments, which fall within the scope of the invention, may be provided. For example, the invention encompasses full 3D prints of high heel footwear (or any portions thereof) complete with one or more of the aforementioned features of the invention

[0078] Preferably, devices, apps, systems, methods, and/or computer readable media according to the invention may be used for, and afford advantageous utilities with, industries and/or user environments other than those associated with insoles, soles, and/or footwear.

[0079] The foregoing description has been presented for the purpose of illustration and is not intended to be exhaustive or to limit the invention to the precise form disclosed.

[0080] Naturally, in view of the teachings and disclosures herein, persons having ordinary skill in the art may appreciate that alternate designs and/or embodiments of the invention may be possible (e.g., with substitution of one or more components for others, with alternate configurations of components, etc). Although some of the components, relations, configurations and/or steps according to the invention are not specifically referenced in the accompanying drawings or in association with one another, they may be used, and/or adapted for use, in association therewith. For example, features may be depicted or discussed herein in the context of the device, which clearly could be recast as the steps of a method, the inter-workings of a system, and/or recorded on computer readable media. (And, vice-versa.) All of the depicted and aforementioned and various other features, steps, inter-workings, structures, configurations, relationships, utilities, and/or the like (any of which may be depicted and/or based hereon) may be, but are not necessarily, incorporated into and/or achieved by the invention. Any one or more of the depicted and aforementioned features, steps, inter-workings, structures, configurations, relationships, utilities and the like may be implemented in and/or by the invention, on their own, and/or without reference, regard or likewise implementation of any of the other depicted or aforementioned features, steps, inter-workings, structures, configurations, relationships, utilities and the like, in various permutations and combinations, as will be readily apparent to those skilled in the art, without departing from the pith, marrow, and spirit of the disclosed invention.

[0081] Other modifications and alterations may be used in the design, manufacture, and/or implementation of other embodiments according to the present invention without departing from the spirit and scope of the invention, which is limited only by the claims of this patent application.