SYSTEM AND METHOD FOR FORMING CUSTOM INSOLES FOR USE IN FOOTWEAR

Abstract

Systems and methods for forming a custom fitted shoe insole. The method includes placing a shoe insole template plate proximate a heating element that heats the shoe insole template plate to a temperature sufficient to make it deformable. The method further includes placing the sufficiently heated shoe insole template plate onto a foam structure, placing a foot of a user on the heated shoe insole template plate, and applying foot pressure to the heated shoe insole template plate, causing it to deform to match a topology of the sole of the user's foot. The shoe insole template plate is then removed from the foam structure, cooled and hardened, and inserted into a shoe as the custom fitted shoe insole.

Claims

1. A method for forming a custom fitted shoe insole, comprising: heating a shoe insole template plate to a temperature sufficient to make the shoe insole template plate deformable; placing the heated shoe insole template plate onto a foam structure; placing a foot of a user on the heated shoe insole template plate on the foam structure; applying pressure by the user with the foot to the heated shoe insole template plate on the foam structure, causing the shoe insole template plate to deform to match a topology of the bottom of the foot of the user; and cooling the shoe insole template to harden with the matching topology as the custom fitted shoe insole.

2. The method as recited in claim 1, wherein the temperature is predetermined based on the composition of the shoe insole template plate.

3. The method as recited in claim 2, wherein the shoe insole template plate comprises ethylene terephthalateco-1,4-cylclohexylenedimethylene terephthalate (PETG), and the predetermined temperature is 200 degrees Fahrenheit.

4. The method as recited in claim 1, wherein the shoe insole template plate includes a top layer configured to be breathable, wear-resistant, and non-slip.

5. The method as recited in claim 4, wherein the top layer comprises polyester.

6. The method as recited in claim 1, wherein the shoe insole template plate includes a comfort layer configured to be wear resistant, soft, comfortable to the user, and capable of shock absorption.

7. The method as recited in claim 6, wherein the comfort layer comprises rubber or ethylene-vinyl acetate (EVA).

8. The method as recited in claim 1, further comprising: inserting the custom fitted shoe insole into an article of footwear.

9. The method as recited in claim 1, wherein the shoe insole template plate is configured to accommodate one of a left foot and a right foot.

10. A system for forming a custom fitted shoe insole, comprising: a shoe insole template plate containing a material that deforms when sufficiently heated and subjected to pressure, and hardens when cooled to keep its deformed shape; a foam structure configured to receive the sufficiently heated shoe insole template plate and to guide a user to apply foot pressure to deform the shoe insole template plate to match the topology of the bottom of the user's foot; and a casing configured to house the foam structure.

11. The system as recited in claim 10, wherein the temperature is predetermined based on the composition of the shoe insole template plate.

12. The system as recited in claim 11, wherein the shoe insole template plate comprises ethylene terephthalateco-1,4-cylclohexylenedimethylene terephthalate (PETG), and the predetermined temperature is 200 degrees Fahrenheit.

13. The system as recited in claim 10, wherein the shoe insole template plate includes a top layer configured to be breathable, wear-resistant, and non-slip.

14. The system as recited in claim 13, wherein the top layer comprises polyester.

15. The system as recited in claim 10, wherein the shoe insole template plate includes a comfort layer configured to be wear resistant, soft, comfortable to the user, and capable of shock absorption.

16. The system as recited in claim 15, wherein the comfort layer comprises rubber or ethylene-vinyl acetate (EVA).

17. The system as recited in claim 1, wherein the shoe insole template plate is configured to accommodate one of a left foot and a right foot.

18. The system as recited in claim 10, wherein the shoe insole template plate includes a rigid structure core portion positioned on a heel portion of the shoe insole template plate.

19. The system as recited in claim 18, wherein the shoe insole template plate includes a flexible portion surrounding the rigid structure core portion.

20. The system as recited in claim 10, wherein the casing includes a notched portion configured to guide the user where to position the shoe insole template plate on the foam structure, and the casing includes at least one material selected from the group consisting of cardboard, wood, plastic, and metal.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Embodiments of the present invention will be described with reference to the drawings, in which the same elements in the various figures are identified with the same reference numerals.

[0027] FIG. 1 shows a perspective view of a system for forming custom shoe insoles, according to an embodiment of the present invention.

[0028] FIG. 2 shows a foam pillow housed within a casing, according to an embodiment of the present invention.

[0029] FIG. 3 shows an upper perspective view of a pair of shoe insole template plates, according to an embodiment of the present invention.

[0030] FIG. 4 shows a bottom perspective view of a pair of shoe insole template plates, according to an embodiment of the present invention.

[0031] FIG. 5 shows an upper perspective view of a pair of formed shoe insoles, according to an embodiment of the present invention.

[0032] FIG. 6 shows a flowchart of a method for forming custom shoe insoles, according to an embodiment of the present invention.

[0033] FIG. 7 shows an exploded view of a shoe insole template plate, according to an embodiment of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS

[0034] Reference will now be made to certain exemplary embodiments of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not limited thereto. Those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations may be made thereto.

[0035] Referring now to FIG. 1, an exemplary embodiment of a system 100 for forming a custom shoe insole is depicted. The system 100 includes one or more shoe insole template plates 110. The system also includes a housing 120 that contains a soft pillow-like element 115. The housing may also have a notch 125 showing where a shoe insole template plate 110 should be placed when forming a custom fitted shoe insert, as will be described. In embodiments, some or all of the components of the system 100 may be slid into an exterior case 105 to be stored. The cast 105 may comprise cardboard, wood, plastic, metal, and/or any other materials rigid enough to protect the stored components.

[0036] FIG. 2 is a perspective view of the pillow 115 and the housing 120. The pillow may comprise a layer of compressible material such as rubber, an elastomeric plastic, or a rubberized, rigid or stiff, flexible substrate. The housing 120 may also comprise a notch 125 or other marker to indicate to the user where to place a shoe insole template plate 110 as a customized shoe insole is being made, as will be described.

[0037] FIG. 3 is a perspective view of a pair of shoe insole template plates 110. It is contemplated a pair of shoe insole template plates 110 will be sold together, one of the template plates 110 cut for making a customized shoe insert for a user's left foot, and another cut for the user's right foot. Alternatively, a left or right foot shaped shoe insole template plate 110 may be sold individually, such as to make a replacement or a spare insert.

[0038] FIG. 4 is a perspective view of another exemplary embodiment of a pair of shoe insole template plates 110. As shown, in this embodiment the shoe insole template plates 110 each include a rigid structure core portion 130 on and/or near the heel of the template plate 110. The shoe insole template plates 110 may also include a flexible material 135 surrounding the rigid structure 130.

[0039] FIG. 5 is a perspective view of a pair of customized shoe inserts 140 made from a pair of shoe insole template plates 110. As shown, the shoe insole template plates 110 have been permanently deformed and are now ready to be used as fitted shoe insoles 140. According to an embodiment, the shoe insole 140 and/or template plate 110 may comprise an indicator of the shoe size 150 the custom shoe insole 140 is sized to fit in. The shoe insole 140 and/or template plate 110 may also include a graphical element 145, such as a graphic showing the manufacturer's name or logo.

[0040] FIG. 6 is a flowchart showing an exemplary method 200 for forming a custom shoe insole 140, such as the insole shown in FIG. 5. The method begins by heating a heating element to a predetermined temperature sufficient to make the shoe insole template plate 110 deformable, step 205. In an exemplary embodiment, the predetermined temperature is 200 degrees Fahrenheit. However, it is noted that a different predetermined temperature may be used to accomplish the desired effect on the custom shoe insole template plate 110, without departing from the scope of the present invention. In embodiments, the heating element may be an oven or hotplate. However it is noted that any suitable heating element may be used to heat the insole template plate 110 without departing from the scope of the present invention.

[0041] The insole template plate 110 is placed in or near the heating element until the template plate 110 reaches a temperature at which the template plate 110 is deformable, step 210. In embodiments, the insole template plate 110 comprises a rigid structure core portion 130 that becomes flexible. After the insole template plate 110 has reached the desired temperature and flexibility, the insole template plate 110 is placed on the foam pillow 115, step 215.

[0042] At step 220, the user places their foot onto the heated insole template plate 110 that has been placed onto the foam pillow 115, and applies pressure to the insole template plate 110, such as by standing and putting weight on the foot on the heated insole template plate 110. The foot (whether left or right) should match the shape of the insole template plate 110. The pressure applied by the user causes the heated insole template plate 110 to deform to match the topology of the sole of the user's foot.

[0043] At step 225, the user removes their foot from the deformed insole template plate 110, and, at step 230, the deformed insole template plate 110 is removed from the foam pillow 115 and cooled, hardening to permanently retain an upper surface that matches the topology of the user's sole. The deformed and cooled insole template plate 110 forms the custom fitted shoe insole 140. The custom fitted insole 140 can then be inserted into an article of footwear, step 235, to be worn by the user.

[0044] Referring now to FIG. 7, in embodiments the shoe insole template plate 110 may include a plurality of layers. For example, the shoe insole template plate 110 may include one or more of a top layer 305, a comfort layer 310, a functional layer 315, and/or a base layer 320.

[0045] In embodiments, the top layer 305 is configured to be breathable and wear-resistant, with a non-slip top surface. The top layer 305 may include, e.g., polyester and/or any other suitable material or materials that provide these properties.

[0046] In embodiments, the comfort layer 310 is configured to be wear resistant, soft, and comfortable to the user. In particular, the comfort layer 310 is made of a material that absorbs shocks, such as rubber, ethylene-vinyl acetate (EVA), an elastomer, and/or any other suitable material or materials that provide these properties.

[0047] In embodiments, the functional layer 315 provides impact resistance. It may be configured to be environmentally friendly and may include recyclable thermoplastics that have a low and stable melting point. This layer may include, e.g., PETG (ethylene terephthalateco-1,4-cylclohexylenedimethylene terephthalate), and/or any other suitable material or materials that provide these properties. According to an embodiment, the functional layer 315 has a thickness of approximately 2 mm, although any suitable thickness may be used.

[0048] In embodiments, the base layer 320 may include, e.g., a nylon fabric and/or other similar material.

[0049] 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. 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.

[0050] 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 scope of the invention, which is determined by the following claims.