Method and apparatus for customizing insoles for footwear

Abstract

A customizable insole has a base layer, a foot engaging top layer and a resiliently deformable layer therebetween. The top layer and the resiliently deformable layer are matrix cut into a plurality of adjacent plugs, wherein the plugs are removably fixedly bound to a base layer or a substrate. To customize an insole one or more plugs are removed in a spot to relieve pressure or reduce pain.

Claims

1. A customizable insole comprising a base layer, a foot engaging top layer and a resiliently deformable layer therebetween, wherein the top layer and the resiliently deformable layer are matrix cut into a plurality of adjacent plugs, wherein said plugs are initially individually removably fixed to the base layer by a B-stage adhesive, which plugs become permanently fixed to the base layer after the adhesive achieves a secondary cure upon exposure to heat and/or humidity.

2. The insole according to claim 1, wherein all the plugs have the same size and shape.

3. The insole according to claim 1, wherein the plugs have different sizes and shapes.

4. The insole according to claim 1, wherein the plugs have different densities in selected areas.

5. The insole according to claim 1, wherein the plugs are hexagonal in shape.

6. The insole according to claim 5, wherein the hexagonal plugs are 0.5 to 2.0 cm on a side.

7. The insole according to claim 5, wherein the hexagonal plugs are 1.0 to 2.0 cm on a side.

8. The insole according to claim 5, wherein the hexagonal plugs are about 1.5 on a side.

9. A method making a customized insole for an individual comprising providing an insole having a plurality of removable plugs as claimed in claim 1, modifying the insole by selectively removing plugs from portions of the insole, and exposing the modified insole to heat and/or humidity to achieve a secondary cure, and permanently bond plugs not removed to the base layer.

10. The method according to claim 9, wherein all the plugs have the same size and shape.

11. The method according to claim 9, wherein the plugs have different sizes and shapes.

12. The method according to claim 9, wherein the plugs have different densities in selected areas.

13. The method according to claim 9, wherein the plugs are hexagonal in shape.

14. The method according to claim 13, wherein the hexagonal plugs are 0.5 to 2.0 cm on a side.

15. The method according to claim 13, wherein the hexagonal plugs are 1.0 to 2.0 cm on a side.

16. The method according to claim 13, wherein the hexagonal plugs are about 1.5 on a side.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features and advantages of the present invention will be seen from the following detailed description, taken in conjunction with the accompanying drawings, wherein like numerals like parts, and wherein:

(2) FIGS. 1 and 2 are top and bottom plan views of a customizable insole in accordance with the present invention; and

(3) FIG. 3 is a perspective view of a removable plug element of the insole of the present invention.

DETAILED DESCRIPTION

(4) Referring to FIGS. 1-3, the present invention comprises customizable insole 10 having a foot supporting surface 12 typically formed of a fabric. Alternatively, top layer 12 may be formed of a leather or synthetic material. Top layer 12 is fixed to an open or closed cell foam material 14, which in turn is fixed to a bottom layer 16 by an adhesive of sufficient strength under normal circumstances to maintain the integrity of the assembly, but having sufficient low tack so that individual plugs may be removed. In a preferred embodiment the adhesive comprises a low tack B-stage adhesive that allows selected geometric plugs to be removed, but which adhesive then achieves a secondary cure by exposure to heat and/or humidity accumulating in the footwear when the footwear is worn. Top layer 12 and foam layer 14 are matrix cut into geometric shapes from the top layer through the foam layer to form a plurality of plugs 18. However, the bottom layer 16 is uncut so as to maintain integrity of the insole 10. The geometric cuts may take a variety of shapes and may be the same or different sizes. In a preferred embodiment, the plugs 18 are formed in identical regular hexagonal shapes and sizes, typically 0.5-2.0 cm on a side, preferably 1.0-2.0 cm on a side, more preferably about 1.5 cm on a side.

(5) In order to customize an insole for a particular wearer, it is a simple matter to remove one or more plugs in a spot to relieve pressure or reduce pain. As an example a wearer may have a prominent 2.sup.nd metatarsal head causing pain and callus formation. The wearer or care provider would remove one or more hexagonal plugs under the second metatarsal to relieve pressure and reduce pain.

(6) The insole may be customized by a healthcare provider, or alternatively sold over-the-counter for customization by the consumer.

(7) Various changes may be made in the invention without departing from the spirit and scope thereof. For example, the insole may be packaged with plugs similar in hexagonal shapes as plugs 18, but having a reduced thickness so that selected plugs may be removed and replaced with reduced thickness plugs for further customization. The replacement plugs should have a pressure sensitive adhesive on one side so that the plugs may be fixed to the bottom layer 16. Still other changes may be possible without departing from the spirit and scope of the invention.