JP2024515116A - Shoes and inserts or layers for shoes - Google Patents

Abstract

A shoe insole may include a compressible soft material, a first fiberboard layer below the compressible soft material, a composite stiffener layer below the first fiberboard layer, the composite stiffener layer extending over 60% or less of the area of the insole, a stiff and flexible composite arch core layer below the composite stiffener layer, and a reinforcing layer. Shoes such as high heel shoes may include such an insole.

Description

The present invention relates generally to shoes and improved inner layers and/or inserts for shoes.

High heels are notoriously uncomfortable to wear. Over the last 100 years, there has been minimal improvement and innovation to the structural integrity of high heels. High heels do not take into account the anatomy of the human foot, much less the biomechanics.

Footwear such as those with heel heights of 2 cm or more generally have a shoe shape that includes multiple layers and regions: an upper and a sole assembly connected to the upper. The sole assembly may include multiple layers and regions. An "insert" for the shoe may include compressible materials and may be placed within the completed shoe. The midsole of the shoe may be directly incorporated into the shoe structure. The insert and midsole together may comprise the entire insole of the shoe. To account for the correct volume, the model of the shoe itself (sometimes called a last) takes into account all of the insole layers, as well as their dimensions and size, so that there is enough room for the volume of the foot present inside the shoe along with the additional volume from the addition of all the layers of the insole.

A shoe insole comprises a compressible soft material, a first fiberboard material layer below the compressible soft material, a rigid composite arch core stiffener layer below the first fiberboard layer, the composite arch core stiffener layer extending over 60% or less of the area of the insole, and a stiff and flexible composite layer (e.g., extending from heel to toe) below the composite stiffener layer, which may be a reinforcing layer. Shoes, such as high heeled shoes, may comprise such an insole. Embodiments of the present invention include new structures, processes, and manufacturing improvements for producing insoles or shoes with improved wearability and comfort.

Non-limiting examples of embodiments of the present disclosure are described below with reference to the drawings listed below. The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. The invention, however, both as to its organization and method of operation, together with its objects, features, and advantages, may best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings.

1 shows an exploded view of a shoe according to an embodiment of the present invention. 1 shows an insole or insert according to an embodiment of the present invention. 1 illustrates a portion of a midsole that flexes in accordance with propulsion and the natural walking pattern of the foot, according to an embodiment of the present invention. 1 illustrates a portion of a midsole including a composite arch pad and stiffener according to an embodiment of the present invention. 2 shows a flowchart of a method according to an embodiment of the present invention.

It will be understood that for simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn accurately or to scale. For example, dimensions of some of the elements may be exaggerated relative to other elements for clarity or several physical components may be included in one functional block or element. Reference numerals may be repeated among the figures to indicate corresponding or similar elements.

In the following detailed description, numerous specific details are set forth to provide a thorough understanding of the present invention. However, those skilled in the art will appreciate that the present invention may be practiced without these specific details. In some cases, well-known methods, procedures, components and modules have not been described in detail so as not to obscure the present invention. For purposes of clarity, descriptions of the same or similar features or elements may not be repeated.

An embodiment of the present invention may comprise an insole with varying stiffness across its length or surface, for example, with a arch stiffener extending over 60% or less of the area of the insole or midsole included above, below, or adjacent to a composite layer that may extend the entire length or a majority of the length of the insole. The insole or insert located under the upper may comprise a first flexible, shock absorbing, foot conforming and deformable, natural and/or synthetic polymer, closed or open cell, woven or nonwoven, composite or hybrid material layer, such as gel, silicone, foam, sponge, leather, felt, viscoelastic, softener, EPDM rubber, latex, wool, polyurethane (PU), elastomer, EVA (ethylene vinyl acetate), thermoplastic, TPU, thermoset, copolymer, polyamide, or other foamed deformable and/or viscoelastic material. These soft and/or compressible layers may include gel or foam. Such a layer may extend the length of the shoe from heel to toe and may or may not be paired with a further second layer beneath this first layer of woven and/or nonwoven natural or synthetic polymers, woven and/or nonwoven composite and/or hybrid materials (e.g., the same list of materials listed above).

Unlike high heel shoes of the prior art, shoes according to embodiments of the present invention can take into account the body's force pressure and natural gait. Insoles according to some embodiments may have a strategic design with additional raised/bulging shock absorbing material placed, for example, at the heel, arch, and directly under the arch towards the center of the shoe, with or without additional material under the phalanges that provide additional comfort and help relieve some of the static and dynamic pressure on the foot, pressure natural gravity.

The midsole (including, for example, the exemplary layer 30 of FIG. 1) according to some embodiments may be made of materials such as woven and nonwoven materials that flex with the natural gait of the foot and are used collectively, or individually made of woven and nonwoven or synthetic composite and/or hybrid materials, such as manmade fibers such as carbon, glass, Kevlar, rubber grades, and natural and/or synthetic fiber composites with or without laminates, thermoplastics, polylactic acid (PLA), natural fibers, plastics, thermosets, thermoplastics, elastomeric or plastic polymer resins, used in combination or individually, and may be made of a first stiff and flexible material with a shape that extends from the heel to the toe. This first material may help to reduce overpronation and may resist torque. The midsole may be placed under a sockliner/insole that includes several layers. The midsole may extend from the heel to the toe and may include, for example, a foot-length composite layer with stiffeners.

The midsole stiffener or arch stiffener may be attached or adhered adjacent to the midsole and made from a second rigid material that may support the stiffness of the midsole, the second rigid material being less flexible than the composite laminate arch and toe reinforcement layer (which may be, for example, layer 30 in FIG. 1), and may extend from the heel to the bottom of the arch and may extend the entire length, or substantially the entire length, of the shoe. The midsole stiffener (e.g., layer 25 in FIG. 1) may be, for example, thermoplastics, polylactic acid (PLA), natural and/or synthetic fibers, plastics, carbon thermosets, thermoplastics, elastomers, plastic polymer resins, arch boards, cardboard, rubber grades, fiberboard, MDF, woven or non-woven insole boards, wood, wood pulp, polyester fibers, biomaterials, Straubel insole boards, leather, EVA, nylon, paper, laminated or non-laminated synthetic or natural materials, open or closed cell materials, fiber reinforced resin laminates, leather boards, particle pressboards, fiber reinforced composites with or without laminates of cellulose or other natural or synthetic composites. The midsole stiffener can prevent the shank (e.g., layer 30) from moving and maintain the shape of the harness.

The stiffeners (e.g., layer 25 in FIG. 1) and composite arch core layers (e.g., layer 30 in FIG. 1) may be sandwiched or surrounded by layers of arch plate members, fiberboard materials such as cardboard (e.g., layers 20 and 35 in FIG. 1), woven or nonwoven materials, cellulose, insole board, nylon, laminated or non-laminated natural or synthetic materials, fiber reinforced resin laminates and other advanced composite materials, paper, wood, biomaterials, polyester fiber, open or closed cell materials, nonwoven or woven insole board, polyester, wool, Straubel insole board, EVA, rubber grades, copolymers, PMMA, PESU, PET, PBT, ABS, PEEK, PEI, PCT, or thermoplastics, wood pulp, paper, leather board, leather, particle pressboard, MDF, fabric, felt, scrim, nylon, other natural and composite materials, and the like. These sandwich layers may be wider than the internal stiffener and composite layers. The "inner" layer(s) (e.g., layers 25 and 30 in FIG. 1) may be sandwiched between the arch plate members, fiberboard material such as cardboard, bamboo, cork, MDF, cellulose, or other materials, and an additional arch core stiffener may be used, which may be made of plastic, bamboo, felt, paper, fabric, scrim, wood, cellulose, leather board, cork, polyester, wool, particle pressboard, leather board, nylon, insole board, laminated or non-laminated, natural or synthetic compound materials, open or closed cell materials, woven or non-woven fabrics, or other fiberboard materials, composite materials, thermoset resins, etc. The stiffener layer and arch core layer may be sandwiched between the arch plate members, fiberboard material such as cardboard, MDF, or cellulose. The layer of fiberboard material may be, for example, ¼ inch, or another dimension wider than the arch core and arch core stiffener layer. The periphery of the fiberboard or arch plate member layers may, for example, be glued, tacked, bonded, pressure or heat applied, sewn, stitched, stapled, fastened, laced, screwed, nailed, formed, molded, or nailed together to encase the composite layer. The nails, tacks, staples that may be used in the manufacture of the shoe product may penetrate the fiberboard material, the cellulose, the arch plate member, or may not penetrate the composite, for example, by being placed at the edge of the "sandwich construction". The stiffener may extend from the heel to the arch to provide support for the arch, may maintain the longitudinal arch, may define the shape of the shoe, may maintain alignment of the forefoot and heel through all stresses during the life of the shoe, may maintain the integrity of the shape of the shoe, and may be used as additional reinforcement for the foot. The composite and stiffening layers can provide additional shock absorption and strength to the entire shoe, and also reduce the overall weight of the shoe, making it lighter than conventional shoes and taking into account the natural gait and biomechanics of the wearer. The midsole may be attached or wrapped between, for example, the arch plate member, cardboard, fiberboard, cellulose, particle pressboard, leather board, leather, and other fiberboard materials, and located under the insole. This material may provide additional support to the shoe, may absorb moisture, may be durable enough to withstand friction during wear, may be flexible, may not harden and crack during wear or with moisture or sweat, may be uniform in thickness, may be lightweight, may be resistant to shrinkage or stretching, may be able to hold tacks, glue, nails, screws, staples, or stitches, may be dimensionally stable and may not change during manufacture or wear, and may be used for purposes including the layers of the midsole and for manufacturing purposes.

The two intermediate layers on the inside of the "sandwich structure" can include a rigid arch core stiffener, which can provide a rigid support that runs from the heel to the arch to provide arch support (e.g. layer 25 in FIG. 1), defines the shape of the shoe, maintains the integrity of the shoe, and is attached to a rigid and flexible material that runs from the heel to the toe (e.g. layer 30, e.g. arch core). These layers provide additional shock absorption and strength to the entire shoe, and also reduce the overall weight of the shoe, making it lighter than conventional shoes and taking into account the wearer's natural gait and biomechanics. While prior art shoes use metal or plastic, the layers in the present embodiment may include woven and nonwoven materials used collectively or individually, made from natural and/or synthetic composites and/or hybrid materials, such as fiber-reinforced resin laminates, man-made fibers such as carbon, composite laminates, thermoplastics, polylactic acid (PLA), natural fibers, plastics, thermosets, thermoplastics, elastomeric or plastic polymer resins, or fiber-reinforced composite laminates. These two intermediate layers may be sandwiched between fiberboard materials, such as arch plates, cardboard, cellulose, leather, particle pressboard, which are disposed above and below the two intermediate layers. This material is used for the purposes of providing additional shock absorption, including the intermediate layers of the midsole, and for manufacturing purposes. Layer 20 may be thinner than layer 35, may be the same or different in material, may be more flexible than layer 35, may provide shape retention, may absorb moisture, may be resistant to hardening or cracking due to moisture or sweat, and may be resistant to shrinkage or stretching due to moisture and heat. Layer 35 (e.g., fiberboard or arch plate member) may be harder and thicker than layer 20, may be able to withstand the significant loads generated by the lower back/arch and heel of the shoe, may be durable enough to withstand wear friction, may be lightweight, may have the ability to hold tacks, adhesives, screws, nails, staples, stitches, may have improved nail holding strength, bending strength (is dimensionally stable and does not change during wear or manufacturing process), may be flexible, and may have shape retention.

Embodiments of the shoe described herein may allow flexibility in the sagittal plane while providing stiffness in the frontal and transverse planes to ensure stability throughout the gait cycle. This stiffness may be a particular need for high heeled shoes. This increased stability throughout the gait cycle may allow for a more fluid and pain-free gait. These properties may be achieved through a combination of material selection and design of the material structure of the composite, including but not limited to the amount, orientation, length, and direction of the fibers in each layer of the laminate and collectively in the layers.

Embodiments of the invention may include compressible materials, e.g., a custom foot-conforming composite or hybrid material such as a gel and/or foam deformable insole (which may be used collectively or individually in one or more layers, e.g., layers 10 and 15 of FIG. 1 ) with a biomechanical supportive shape inspired by orthotics that help stabilize and support the foot, reduce stress on the foot, ankle, knee, improve stability, lower back, have shock absorption to reduce heel and forefoot impact with each step, provide comfort and support, exceptional ability to resist change, excellent pressure distribution, high elasticity to retain shape after each step and retain shape over time, provide thermoregulated cooling properties that give an optimal temperature to keep the foot cool and minimize heat generated in the foot that would cause friction and cause friction to cause pain, provide ergonomic support and improved breathability. The insole or insert may include, for example, some or all of the following designs: full length footbed and full foot insole with or without metpad that can reduce pressure on the ball of the foot, thereby reducing pressure on the metatarsals and preventing the foot from slipping forward in the shoe; flexible arch support may be incorporated into the shoe to allow for maximum comfort and form a foot shape that keeps the foot secure in the shoe while walking and also prevents pronation; a cobra cut design in the heel can provide additional cushioning to the heel, reduce pressure on the plantar fascia, and hold the foot from moving too much in the shoe; a footbed and/or toe bar can reduce pressure on the phalanges/toes and prevent hammertoes from forming.

In some embodiments of the present invention, the toe box of the shoe can be made deeper (e.g., wider) to cushion and relieve pressure on the phalanges (e.g., toes) and reduce the aggravation and progression of hallux valgus deformity. The outsole (e.g., layer 40 of FIG. 1) in some embodiments can be composite, synthetic or natural materials, or hybrid materials (e.g., fiber-reinforced resin laminate, leather, polyurethane (PU), ethylene vinyl acetate (EVA), plastic, ASA, PMMA, PEEK, TPU, EDPM rubber, biomaterials, thermoplastics, copolymers, bioplastics, cork, latex, thermoplastic rubber (TRP), polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS), natural or synthetic rubber, custom polyurethane (BPU)), or other materials to reduce midsole wear, provide grip and prevent the wearer from slipping, provide shoe reinforcement in direct contact with the ground, improve the durability of the shoe, and can be flexible, waterproof, or provide additional shock absorption. A heel tip or protector may be used to protect the shoe and the wearer when striking the ground. The heel protector may be a flat or corrugated material and may be molded to fit the exact size and shape of the bottom of the heel tip. The heel may be attached to the bottom of the outer sole. The heel tip may be made of composite, or hybrid, or natural materials (e.g., rubber, TPU, plastic, TPU, nylon, etc.). The heel in some embodiments may be, for example, 2.5 cm or more, located under the heel of the foot and in contact with the ground. A metal rod may provide safety and may be placed along the wearer's ankle joint, centered under the heel bone. The heel counter may be used to support the foot and keep the heel counter rigid with or without additional padding to help minimize the deformation of the Haglund, also known as the "pump bump," and keep it in the shoe.

In some embodiments, the shoes are lighter and more shock absorbing than prior art high heel shoes.

FIG. 1 shows an exploded view of a shoe including an insert or insole and a midsole according to some embodiments of the present invention. Although FIG. 1 shows a high heeled shoe, other types of shoes may be used with embodiments of the present invention. Other layers or arrangements of layers may be used. With reference to FIG. 1, the shoe insert may include an insole (e.g., layers 5-20) and a midsole (e.g., layers 25-35). The shoe may include an upper 1 that covers the foot or contains or holds the foot within the shoe, as is known in the art. The upper 1 may have a slightly wider toe box and a larger overall volume than other comparable shoes to better fit the majority of a person's foot. The insole 5 may be placed over the midsole and insole, may be in direct contact with the foot inserted into the shoe, and may be made with or without antibacterial, sweat wicking, and/or anti-odor properties. The insole 5 may be a thin piece of material that sits on top of the insole or midsole 3. The insole 5 can protect the wearer's foot from any internal structure and medial seams of the shoe, and can be attached directly to the insole, for example, a gel or foam material that includes or is used with additional soft hybrid or composite materials such as foam or gel.

Layer 10 may comprise a deformable material that conforms to the foot, e.g., a soft deformable material, or a compressible soft material, including gel, foam, silicone, or an open or closed cell, or open cell, sponge-like top. Layer 10 may provide more shock absorption of gravity, reduce muscle fatigue, conform to the wearer's foot, provide pressure distribution and relief, reduce muscle fatigue allowing the wearer to stand, walk, or dance longer and more comfortably, provide a full-length footbed from heel to metatarsal, maintain stability and dimensions regardless of temperature/pressure/humidity conditions, provide thermo-regulated cooling properties that give optimal temperature, provide enhanced breathability, provide ergonomic support, return to original shape when pressure is removed, and absorb energy. Various layers may be omitted, e.g., layer 10 may be used with or without layer 15, and additional layers, materials, or structures may be included. Layers 5 and 10 may be attached (e.g., attached, cemented, fused, heat bonded, bonded, formed, pressurized, heated, fastened, molded, or glued together). Layers 10 and 15 may be attached (e.g., attached, fused, molded, bonded, heat bonded, cemented, fastened, formed, pressurized, heated, glued, or glued together).

An insole insert 15 of a deformable compressible layer (e.g., gel or foam) that conforms to the foot may be placed under layer 10 (relative to the foot above and the bottom of the shoe below). Layers 10 and 15 may be compressible and may be made of the same or different materials, in one embodiment, layer 10 is gel and layer 15 is foam. In one embodiment, different materials may be used for layers 10 and 15 to increase flexibility. Using a gel for one layer and a softer foam for the gel for the other layer may be too stiff in some cases. In other embodiments, different foams and/or gels that behave differently may be used for each of the two layers to make a more well-balanced shoe. Layers 10 and 15 may be considered part of the insole or insert, or may be considered part of the insole. In some embodiments, layers 10 and 15 may be combined into one layer.

A fiberboard material (e.g., cellulose or cardboard) layer 20 disposed under layers 5 and 10 can provide additional cushioning, can assist in manufacturing/production, can provide protection for the composite materials or layers (e.g., layers 25 and 30), and can provide additional reinforcement for the midsole. A arch core layer (e.g., layer 30) may be disposed between fiberboard material layer 20 and a stiffener layer (e.g., layer 25). Layers 20 and 35 may be used in place of or in addition to fiberboard, arch plate members, natural or synthetic compositions, woven or nonwoven, laminate or non-laminated, scrim, fabric, felt, cork, leather, paper, insole board, cardboard, cellulose, leather board/leather, particle pressboard, MDF, or natural or synthetic woven or nonwoven open or closed cell materials. Layers 20, 35, and 40 allow for easy manufacturing and may be sandwiched around layers 25 and 30, with layers 20, 25, 30, and 35 all forming a "sandwich structure." Layer 40 may form the outer layer of this sandwich structure. Layer 35 protects the midsole from friction and wear. Layers 35 and 40 allow for good handling and may allow easy repairs for the wearer, for example by a shoemaker, if the outer sole needs to be replaced due to wear.

The arch core stiffener or stiffener layer 25 may be a composite, high strength composite, or hybrid material (e.g., composite laminate, or hybrid, or thermoplastic, or thermoset, or plastic). In some embodiments, the stiffener layer 25 may be a fiberboard layer, MDF, or cardboard or leather board, leather or particle pressboard, or arch plate member that is typically thicker than the thermoplastic version of layer 25. The arch core stiffener 25 may be located under the fiberboard material layer 20, prevent the shoe from collapsing, provide maximum support to the wearer while in the shoe, may be lightweight (when compared to a metal strip), and in some embodiments does not stretch. The arch core stiffener 25 may extend over 60% or less of the area of the insole or midsole 3, or over 60% or less of the area of the arch core layer (e.g., layer 30), in some embodiments. In other embodiments, the arch core stiffener 25 may extend only over other areas, such as substantially 60%, substantially 55%, substantially 65%, or other portions of the area of the insole or midsole 3 or arch core layer. Additionally, other layers, such as composite or gel layers, may not extend the entire length of the shoe from the heel to the tip of the shoe, for example, one or more of these layers may extend from the heel to the toe area. Typically, fiberboard layers 20 and 35 are wider, longer, and span a larger area than layers 35 and 30.

Stiffener layer 25 may be attached (e.g., attached, fused, heat bonded, bonded, formed, molded, fastened, pressurized, heated, or glued) directly to composite or arch core layer 30 as if they were one piece, or layers 25 and 30 may be attached as one piece, with layer 25 located above or below composite layer 30 (e.g., above when in a shoe, e.g., layer 25 may be closer to the foot than layer 30). If stiffener 25 is a fiberboard material or cellulose, it may not be attached to layer 30. Stiffener layer 25 may ensure that the composite of layer 30 is less flexible and stiffer and does not move from the heel to the arch (compared to portions of layer 30 that are not coextensive or bonded with stiffener 25). Prior art high heel shoes, which do not incorporate a molded-in midsole, may use metal for the sole, which is attached to a shoe last and pressed into the appropriate shape with a hammer or machine.

Instead of a metallic arch core or a complete metallic arch core repair as in prior art shoes, embodiments may use an additional piece of arch plate material, fiberboard, cellulose, thermoset, copolymer, polyamide, plastic, or thermoplastic in layer 25 that may be attached (e.g., glued, fastened, formed, molded, or bonded) onto the composite arch core 30 as an arch core stiffener, for example, regarding the arch to heel area.

The arch and toe reinforcement 30 may be a stiff and flexible arch core layer located under the arch core stiffener 25 and may be formed from a bendable composite laminate (e.g., carbon fiber) that can provide underfoot support, protect the shoe wearer from feeling hard objects on the ground, improve stability, provide additional shock absorption, improve foot flexibility to reduce fatigue, prevent the foot from rolling in the wrong direction, and improve foot protection. The composite layer 30 may be stiff and flexible in that a portion of it can bend up instead of down, as shown, for example, in FIG. 3. The arch core layer 30 is a reinforcing layer, the part that gives the shoe its shape and also the part that keeps the shoe sturdy. The arch and toe reinforcement 30 may extend from the heel area of the insole to the toe area of the insole. The arch pad and underfoot reinforcement can protect the wearer from feeling hard objects on the ground, can improve stability, can provide additional shock absorption, can increase foot flexibility to reduce fatigue, can improve foot protection, can be lightweight (compared to metal in the prior art), can allow for more energy when stepping out, can optimize and enhance natural foot movement according to natural gait patterns, can save energy, can reduce the size and volume of the midsole to create a lightweight shoe that further reduces fatigue, and can be non-stretchy.

The arch core and toe reinforcement layer 30 and the arch plate member layer 35 can bend in only one direction of motion, upward, dorsiflexion and plantarflexion (sagittal plane), with the propulsive forces following the natural gait of the foot, e.g., this flexion may be unidirectional, typically this layer cannot or should not move/flex in the opposite direction (downward) as the foot does not move in the transverse plane or anteriorly. This acts to protect the foot and minimizes excessive flexion to reduce fatigue. Frequent wearing of high heels can keep the toes in an overextended position, which the midsole according to one embodiment can accommodate. It may not be desirable to move from the heel to the arch area, and therefore in some embodiments the layer 30 is held in place in the area from the heel area 3 to the arch area 23, e.g., 60% or less of the range of layer 25. As a person walks, the force pressure and ground reaction forces are absorbed throughout the foot in a cyclical motion.

The foot may act as a shock absorber in three different ways. The first is pronation, the movement of the foot during the gait cycle, where the foot rolls inward to eliminate shock. When a person runs or jumps, the foot strikes the ground primarily with the outer edge of the foot facing inward with the ankle facing inward. As a person's weight is distributed across the foot, the foot and ankle turn inward and the arch flattens. The second way the foot absorbs shock is by flattening the transverse arch. There are five metatarsal bones in the foot. The transverse arch crosses these metatarsals. When walking, the foot rolls inward across the ball of the foot, from the outside of the foot to the big toe.

The foot makes contact with the ground at the fifth metatarsal. Because the fifth metatarsal is very flexible, it provides a gentle impact. The transverse arch begins to flatten, spreading the ball of the foot. The third way the foot absorbs shock is by spreading the toes. As weight is placed on the foot, the metatarsals spread and the toes spread apart, providing a stable base for the body. In addition, this spreading of the toes increases the area of contact with the ground, allowing the nerve endings in the foot to receive and transmit information from the ground.

Having a bendable layer that follows the gait allows for increased support of the foot's propulsion (toe area). The unidirectional layer 30 may be designed to provide flexibility when the wearer's foot strikes the ground, a toe-off that allows for maximum propulsion, and an economical, ergonomically guided stride. Such features are not used in prior art high heeled shoes. The toe area/footbed 33 may be flexible or more flexible than the area between the heel and arch area.

Layers 20 and 35 may be arch plate members, MDF or fiberboard materials such as cardboard or cellulose. Layers 20 and 35 may be wrapped together around composite laminate layer 30 and stiffener layer 25, and possibly other layers. The edges or sides of layers 20 and 35 may extend beyond the layers they wrap, surround, or sandwich (e.g., beyond the width of the arch core layer and beyond the width of the stiffener layer). The edges or sides of layers 20 and 35 may be scraped or torn and bonded together (e.g., attached, fused, heat bonded, bonded, cemented, pressurized, heated, formed, molded, stapled, sewn, screwed, stitched, strapped, nailed, fastened, tacked, or glued) to attach to each other at the edges or periphery to seal at least the composite and stiffener layers. In one embodiment, the composite and stiffener layers are connected or attached to each other but not to the encapsulation layers 20 and 35. The composite and stiffener layers may be disposed inside the sandwich of fiberboard layers, and the fiberboard layers may be attached to each other only at their peripheries where they extend beyond the composite and stiffener layers. Layers 10, 15 and/or 20 may be attached (e.g., fused, molded, attached, glued, heat bonded, cemented, heated, pressured, formed, bonded, fastened). Layers 25 and 30 may be constrained or sandwiched between layers 20 and 35, or may be attached directly to layers 25 and 35.

The outer sole 40 can provide reinforcement and additional shock absorption to the shoe when it strikes the ground. In one embodiment, the heel 45 is 2.5 cm or greater and can be located under the wearer's heel and can touch the ground. The heel 45 can be centered under the heel bone and positioned in line with the wearer's ankle so that the rear of the shoe can touch the ground.

The insole or midsole 3 may include layers 5-35 and may provide a significant reduction in mass compared to metal, steel or brass components, ensuring safe, stable and maximum support for the wearer.

The arch core stiffener or stiffener layer 25 can provide and enhance the stiffness and rigidity of a portion of the midsole, for example, in one example, 60% or less of the composite arch core layer 30 may be reinforced by the layer 25, for example, from the arch to the heel, from the heel to the metatarsal, or from the rear to the middle portion of the midsole. The stiffener layer 25 may extend over other portions of the composite layer, for example, 50% or 60% of the layer. The material of the stiffener 25 may be any suitable material that may work with the composite material, such as thermoplastics, plastics, thermosets, rubber grades, copolymers, fiberboard, arch plate members, cardboard, or cellulose. Typically, the stiffener 25 is made from a second material that is less flexible and rigid than the arch core and toe reinforcement 30. In contrast to flat shoes, the manufacture of shoes with heels is different because more attention must be paid to the strength of the arch of the foot (measured, for example, in MPa). Therefore, the arch pad and arch pad stiffener of the present invention can improve on shoes of the prior art.

2 shows an insole according to an embodiment of the invention. In FIG. 2, insole layer 100 (which may correspond to layer 10 in FIG. 1) may include a circular region 105 at the bottom of FIG. 2, e.g., on the back side of the layer, which may be, for example, gel. Triangular region 110 with a raised region in the middle may be, for example, gel. A raised curved region 115 near or above the arch may be, for example, gel, as may smaller triangular region 117, and a horizontal "foot" shaped region 120 at the top of the figure near the front of the layer. The entire gel insole 100 may be encased in film. Other shapes or locations of regions 105-120 may be used, and materials for cushioning or padding other than gel may be used.

3 shows a portion of a composite layer that bends under propulsive forces and in line with the natural gait pattern of the foot, according to an embodiment of the present invention. In FIG. 3, the front of the composite layer is bent at the front by the composite layer arch and toe reinforcement layer (e.g., layer 30 in FIG. 1) and bends upward (e.g., toward the foot and away from the ground), while in the middle to the back, the stiffener (e.g., layer 25 in FIG. 1) prevents the composite layer from bending in any direction. The portion without stiffener (e.g., under the arch) bends upward to follow the natural gait pattern of the foot. While this portion bends upward, it is undesirable for the composite layer to bend in other directions. To better support the foot, layer 30 can bend upward. In some embodiments, it is undesirable for the composite layer to bend in other directions.

At about age 2, a person's foot is still flexible and soft, but the muscles and arch begin to mature. As we age, the foot begins to look narrower and more developed. As we continue to grow, the soft tissue becomes less adaptive and requires support and stability to support the arch and relieve pressure. The ankle joint moves the foot up and down (plantarflexion and dorsiflexion). The toes also move up and down. The middle of the foot does not move. The reason layer 30 bends upwards is because it supports the toes to dorsiflex and not bend down. Bending over in high heels can cause hammer toes, where the toes are forced together. Layer 30 prevents this from happening in high heeled shoes, unlike prior art shoes. An important function of the foot is the propulsion of body weight during the stance phase. This function is made possible by the locking and unlocking of the transverse tarsal joint (midfoot). During heel strike, the foot needs flexibility to adapt to the surface, and the transverse tarsal joint is unlocked to provide this flexibility. Later in the gait cycle, the foot must then act as a rigid lever to propel the body mass forward, which is made possible by the fixation of the transverse tarsal joint. During pronation/supination, the axes of the talonavicular and calcaneocuboid (midfoot) joints are parallel to each other, so they move independently, facilitating the release of the transverse tarsal joint. During supination/inversion, the axes cross each other, fixing the metatarsophalangeal joint and making it less mobile.

4 shows a portion of a midsole according to an embodiment of the invention. In FIG. 4, the arch core stiffener (e.g., layer 25 in FIG. 1) is shown as a region 400 extending from the heel to the arch, and the arch core and toe reinforcement layer (e.g., layer 30 in FIG. 1) are visible and unconcealed in the heel-to-toe portion 410 (where the arch core and toe reinforcement layer are hidden by the portion over which the stiffener layer is disposed). The arch core stiffener may be a thermoset, thermoplastic, copolymer, or arch plate member, cellulose or cardboard, MDF, or other fiberboard material.

A layer including gel, such as layer 10 or the layer shown in FIG. 2, may include a gel having a shore or durometer level of 55-65 shore or about 55 shore, and in other embodiments, the shore range may be 25-65. A foam or gel having a lower shore level, such as 5-15 shore, may be used under a compatible material, such as a foam or gel having 55-65 shore. One way to achieve the desired softness in some embodiments includes using a material having a 55 shore and combining it with a material in certain areas having a lower shore, such as 5-15 shore, or a gel can be utilized without combination in the 25-50 shore range. One embodiment may use a compressible material, such as a foam or gel, of shore 55, such as an additional foam having a durometer shore scale of 15, to prevent the film from breaking. The embodiment can use a gel insole with a durometer Shore measurement of 55-65 at the base and 25-50 at the ridges or pads (e.g., areas 105, 110, 115, and 120) or lower, e.g., at or around 10 Shore.

From a podiatric point of view, prior art high heel shoes generally perform poorly. Prior art high heel shoes may include the following problems, which embodiments of the present invention can alleviate:
■ Pressure distribution may not be taken into account (for example, most of the body weight is on the forefoot).
■They may not be designed to conform to the shape of your foot and do not provide adequate arch support.
■Even low-profile orthotics can be very difficult to wear with high heels because the arch lift keeps the foot out of the shoe. They also tend to slip out of the shoe.
■ May not have enough padding for comfort.
■ With a distributed heel rod, if the heel of the shoe is located behind the heel bone instead of in the middle, body mass is pushed forward, causing early pain in the ball of the foot. Furthermore, the upper body may tend to lean forward and the knees are kept in a (near) constant bent position, exacerbating muscle fatigue, especially in the quadriceps. The ability to rest with weight on the heel may be greatly reduced. This may affect gait, forcing the wearer to walk with a foot-first strike rather than a natural heel-toe motion.
■ Prior art shoes can exacerbate the symptoms and progression of hallux valgus deformity due to a tight fit/narrow toe box that does not accommodate the normal anatomy of the forefoot. The heel puts pressure on the big toe, pushing it towards the second toe, causing further aggravation.
■ Metatarsalgia - When most of your body weight (pressure) is placed on the ball of your foot, the fat pad in the forefoot becomes overused and thins out.
■ Neuromas – Tight-fitting/narrow shoes can cause inflammation of the nerves in the foot by putting pressure on the ball of the foot and squeezing the metatarsal heads together.
Hammer toe – The height of the heel forces the toes to bend as they tip forward. Over time, the bent toes may no longer straighten naturally. This can also be due to a tight, narrow toe box with not enough room in the shoe.
■ Ankle sprains - Such prior art shoes may not provide sufficient support and the insoles may be very slippery, making the wearer susceptible to twisting their ankle.
■ Ingrown toenail – High heels can cause the toes to be squeezed together and the big toe to dig into the skin, resulting in an ingrown toenail.
Back pain – Shoes can cause the pelvis to tilt forward, which can strain the hip and thigh flexors. This can also cause the body weight to be pushed forward, which can increase the curvature or arch of the back (for example, this can change posture).
Haglund's deformity, also known as "Pump Bump" - The rigid back of a pump-style shoe can create pressure that exacerbates the enlargement when walking.

In some embodiments, the shoe, insert or high heel shoe according to the present invention may be:
■ Use a deformable compressible insole that conforms to the foot to absorb shock and reduce the impact on the heel, arch and forefoot with each step. This can provide comfort and support, good ability to withstand changes (e.g., cushioning), and good pressure distribution. High elasticity is used to help retain its shape after each step and allows it to retain its shape over time (e.g., dimensional stability).
■ Includes a "met pad," for example the circular area 3 near the arch of the foot in Figure 2, which can take weight off the ball of the foot, relieving pressure on the metatarsals and preventing the foot from slipping forward in the shoe.
■ Including a flexible arch support near area 115 and incorporating it into a shoe that molds to the shape of the foot allows for maximum comfort, keeps the foot stable within the shoe throughout the entire stride, and prevents pronation.
■ Including a cobra cut near the circular area 105 to provide cushioning to the heel and relieve pressure on the plantar fascia. The cobra cut may be in the area behind the heel (e.g. starting on the left side), wraps around the rear of the heel, and extends straight down towards the arch (on the right side).
■ Including a toe bar and padding and additional cushioning under the toes near areas 110 and 117 to provide support to the flanges and metatarsals of the foot during static and dynamic movements.
■ Includes a small heel cup (e.g., area 105) with an additional heel bump in the center of the heel (e.g., a raised bump in the center of the heel area 105) to assist in moving the foot forward in the shoe and provide additional padding.
■ The heel placement allows for a centralized heel rod, which is important for comfort and protection.

The embodiments may include custom shoe lasts that may be made to better fit the actual foot anatomy of the modern wearer by widening the toe box, varying the height, shape, upper part, pitch and structure, making it longer, providing ample access to movement in all directions. The embodiments may use updated shoe lasts to fit the internal components of the shoe embodiment, updated to fit the actual foot size and scale of the modern wearer (e.g., women, men, non-binary gender people), and have sufficient volume, size and appropriate shape to fit these factors while maintaining aesthetic integrity. Before the shoe can go into production, a shoe last is produced that must be accurate, mimicking the shape of the foot and giving the shoe both shape and aesthetics. For example, many factors may be considered to better fit the modern person's foot, such as how the foot rotates when walking, heel height, toe box depth or width specifications, and the entire shoe, as well as the internal volume and internal insole/midsole layer (e.g., that of FIG. 1), and aesthetic design may also be considered. Later in the design process, a last can be placed inside the shoe so that it can be molded or formed around the shoe, and used again when the shoe is nearly complete to ensure that the end fit matches the design and aesthetics.

Figure 5 shows a flow chart of a method according to an embodiment of the present invention. The operations of Figure 5 may be used to manufacture components such as those shown in Figures 1-4, but may also be used with other shoes and inserts.

With reference to FIG. 5, in operation 500, a first compressible gel layer (e.g., layer 10 in FIG. 1) may be attached (e.g., adhered, glued, molded, formed, fastened, or bonded) to an insole layer (e.g., layer 5, layer 10 underlying layer 5 when inserted into an upright shoe) and, if present, a second compressible layer (e.g., layer 15 underlying layer 10). Prior to attachment in operation 500, the first compressible layer may be cut, formed, or molded into the required shape associated with the second compressible layer, and the second compressible layer may be cut into the required shape associated with the first fiberboard layer. The order of operations in FIG. 5 may be different. For example, attachment of the first compressible layer to the second compressible layer may occur toward the end of the process.

In operation 505, if present, the second compressible layer (e.g., layer 15) may be attached to the first compressible layer (typically located above the second compressible layer) and the first fiberboard layer (e.g., layer 20, which may be below layer 15). Attachment of the first compressible layer to the second compressible layer may occur toward the end of the process.

In operation 510, the fiberboard layers (e.g., layers 20 and 35) may be cut or formed to be wider than the stiffener layers (e.g., layer 25) and the composite layers (e.g., layer 30).

In operation 515, the stiffener layers (e.g., layer 25) and composite layers (e.g., layer 30) may be cut narrower than the fiberboard layers and may use a more complicated process than prior art shoes.

In operation 520, the stiffener and composite layers may be provided with strategic holes or perforations pre-placed in different areas, e.g., before being placed in the sandwich structure, to prevent screws, nails, staples, needles, tacks from penetrating these materials. The surrounding fiberboard or cardboard layers may be wider than the composite layers, and/or the stiffener and composite layers may have holes pre-made in them to prevent screws, staples, needles, tacks, or nails from penetrating the inner sandwich structure materials and creating holes that may cause the screws, staples, needles, or nails to crack the laminae, especially with wear and increased time. Holes, perforations, or openings may be cut or formed in one or more of the stiffener and composite layers prior to placing each fiberboard layer to surround the stiffener and composite layer combination.

In operation 525, the stiffener layer may be attached (e.g., attached, glued, fastened, bonded, fused, heated, pressurized, molded, or formed) to the composite layer.

In operation 530, depending on the heel height and design, possibly using a more complicated process than in prior art shoes, the stiffener layer (e.g., layer 25) and the composite layer (e.g., layer 30) may be molded, and or formed, and shaped to the exact shape of the last. Layers 15, 20, 35, and 40 may also be molded and/or formed to the exact shape of the last. The layers may be molded and/or formed to the last separately rather than together, or as part of the same operation.

In operation 535, each fiberboard layer may be positioned such that the combination of the two fiberboard layers surrounds the combination of the stiffener and composite layers. For example, fiberboard layers 20 and 35 may be positioned to sandwich or surround the intermediate stiffener and composite layers and may be attached (e.g., attached, glued, nailed, stapled, sewn, sewn, tacked, screwed, fastened, bonded, molded, formed, fused) about their periphery (typically layers 20 and 35 are attached (e.g., nailed, fused, stapled, tacked, attached) to one another, and this connection between layers 20 and 35 does not connect to the inner layers of the stiffener and composite). The fiberboard layers may be glued to the stiffener layers. This may be done, for example, to prevent nails or machines used during the manufacturing process from penetrating the composite and stiffener layers.

In operation 540, an upper (e.g., Upper 1) may be attached (e.g., attached, sewn, stitched, nailed, stapled, glued, bonded, screwed, laced, tacked, fused, or molded, formed, fastened) around a last (which may be used to construct an insole and midsole), over or under a compressible insole, and/or over or under a midsole, and/or over or under layer 35. This layer may be scraped, torn, or sanded at the edges to keep the layer uniform.

In operation 545, the outer sole layer 40 may be attached (e.g., adhered, glued, molded, formed, stitched, nailed, sewn or bonded, formed, molded, tacked, stapled, strapped, screwed, fused, fastened) to the second fiberboard material layer (e.g., layer 35).

In operation 550, the heel 45 may be attached (e.g., screwed, glued, attached, nailed, sewn, stitched, bonded, molded, formed, fused, fastened, laced, welted, strobeled, stapled) to the shoe, e.g., layers 20-40, or may otherwise be connected or may be connected only to the outsole (e.g., layer 40).

In operation 555, the insole layer 5 and the compressible layer may be inserted into the shoe before or after the upper 1 is attached. The compressible layers (e.g., 10-15) may be inserted before or after the upper 1 is attached. In some embodiments, all of the soft insole layers are inserted into the shoe after the heel is attached. For example, the insole material may be attached first and the second compressible layer may not be molded or formed with the first fiberboard material, and the insole/insert may not be attached to the first fiberboard material until after or before the heel is attached. In some embodiments, the insole and first compressible layer are inserted before or after the heel is attached, for example, only the insole and first compressible layer are attached and not the second compressible (e.g., second compressible layer 15) layer is attached until after the heel is attached.

Other operations or series of operations may be used. In the description and claims of this application, the verbs "comprise", "include", and "have", as well as their conjugations, are used to indicate that the object(s) of the verb are not necessarily a complete list of components, elements, or parts of the subject(s) of the verb. Unless otherwise indicated, adjectives such as "substantially" and "about" modifying a condition or relationship characteristic of a feature(s) of an embodiment of the present disclosure are understood to mean that the condition or characteristic is defined within the permissible limits of the operation of the described embodiment. Additionally, the word "or" is considered an inclusive "or" rather than an exclusive or, indicating at least one, or any combination, of the items it combines.

The descriptions of embodiments of the invention in this application are provided by way of example and are not intended to limit the scope of the invention. The described embodiments include different features, not all of which are required for all embodiments. Embodiments including different combinations of features shown in the described embodiments will occur to those of ordinary skill in the art. Some elements described with respect to one embodiment can be combined with features or elements described with respect to other embodiments. The scope of the invention is limited only by the claims.

While certain features of the invention have been illustrated and described herein, many modifications, substitutions, changes, and equivalents may occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.

Claims (21)

a compressible soft material;
a first layer of fiberboard material beneath the compressible soft material; and
a stiffening layer beneath the first fiberboard, the stiffening layer extending over no more than 60% of the area of the insole;
and a stiff and flexible composite arch core layer beneath the stiffener layer. The shoe insole of claim 1, further comprising a second fiberboard material layer beneath the stiff and flexible composite arch core layer, the first fiberboard material layer and the second fiberboard material layer surrounding the stiffener layer and arch core layer. The shoe insole of claim 2, wherein the first layer of fiberboard material is attached to the second layer of fiberboard material around the periphery of the first layer of fiberboard material. The shoe insole of claim 1, wherein the rigid and flexible arch pad extends from the heel region of the insole to the toe region of the insole. The shoe insole of claim 1, in which the rigid and flexible arch core layer and the stiffener are attached as a single unit. The shoe insole of claim 1, wherein the first fiberboard material layer extends beyond the width of the arch core layer and beyond the width of the stiffener layer. The shoe insole of claim 1, wherein the toe area is flexible. a compressible material layer;
a first layer of fiberboard material;
a composite arch core layer below the stiffener layer;
The shoe, wherein the stiffener layer extends over no more than 60% of an area of the composite arch core layer, the stiffener layer being disposed between the first layer of fiberboard material and the arch core layer. The high heel shoe of claim 8, further comprising a second fiberboard material layer disposed under the stiff and flexible arch core layer, the first fiberboard material layer and the second fiberboard material layer forming a sandwich structure around the stiffener layer and the arch core layer. The high heel shoe of claim 9, wherein the first fiberboard material layer is attached to the second fiberboard material layer at an edge of the first fiberboard material layer. The high heel shoe of claim 8, wherein a stiff and flexible arch pad extends from the heel area of the shoe to the toe area of the shoe. The high heel shoe of claim 8, in which the stiff and flexible arch core layer and the stiffener are attached as a single unit. The high heel shoe of claim 8, wherein the first fiberboard material layer extends beyond the width of the arch core layer and beyond the width of the stiffener layer. The high heel shoe of claim 8, wherein the toe area is flexible. cutting two fiberboard layers each wider than each of the stiffener layer and the composite layer;
attaching the stiffener layer to the composite layer;
and placing each fiberboard layer around the stiffener layer and composite layer combination. The method of claim 15, further comprising attaching the two fiberboard layers to one another. The method of claim 15, comprising attaching the two fiberboard layers to each other around their periphery. The method of claim 15, including attaching the two fiberboard layers to each other such that the fiberboard layer is not attached to the stiffener layer and the composite layer. The method of claim 15, wherein the stiffener layer extends over no more than 60% of the area of the composite layer. The method of claim 15, wherein the stiffener layer and the composite are attached together. The method of claim 15, comprising forming or drilling holes in one or more of the stiffener layers and composite layers prior to placing each fiberboard layer around the stiffener layer and composite layer combination.

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