US20200085141A1 - Abrasive Insole and Method of Manufacture - Google Patents

Abrasive Insole and Method of Manufacture Download PDF

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Publication number
US20200085141A1
US20200085141A1 US16/562,519 US201916562519A US2020085141A1 US 20200085141 A1 US20200085141 A1 US 20200085141A1 US 201916562519 A US201916562519 A US 201916562519A US 2020085141 A1 US2020085141 A1 US 2020085141A1
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United States
Prior art keywords
insole
polymer
sand
shoe
manufacture
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US16/562,519
Inventor
Robert S. Blasi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
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Filing date
Publication date
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Priority to US16/562,519 priority Critical patent/US20200085141A1/en
Publication of US20200085141A1 publication Critical patent/US20200085141A1/en
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    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/02—Soles; Sole-and-heel integral units characterised by the material
    • A43B13/026—Composites, e.g. carbon fibre or aramid fibre; the sole, one or more sole layers or sole part being made of a composite
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
    • A43B17/003—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined characterised by the material
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/02—Soles; Sole-and-heel integral units characterised by the material
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/02—Soles; Sole-and-heel integral units characterised by the material
    • A43B13/12—Soles with several layers of different materials
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/38—Built-in insoles joined to uppers during the manufacturing process, e.g. structural insoles; Insoles glued to shoes during the manufacturing process
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B3/00—Footwear characterised by the shape or the use
    • A43B3/12—Sandals; Strap guides thereon
    • A43B3/128—Sandals; Strap guides thereon characterised by the sole
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B7/00—Footwear with health or hygienic arrangements
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B7/00—Footwear with health or hygienic arrangements
    • A43B7/14—Footwear with health or hygienic arrangements with foot-supporting parts
    • A43B7/1405—Footwear with health or hygienic arrangements with foot-supporting parts with pads or holes on one or more locations, or having an anatomical or curved form
    • A43B7/1455—Footwear with health or hygienic arrangements with foot-supporting parts with pads or holes on one or more locations, or having an anatomical or curved form with special properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D35/00—Producing footwear
    • B29D35/12—Producing parts thereof, e.g. soles, heels, uppers, by a moulding technique
    • B29D35/122—Soles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/10—Removing layers, or parts of layers, mechanically or chemically

Definitions

  • the present disclosure relates to characteristic features of footwear; parts of footwear; and specifically to insoles that have an abrasive surface; low shoes; slippers characterized by the sole; and to methods of manufacturing the same.
  • Shoe insoles and replaceable insoles are made in various shapes and materials to support human posture and foot comfort. They may be molded into a shoe at the time of manufacture or constructed and sold separately. Some insoles have tactile surfaces that serve to massage the foot.
  • Abrasion tools are used in pedicure to slough dead skin and soften the soles of the feet. Tools for this purpose range from steel blades to pumice stones. Consumers use these tools for cosmetic and health purposes such as to keep foot skin from drying and cracking, which could lead to skin breaks that could introduce infection.
  • Polymers used in shoe manufacturing may be of the type of thermosetting polymers, resins or plastics, i.e., those which are hardened by curing from a soft-solid or viscous liquid prepolymer or resin. In the curing process, heat, pressure and sometimes an introduced catalyst are used to produce the resulting, hardened state of the material. Once hardened, a thermoset cannot be melted for reshaping. Thermoplastic polymers, on the other hand, can be reshaped into final form by melting, pressing or injection-molding.
  • Silicones (polysiloxanes a polymers that harden to a rubber-like material.
  • Overmolding is a process where a single part is created using two or more materials in combination.
  • the first material the substrate
  • the substrate material is partially or fully covered by subsequent materials (overmold materials) during the manufacturing process.
  • the substrate material or part is placed into an injection molding tool at which point the overmold material is shot into, onto, or around the substrate.
  • the overmold material cures or solidifies, the two materials become joined together as a single part.
  • the insole is of a rough texture that abrades the skin on the soles of the feet for cosmetic and skin-health purposes.
  • the abrasive insole works similarly to the textured, sandpaper-like tools that are used in pedicure to soften the skin of the foot by exfoliation.
  • One iteration of the embodiment is manufactured by molding a sand and polymer mixture to produce a flexible insole.
  • the insole is between 3/32′′ to 1 ⁇ 4′′ thick.
  • the flexible insole is co-molded into the shoe at the time of manufacture.
  • Another iteration is an after-market replacement insole that may be manufactured in specific sizes or cut to fit a range of shoe sizes and used to replace an existing insole.
  • This iteration may be manufactured by rolling the aforementioned sand and polymer insole material into sheets and die-cutting it to fit various-sized shoes.
  • sand and silicone are two of many materials that can be combined to make an abrasive material, and that these materials may be manufactured in various hues, various grit sizes and varying densities.
  • An embodiment of the present invention is a method of manufacture in which sand and silicone are mixed and poured into a mold that produces an insole.
  • the thickness of an insole may vary between 0.09375 and 0.5 inches.
  • Various molds can be formed to produce insoles of varying footbed textures.
  • the insole may be manufactured with or without arch and side supports for fitting the shape of various types of feet.
  • FIG. 1 is a perspective, front view of an iteration of the embodiment, shown installed in a sandal.
  • FIG. 2 is a perspective, rear view of an iteration of the embodiment, shown installed in a sandal.
  • FIG. 3 is a section view of an example embodiment.
  • FIG. 4 is a front, perspective view of another iteration of the embodiment shown separately and as inserted into a sandal.
  • an example embodiment 100 shows a provided sandal 110 , onto which is installed the insole 114 onto a outsole 112 to fit within the boundaries of an upper 116 .
  • the provided sandal represents any type of shoe.
  • FIG. 2 100 shows in rear view an iteration of the embodiment 100 , with the insole 114 installed in a provided sandal 110 .
  • Other reference numbers are shown for reference.
  • FIG. 3 is a section view of the embodiment 100 showing the insole 114 co-molded with the outsole 112 and fitting within the upper 116 of a sandal 110 .
  • an iteration of the example embodiment 200 shows a provided sandal 210 , onto which is installed the insole 214 to fit within the boundaries of an outsole 212 and an upper 216 .
  • the provided sandal represents any type of shoe.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Epidemiology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)

Abstract

An abrasive insole and method of manufacture. The insole is integrated into the shoe at the time of manufacture. The insole provides a roughly textured surface to abrade the skin on the soles of the feet for purposes of cosmetic appeal and skin health. The abrasive insole works similarly to the textured, sandpaper-like tools that are used in pedicure to soften the skin of the foot by exfoliation. The method of manufacture involves a mold of a sand-and-polymer mixture to produce a flexible insole; one iteration is of 3/32 to 0.25-inch thickness.

Description

    TECHNICAL FIELD
  • The present disclosure relates to characteristic features of footwear; parts of footwear; and specifically to insoles that have an abrasive surface; low shoes; slippers characterized by the sole; and to methods of manufacturing the same.
    • BACKGROUND
  • Shoe insoles and replaceable insoles are made in various shapes and materials to support human posture and foot comfort. They may be molded into a shoe at the time of manufacture or constructed and sold separately. Some insoles have tactile surfaces that serve to massage the foot.
  • Abrasion tools are used in pedicure to slough dead skin and soften the soles of the feet. Tools for this purpose range from steel blades to pumice stones. Consumers use these tools for cosmetic and health purposes such as to keep foot skin from drying and cracking, which could lead to skin breaks that could introduce infection.
  • Polymers used in shoe manufacturing may be of the type of thermosetting polymers, resins or plastics, i.e., those which are hardened by curing from a soft-solid or viscous liquid prepolymer or resin. In the curing process, heat, pressure and sometimes an introduced catalyst are used to produce the resulting, hardened state of the material. Once hardened, a thermoset cannot be melted for reshaping. Thermoplastic polymers, on the other hand, can be reshaped into final form by melting, pressing or injection-molding.
  • Silicones (polysiloxanes a polymers that harden to a rubber-like material.
  • Overmolding is a process where a single part is created using two or more materials in combination. Typically the first material (the substrate) is partially or fully covered by subsequent materials (overmold materials) during the manufacturing process. The substrate material or part is placed into an injection molding tool at which point the overmold material is shot into, onto, or around the substrate. When the overmold material cures or solidifies, the two materials become joined together as a single part.
    • SUMMARY
  • An abrasive insole of a sand-and-polymer construction, molded into a shoe. The insole is of a rough texture that abrades the skin on the soles of the feet for cosmetic and skin-health purposes. The abrasive insole works similarly to the textured, sandpaper-like tools that are used in pedicure to soften the skin of the foot by exfoliation.
  • One iteration of the embodiment is manufactured by molding a sand and polymer mixture to produce a flexible insole. In some embodiments the insole is between 3/32″ to ¼″ thick. The flexible insole is co-molded into the shoe at the time of manufacture.
  • Another iteration is an after-market replacement insole that may be manufactured in specific sizes or cut to fit a range of shoe sizes and used to replace an existing insole. This iteration may be manufactured by rolling the aforementioned sand and polymer insole material into sheets and die-cutting it to fit various-sized shoes.
  • One skilled in the art understands that sand and silicone are two of many materials that can be combined to make an abrasive material, and that these materials may be manufactured in various hues, various grit sizes and varying densities.
  • An embodiment of the present invention is a method of manufacture in which sand and silicone are mixed and poured into a mold that produces an insole. The thickness of an insole may vary between 0.09375 and 0.5 inches. Various molds can be formed to produce insoles of varying footbed textures.
  • The insole may be manufactured with or without arch and side supports for fitting the shape of various types of feet.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a perspective, front view of an iteration of the embodiment, shown installed in a sandal.
  • FIG. 2 is a perspective, rear view of an iteration of the embodiment, shown installed in a sandal.
  • FIG. 3 is a section view of an example embodiment.
  • FIG. 4 is a front, perspective view of another iteration of the embodiment shown separately and as inserted into a sandal.
    •  DESCRIPTION
  • In FIG. 1 an example embodiment 100 shows a provided sandal 110, onto which is installed the insole 114 onto a outsole 112 to fit within the boundaries of an upper 116. One skilled in the art understands that the provided sandal represents any type of shoe.
  • FIG. 2, 100 shows in rear view an iteration of the embodiment 100, with the insole 114 installed in a provided sandal 110. Other reference numbers are shown for reference.
  • FIG. 3 is a section view of the embodiment 100 showing the insole 114 co-molded with the outsole 112 and fitting within the upper 116 of a sandal 110.
  • In FIG. 4 an iteration of the example embodiment 200 shows a provided sandal 210, onto which is installed the insole 214 to fit within the boundaries of an outsole 212 and an upper 216. One skilled in the art understands that the provided sandal represents any type of shoe.
  • These embodiments should not be construed as limiting.

Claims (16)

1. An apparatus and method of manufacture of an abrasive insole comprising:
a polymer combined with sand; and
said polymer-and-sand combination molded to form an insole of a shoe; wherein
the polymer-and-sand combination comes in contact with at least the bottom of a foot when the shoe is worn.
2. The apparatus and method of claim 1 wherein the polymer is a thermoplastic polymer.
3. The apparatus and method of claim 1 wherein the polymer is a thermoset polymer.
4. The apparatus and method of claim 1 wherein the polymer is silicone.
5. The apparatus and method of claim 1 wherein the sand is basalt.
6. The apparatus and method of claim 1 wherein the sand is garnet.
7. The apparatus and method of claim 1 wherein the polymer-and-sand combination is co-molded with a sole of a shoe to form an insole of a shoe at a thickness of 0.09375″-0.25″.
8. The apparatus and method of claim 1 wherein the polymer-and-sand combination is co-molded with a sole of a shoe forming an insole of a solid-core material.
9. An apparatus and method of manufacture of an abrasive shoe insole comprising:
a polymer combined with sand; and
said polymer-and-sand combination molded in sheet form; and
said sheet die-cut into shapes; wherein
said shapes are configured to fit into a shoe.
10. The apparatus and method of claim 9 wherein said shapes are specific to a given shoe size.
11. The apparatus and method of claim 9 wherein said shapes are configured to be cut to fit a given shoe size.
12. The apparatus and method of claim 9 wherein the polymer is a thermoplastic polymer.
13. The apparatus and method of claim 9 wherein the polymer is a thermoset polymer.
14. The apparatus and method of claim 9 wherein the polymer is silicone.
15. The apparatus and method of claim 9 wherein the sand is basalt.
16. The apparatus and method of claim 9 wherein the sand is garnet.
US16/562,519 2018-09-17 2019-09-06 Abrasive Insole and Method of Manufacture Abandoned US20200085141A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US16/562,519 US20200085141A1 (en) 2018-09-17 2019-09-06 Abrasive Insole and Method of Manufacture

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201862765834P 2018-09-17 2018-09-17
US16/562,519 US20200085141A1 (en) 2018-09-17 2019-09-06 Abrasive Insole and Method of Manufacture

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US20200085141A1 true US20200085141A1 (en) 2020-03-19

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