WO2017142972A1 - Système d'ajustement et procédé pour article chaussant personnalisable - Google Patents

Système d'ajustement et procédé pour article chaussant personnalisable Download PDF

Info

Publication number
WO2017142972A1
WO2017142972A1 PCT/US2017/018006 US2017018006W WO2017142972A1 WO 2017142972 A1 WO2017142972 A1 WO 2017142972A1 US 2017018006 W US2017018006 W US 2017018006W WO 2017142972 A1 WO2017142972 A1 WO 2017142972A1
Authority
WO
WIPO (PCT)
Prior art keywords
insole
shoe
imprint
packets
mold
Prior art date
Application number
PCT/US2017/018006
Other languages
English (en)
Inventor
Jonathan Luis Nuñez
Dave Ortley
Noah Tremblay
Mark Somers
Austin ARROCO
Original Assignee
Djo Consumer, Llc
Nano Terra, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Djo Consumer, Llc, Nano Terra, Inc. filed Critical Djo Consumer, Llc
Publication of WO2017142972A1 publication Critical patent/WO2017142972A1/fr
Priority to US16/052,268 priority Critical patent/US20180368512A1/en

Links

Classifications

    • 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
    • A43B7/1464—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 with adjustable pads to allow custom fit
    • 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
    • A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
    • A43B17/14—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined made of sponge, rubber, or plastic materials
    • 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
    • A43B7/28—Adapting the inner sole or the side of the upper of the shoe to the sole of the foot
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
    • A43B13/18—Resilient soles
    • A43B13/187—Resiliency achieved by the features of the material, e.g. foam, non liquid 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
    • A43B13/386—Built-in insoles joined to uppers during the manufacturing process, e.g. structural insoles; Insoles glued to shoes during the manufacturing process multilayered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/48—Wearing apparel
    • B29L2031/50—Footwear, e.g. shoes or parts thereof
    • B29L2031/504—Soles

Definitions

  • This application relates to a fitting system for self-customizing footwear. More particularly, this application relates to insole systems and methods which provide a precision fit for footwear.
  • Shoe inserts have long been used to provide better fit, feel and support for the foot within a shoe. Such inserts range from simple linings, to contoured paddings, to support orthotics. They also range from inexpensive standard insoles, to very expensive custom-fit inserts. Inexpensive insole options, which often fail to provide sufficient fit and comfort, are currently produced by one of the following methods: "boil and wear" type solutions, ski-shop spray or heat form solutions. More custom-fit or personalized shoe inserts tend to be very expensive and the fitting process sometimes involves a trip to a physician's office or to a location with specialized fitting equipment where a scan or mold of the foot can be made. The customer will often have to wait days or weeks for delivery of the final insert.
  • a kit for providing customizable fit for footwear may include a first imprint insole system having an insole affixed to a cradle; a second imprint insole system having a pressure-sensitive insole affixed to a second cradle; and instructions for activating the customized insole.
  • the first imprint insole system is a fitting insole dimensioned to fit within a shoe.
  • the second imprint insole system may be dimensioned substantially similarly to said first insole and is trimmable to accommodate a plurality of shoe shapes.
  • the second insole includes a pressure sensitive layer configured to conform to the shape of a wearer's foot upon the application of pressure.
  • the first and second cradle may be constructed from a polyurethane foam material.
  • the imprint insole systems may include a cutting guide.
  • the kit may likewise include instructions for trimming the first or second imprint insole systems or both the first and second imprint insole systems along the cutting guide to promote a better fit of the insoles in a shoe.
  • the kit can include thermoformed plastic packaging of the first and second insole system.
  • the packaging may include at least one cut out window.
  • the pressure sensitive layer of the second insole system is a thermoset polymer.
  • the kit for providing customizable fit for footwear can include instructions for activating the second pressure sensitive insole.
  • the instructions may include advising the wearer to insert the first insole system into a shoe. The wearer may then confirm the fit of the shoe by inserting his or her foot in the shoe having the first fitting insole.
  • the instructions may further include a directive to remove the first insole system and replace the first insole system with said second insole system.
  • the instructions may further instruct the wearer to apply pressure to the insole to activate the second imprint insole system.
  • the instructions may include a directive that the wearer reinsert his or her foot into the shoe with the second insole system such that the second insole can conform to the shape of said wearer's foot.
  • Pressure may be applied by hand activation, by stepping on insole when it is in a shoe, or by manipulating the insole to pre-mix the mold-on- demand components prior to placing the insoles directly on a hard surface.
  • the activation of the mold-on-demand insert can be performed one insert at a time or both the left and right insole can be activated substantially simultaneously.
  • a footwear system may include a shoe, a first insole system, and a second insole system.
  • the first insole system may include a fitting insole having a first volume, and adapted to be positioned within the shoe during a fitting of a potential wearer of the shoe and removed after the fitting is completed.
  • the second insole system may include an insole having a volume substantially similar to the first volume.
  • the second insole is adapted to be positioned within the shoe if the first insole demonstrates an appropriate fit, and wherein the second insole is self-customizable and further adapted to conform to the imprint of the sole of the potential wearer.
  • the shoe may include an athletic shoe, sport shoe and the like, casual shoe, sandal, heel, boot, or an orthopedic shoe.
  • the second insole includes a thermoset polymer.
  • the second insole can include an antibacterial layer.
  • the method may include providing a shoe; wherein the shoe includes an outsole having a top layer and a bottom layer; a cushioning element attached to the top layer of said outsole; a first imprint insole system comprising a fitting insole affixed to a cradle and removably inserted in the shoe; and an upper shell.
  • the method further includes confirming fit of the shoe; removing the first imprint insole system from the shoe; replacing the first imprint insole system with a mold-on-demand insole system; applying pressure to the mold-on-demand insole system; and imprinting the mold-on- demand insole to the shape of a wearer's foot.
  • the fitting insole comprises a memory foam.
  • the memory foam is a slow return memory foam.
  • a customized footwear system may include a shoe; a fitting insole; and a mold-on-demand insole; wherein the fitting insole has a first volume; wherein the mold-on-demand insole has a volume substantially similar to the first volume; and wherein the mold-on-demand insole is configured to conform with the shape of the wearer' s foot upon application of pressure.
  • the mold-on-demand insole may be a thermoset resin.
  • the shoe is selected from the group consisting of an athletic shoe, a sandal, a heel, a boot, and an orthopedic shoe.
  • This invention relates also to an improved footbed technology that provides a custom-fit, mold-on-demand footbed which molds to the contours of the foot, is pliable, and has the feel of a gel.
  • footbed insole
  • insert are used interchangeably.
  • the mold-on-demand footbeds of the present invention contain a top layer and bottom layer with packets, capsules, blister packets, or blisters (hereinafter referred to as "packets") arranged in between the two layers.
  • the packets are made of a form and material such that they burst during the custom-fit molding process, thereby releasing the material or materials contained within the packet.
  • These packets contain materials which begin to cure or set when released from the packets, with or without further reaction or stimuli.
  • Figure 1 is an example of an item of footwear according to one or more embodiments disclosed herein.
  • Figure 2 is an exploded view of various components of the item of footwear shown in Figure 1.
  • Figure 3 is a more detailed view of the fitting insole components shown in Figure
  • Figure 4 is an example of a self-customizing insole according to one or more embodiments.
  • Figure 5 is a block diagram illustrating components in a shoe system according to one or more embodiments.
  • Figure 6 is a flow diagram providing an illustration of a fitting process according to one or more embodiments.
  • Figures 7A-7C illustrate a schematic of a portion of a mold-on-demand footbed having burstable packets comprising a curing fluid.
  • Figures 8A and 8B depict a portion of a packet array sheet for use in a mold-on- demand insole system.
  • imprint insole system refers to an insole permanently affixed to a cradle. While an insole or cradle may be described separately, it will be appreciated that the imprint insole system comprises the combination of an insole and a cradle, wherein the component parts (namely the insole and cradle) are permanently joined to form the imprint insole system.
  • the imprint insole system may or may not include a cushioning element, which will be described in greater detail below.
  • Embodiments of this application relate generally to footwear fitting systems comprising a fitting insole and a mold-on-demand insole to provide a customizable fit to a consumer.
  • the fitting insole is provided in order to prevent activation of mold- on-demand insoles during a fitting process.
  • kits comprising a fitting insole and a mold-on-demand insole are specifically contemplated.
  • footwear is provided to a consumer prior to purchase which includes a fitting insole and a separate mold-on-demand insole.
  • the fitting insole has the same initial thickness and volume as the mold-on-demand insole, ensuring a proper fit from heel to toe, tip to tail, and side to side.
  • the consumer may remove the fitting insole from the shoes and replace them with the mold-on-demand insoles. Once inserted, the consumer puts on the shoes and secures the shoes to the feet. The consumer then activates the mold-on-demand technology in the mold-on-demand insole by application of pressure as will be described in greater detail below. For example, activation can be accomplished by the consumer standing up and applying pressure throughout the footbed.
  • Alternative methods of activation include bursting and kneading the mold-on demand imprint insole (by hand or with the aid of a tool such as a roller), placing the imprint insole on a hard surface and manipulating the insole in a rocking motion to ensure activation and mixing of component parts, then placing the insole assembly in a footbed of a shoe, and securing the shoe to a consumer. Once the shoe is secured, the consumer may stand, thereby applying the pressure of the consumer's weight load on the insole to activate and cure the insole as described in the instructions for use.
  • the material contained in the mold-on-demand insole flows into areas of the foot where voids exist, and solidifies to form a customized insole.
  • Figure 1 is an example of an item of footwear 100 which may be used to implement various aspects of the features disclosed herein.
  • the item of footwear may take various forms. It may be any one of types and/or style of shoe, including but not limited to, athletic shoes including specialized athletic shoes such as cleats, ski and snow boots, roller skates, and the like, comfort orthopedic shoes, orthotic shoes, ordinary casual wear shoes, boots, dress shoes, high heels, fashion shoes, slippers, house shoes, sandals, and the like.
  • Footwear construction types may include but are not limited to flat lasting, double lasted, string lasted, strobel stitched, and waterproofing constructs such as full bootie and gasket type.
  • the shoe 100 may include various constituent parts which are described in Figure 2.
  • the shoe and constituent parts can be configured for use with either a right or a left foot.
  • the shoe and constituent parts are shaped for use with a left foot.
  • the shoe may include an upper shell 201.
  • the shell may be of any pattern such as a high leg boot, court shoe, slingback, mule, sandal, ankle boot, wedge brogue, Derby/Gibson, causal, monk, tasseled loafer, Chelsea boot, moccasin, or combinations thereof.
  • the upper comprises the portions of the shoe that cover the toes, the top of the foot, the sides of the foot, and the back of the heel.
  • the upper may be constructed from any number of suitable materials including, for example, leather, textile, synthetic (nonwoven and microfiber backed), microfiber, spacer meshes, plastic, rubber, wood, natural fibers such as jute and the like.
  • the upper shell 201 can be open toed or closed toed.
  • the heel of the upper shell 201 can be open heeled or closed heeled.
  • the shoe 100 may also include an insole 203.
  • the insole 203 may be a mold-on- demand insole or a fitting insole as will be described in greater detail below with reference to Figures 3 and 4.
  • the insole 203 is permanently affixed to a cradle 205, the insole 203 and cradle 205 together form an imprint insole system 213.
  • the imprint insole system 213 is removable and when in use, can be positioned within the enclosure formed by the upper shell 201 and the outsole 211 of a shoe.
  • the imprint insole 213 is preferably constructed from materials which afford the imprint system 213 the properties of being substantially lightweight, providing the consumer with cushioning for comfort and fit, flexibility for ease in inserting and removing said imprint insole system 213 into a shoe, and providing a platform as well as support for the foot.
  • the cradle 205 is preferably a foam material which offers cushioning, support, heel stabilization, and acts as a foundation for the shoe. Suitable foam materials contemplated for use in the manufacturing of the cradle 205 include, without limitation, EVA foam, polyethylene foam, polyurethane foam, foam, and blown polyurethane foam.
  • the cradle 205 may optionally include an antimicrobial additive to inhibit the growth of odor-causing bacteria.
  • the cradle 205 generally has a shape of the inner base of a shoe and is designed to fit within the cavity of a shoe.
  • the cradle 205 includes markings around the exterior perimeter of the cradle to delineate to a consumer where the cradle may be cut/trimmed to accommodate different toe box shapes as will be described in greater detail below.
  • the cradle 205 may be positioned within a foam (or foamlike) cushioning element 207 to provide added comfort and support.
  • the cradle 205 can thus include a single layer of foam or may include a plurality of layers such as a plurality of durometer foam layers, die out or injection stabilization components such as shanks and the like.
  • the stabilization components may be formed from metal, die out, and injection plastics or in any other suitable material as will be appreciated by a person having ordinary skill in the art.
  • the cradle 205 can be formed in a variety of forming processes such as but not limited to reaction, rotary, injection, direct pour, and compression molding.
  • the cradle 205 provides dynamic shock attenuation and stabilization characteristics. Table 1 sets forth exemplary characteristics of the cradle 205 when fabricated from a pour molded polyurethane.
  • the midsole cushioning element 207 may provide additional dynamic shock attenuation, stabilization, comfort and support.
  • the midsole cushioning element 207 is constructed of a material adapted for shock absorption such as, for example, EVA, polyurethane, blown polyurethane, and blown rubber.
  • the midsole cushioning element 207 is fabricated via reaction, rotary, injection, direct pour, compression molding, injection molding or any other techniques known by a person having ordinary skill in the art of foam fabrication.
  • the insole imprint system 213 may further include the cushioning element 207 when the midsole cushioning element 207 is exterior to the midsole of a shoe.
  • the cushioning element is internal to the midsole of a shoe and is thus not part of the insole imprint system 213.
  • Tables 2 and 3 set forth exemplary materials and characteristics of certain embodiments of the midsole cushioning element 207.
  • Table 1 sets forth the raw materials and characteristics including the minimum-maximum standard for a polyurethane (PU) exposed insole.
  • Table 2 sets forth the raw materials and characteristics including the min-max standards for an EVA foam insole:
  • the outsole 211 comprises the exterior bottom portion of a shoe which is in direct contact with the ground.
  • the outsole may be constructed from any number of materials including, without limitation, leather, natural or synthetic rubber, fabric, plastic, or combinations thereof and may be attached to the bottom of the cushioning system 207, and it forms the outer boundary between the shoe and the ground.
  • the upper shell 201, midsole cushioning element 207, and outsole 211 may be bound together by any conventional means of adhesion. As illustrated in Figure 2, the upper shell 201, midsole cushioning element 207, and outsole 211 can be bound together at the midsole using a binder 209.
  • the binder 209 may be a foxing tape such as crepe foxing tape, or some other binding material known in the art. It is specifically contemplated, however, that in some embodiments, no binder 209 is required for connecting the upper shell 201, midsole cushioning element 207, and the outsole 211. For example, when the footwear is a sandal or high heel, the upper shell 201 can be attached/adhered directly to the outsole 211 with or without a midsole cushioning element 207.
  • the footwear fitting system may include two different insoles— one for trying on the shoe and the other a mold-on-demand insole which customizes to the anatomical shape of the wearer's foot.
  • Figures 3 and 4 examples of a fitting insole 203A and a mold-on-demand insole 203B are provided. Though shown as separate components in Figure 3, the fitting insole 203 A is permanently affixed to the top surface of the cradle 205 and adhered by any of a number of fusing techniques such as stock fitting, direct pour, insert molding, and flame lamination.
  • the fitting insole 203A may be fabricated from any suitable material including, without limitation, polyurethanes and ethyl vinyl acetates (EVA).
  • EVA ethyl vinyl acetates
  • the fitting insole 203A is fabricated from a slow return memory foam.
  • the fitting insole 203A may be fabricated to achieve a variety of densities or hardness as will be appreciated by a skilled artisan. For example, by varying the air, gas, or blowing agent, the imprint insole can be modified. Likewise, EVAs of different density or hardness can be fabricated by varying the amount of monomeric units (e.g. ethylene or vinyl acetate).
  • the fitting imprint insole comprising the fitting insole 203A and the cradle 205, includes a top layer having a substantially soft texture to improve fit and feel of the shoe.
  • the top layer can be felt or imitation felt and may include special ventilation features such as air channels, shock absorption features, anti-bacterial features, antifungal features, or the like.
  • the fitting insole 203A can be manufactured in any suitable manner known to a person having ordinary skill in the art of insole manufacturing.
  • the outline of the fitting insole 203A defined by its outer edge, may substantially follow the profile of a left or a right foot. In some embodiments, the outer edge is sized and shaped to follow the outline of the user's shoe so that the fitting insole 203 can be used within a shoe.
  • the fitting insole 203A permanently affixed to the cradle 205 has substantially similar dimensions as a mold-on-demand insole 203B permanently affixed to a cradle 205, which will be described in greater detail below with reference to Figure 4.
  • the fitting insole 203A may have a flexible, absorbing surface and is dimensioned to have a thickness and volume that is substantially the same as the thickness and volume of the mold-on-demand insole 203B and cradle 205. This allows for the customer to get a sense of how the shoe will fit when the mold-on-demand insole 203B is activated.
  • the mold-on-demand imprint insole comprises the mold-on-demand insole 203B and cradle 205 and provides precision fit, cradling support, and stability to the user. Additionally, the mold-on-demand insole serves to unify the foot of a user with the shoe to improve overall fit of the shoe, propulsion, fatigue reduction, enhance lateral and arch support, and promote proper alignment of the foot and ankle of the user.
  • the mold-on-demand insole 203B may take various forms. In general, the mold-on-demand insole 203 B is configured to provide personalized support in areas of the foot which need it the most.
  • the mold-on-demand insole 203B may be configured to provide a form-fit to the contours of the foot of the consumer, while at the same time providing gel-like pliability and feel.
  • the mold-on-demand insole 203B may be formed using flexible, resilient materials which provide a fully customized fit.
  • the mold-on-demand insole is configured to mold to the foot of the wearer without needing any 3D scan of the foot or any casting whatsoever.
  • the mold-on-demand insole may provide customization in real-time, generally within a few minutes of activation.
  • the mold-on- demand insole 203B is a thermoset formed insole configured to take on the imprint of the wearer's foot.
  • the mold-on-demand insole 203B is fabricated from material which can take on the ability to mold to a user's foot.
  • the mold-on-demand insole 203B is fabricated from a thermoset polymer such as a thermoset resin.
  • the mold-on-demand insole may be fabricated from a slow return memory foam.
  • the mold-on-demand insole 203B can include a top and bottom elastomeric layer. In between the top and bottom layers may be a middle layer having curable fluid stored in pressure sensitive packets which are pressure activated and may burst to release the curable fluid.
  • the packets contain components that set or cure upon release from the activated packets and may combine and react with contents of adjacent packets to initiate curing.
  • Exemplary curable fluids suitable for use include, without limitation, polyurethane resins, silicone resins, and epoxy resins.
  • the top and bottom layers of the mold-on-demand insole are both made of an elastomeric film, and the packets are arranged in between the two layers are made from a silicon resin.
  • These packets can contain materials that begin to set or cure upon release from the packets and mixing/reacting with contents of adjacent packets.
  • the packets are arranged in arrays and compartments and can be configured to optimize fit upon cure.
  • the user places the footbed within the shoe, and places his or her foot within the shoe on top of the footbed. The user then presses down on the footbed and rocks the foot back and forth, causing the packets to burst and the packets' contents to mix and react.
  • the mixed material cures to the contours of the foot.
  • the footbed may be enclosed in a compartment within the shoe.
  • curable fluid is contained within a plurality of bladders which are arranged along the length and width of the insole to optimize fit once the fluid cures.
  • These bladders or packets are preferably burstable by hand or foot (0.1N/cm2, ⁇ 500 psi).
  • the packets may contain liquid or gaseous components that, when mixed, result in a chemical reaction that cures the materials to become solid. The mixing or reaction may also produce an added attribute such as heat, cold, light, or color change.
  • the packets can be filled with a range of two-component or multi-component reactive liquids.
  • reactive liquids are two-component resins, such as polyurethane resins, silicone resins, epoxy resins, melamin resins, and polyurea resins; multi-component liquid reactants to affect the production of heat, such as in the dissolution of calcium chloride into water; multi-component liquid reactants to affect the lowering of the temperature, such as the dissolution of ammonium chloride into water; and multi-component liquid reactants to affect the production of light, such as the mixing of luminol and hydrogen peroxide.
  • resins such as polyurethane resins, silicone resins, epoxy resins, melamin resins, and polyurea resins
  • multi-component liquid reactants to affect the production of heat such as in the dissolution of calcium chloride into water
  • multi-component liquid reactants to affect the lowering of the temperature, such as the dissolution of ammonium chloride into water
  • Figures 7A-7C depict a schematic Depicts a schematic of a portion of footbed of the present invention, with the packet array and compartments on the bottom layer.
  • Figure 7(A) shows a top view of that portion of the footbed, with individual packets (1), and separate compartments or regions such as the toe region (2).
  • Figure 7(B) shows a perspective view of the portion of the footbed with separate compartments or regions such as the toe region (2), arch region (3) and heel region (4).
  • Figure 7(C) shows a cross section view of the portion of the footbed, with individual packets (1) Also depicted is the border surrounding the footbed area allows the footbed to be clamped during manufacturing processes.
  • the packets may be made in different three-dimensional structures, aspect ratios, and overall dimensions for different applications.
  • the three-dimensional structure of the packets can be any three-dimensional closed solid compromising flat, contoured and/or curved surfaces; some examples are hemi-spherical, cubic, hexagonal prism, pentagonal prism, rectangular prism, cone, and tetragonal pyramid shapes.
  • the packets may be arranged two-dimensionally on a flat or curved surface.
  • the curvature of the two-dimensional array may be optimized to maximize the ease of packet bursting by the user.
  • the spacing, distribution, shape, and size of the packets can also be varied to maximize the ease of bursting by the user.
  • the spacing between the packets may vary between a nil thickness and 100 centimeters. Packets may be all the same size and shape or comprise a variety of different shapes within the same footbed.
  • Packets may take different shapes, sizes, two-dimensional positioning, or wall thickness in order to tune the packet's burst strength. In some applications, it may be important that certain packets burst before others so a mixture of burst strengths may be desired.
  • the most preferable arrangement of packets is a pattern of identical shaped and sized close-packed polygonal prisms, such as cubes, rectangular prisms, or hexagonal prisms.
  • This arrangement allows the air to be evacuated efficiently from the outside thermoplastic, elastomeric bag.
  • a two-component resin can be distributed in packets such that parts A and B (i.e., the parts to be mixed) are spaced out in separate packets an alternating fashion.
  • the two plastic sheets that bond together to form the packet may both be thermoformed, blow molded, or otherwise shaped to define the packet volume or only one sheet can be shaped.
  • the preferred embodiment for the moldable footbeds is a singly shaped low-density polyethylene sheet bonded to a flat low-density polyethylene sheet.
  • the polyethylene is thermally welded to the adjacent sheet to define the seams of each packet.
  • Packets may be formed from any materials that can be sealed to each other by some means. Methods of sealing the packet seams include thermally welding, sonically welding, mechanically folded together, using a curable adhesive, or using a hot-melt adhesive or thermoplastic). For other applications, the packets could be formed by thermal or sonic welding of thermoplastic sheets or it may be desirable to use an adhesive or other material to form a significantly stronger or weaker bond to tune the delamination of the packet seam. For example, all inner seams of the individual packets in the array may be tuned to delaminate while the outer seams are meant to remain laminated such that the packet array becomes one continuous pouch after bursting. The shaped plastic sheet could also form packets with hard non-porous surfaces, such as glass, metal, rock, or a coated surface.
  • the packet arrays are formed by vacuum forming thermoplastic sheets into bubble sheets.
  • the thermoplastic material can survive strenuous conditions during manufacturing, shipment and handling but bursts when body weight pressure is applied. This prevents premature curing and preserves on-demand molding functionality.
  • the arrayed packets are filled with resin and a backing layer is thermally sealed to the open back of the packets to form an arrayed sheet of packets, which can be seen in Figures 8 A and 8B.
  • Figures 8 A and 8B illustrate a portion of a packet array sheet 5 where the packets have been filled with silicone resin prior to sealing within elastomeric top and bottom layers.
  • Figure 8 A is a side profile of the filled packet array 5.
  • Figure 8B is a top view of a portion of the filled packet array 5.
  • the arrayed packet spacing and individual packet volume can be optimized in order to achieve the desired resin volume.
  • packet characteristics can be customized in order to contain the required volume.
  • an arrayed packet design allows for quick mixing by holding components in close proximity to each other. Upon bursting, each packet of material can be in close proximity to other packets.
  • the preferred embodiment has an array of packets optimized for the desired volume and with curing components in close proximity.
  • the upper and lower elastomeric layers are preferably made from a breathable, antibacterial and/or anti-odor material.
  • fluid from the packets may pool to areas of the foot where voids exist, and a curing process takes place. After a short period of time, the fluid may solidify, surrounding and defining the perimeter of the foot, and also flowing in between the toes and across the metatarsal area. In some embodiments, curing can be achieved in less than five minutes. In another aspect, curing can be achieved in approximately three minutes. In addition, the curing material may also flow under the midfoot or arch area, ultimately leaving a cured, soft, flexible and lasting impression of the foot. In some embodiments, the curable fluid may be compartmentalized to control the flow of the material to different areas of the foot.
  • the toe area may include one compartment of curing material, the ball and arch area another, and the heel yet another to ensure proper support in those areas.
  • the mold-on-demand insole 203B may include memory foam infused with a pressure-activated resin.
  • the memory foam takes the shape of the consumer's foot and the insole molds to that shape.
  • the application of pressure also activates a resin.
  • the resin is released and sets the memory foam in the shape of the consumer's foot imprint.
  • the mold-on-demand insole 203B is permanently affixed to the cradle 205.
  • the cradle 205 can include markings (not illustrated) around the exterior perimeter of the cradle to delineate to a consumer where the cradle may be cut/trimmed to accommodate different toe box shapes as well as different shoe sizes.
  • self-customizing footwear may be provided as a footwear system which includes both a fitting imprint insole and a mold-on-demand imprint insole.
  • the footwear system 500 includes left and right shoes 502A and 502B. Inside the shoes 502A and 502B are the left fitting insole 504A and right fitting insole 504B, respectively.
  • the fitting insoles are provided within the shoe so that the consumer may try on the shoe without activating the mold-on-demand technology provided in the customizable insoles 506A and 506B.
  • the customizable insoles 506A and 506B are positioned outside of the shoe so that they can replace the fitting insoles 504A and 504B after a purchase has been made.
  • FIG. 6 an example of a fitting process for according to one or more embodiments is provided.
  • the process begins at block 601, where a pair of shoes is prepared with the fitting insole (such as fitting insole 502A and 502B) inserted into each shoe.
  • the fitting insole such as fitting insole 502A and 502B
  • the mold-on-demand insoles such as insoles 504 A and 504B
  • the customer selects a pair of shoes and tries on the pair of shoes using the fitting insole.
  • the fitting insoles and the mold-on-demand insoles (in a pre-activated state) will generally have substantially the same initial thickness from heel to insuring a proper fit from heel to toe, tip to tail, and front to back.
  • decision block 607 the customer decides whether the shoes are a good fit. If not, the process returns to block 605, and the customer selects a new pair of shoes and tries them on with the fitting insole. [0059] If at decision block 607 the customer determines that the shoes are a good fit, the process moves ahead to block 609. There, the fitting insoles are removed from the shoes.
  • the process moves to block 611, where the mold-on-demand insoles are inserted to replace the fitting insoles.
  • the process moves to block 613. There, the customer secures the shoes to their feet.
  • the process then moves to block 615, where the customer, now wearing the shoes, activates the mold-on-demand insole. Activation is generally accomplished by the application of pressure. In practice, the application of pressure can be achieved in any number of ways.
  • activation can be achieved by stepping into a shoe with the mold-on-demand insert, applying a force to the sole of the shoe having the mold-on-demand insole inside the shoe, standing up with the shoe and insole on the consumer's foot such that the weight of the customer applies sufficient pressure throughout the footbed to activate the mold-on-demand technology.
  • pressure may be applied by hand activation or by manipulating the insole to pre-mix the mold-on- demand components prior to placing the insoles directly on a hard surface.
  • the activation of the mold-on-demand insert can be performed one insert at a time or both the left and right insole can be activated substantially simultaneously.
  • the customer may stand with his or her feet shoulder width apart as the molding process begins. Depending upon the configuration of the mold-on-demand insole, the customer may stand for one or two minutes, or possibly more.
  • the process moves to block 617 where the customer stands with their feet shoulder width apart, and the material in the footbed flows.
  • the curing material may flow into those areas of the foot where a void exists and the pre-existing shape of the mold-on-demand insole fails to provide adequate support.
  • material will surround and define the perimeter of the foot, flow in between the toes and across the metatarsal area, and under the midfoot or arch area leaving a cured, soft, flexible and lasting impression of the foot in intricate detail.
  • curing occurs within around five minutes of activation.
  • a kit for promoting fit and customized footwear comprises an insole/imprint system having at least one mold-on-demand insole adhered to a cradle.
  • the kit can include a left footed mold on demand insole/imprint system, a right footed insole/imprint system, or both.
  • the kit further comprises a fitting insole permanently affixed to a cradle.
  • the fitting insole/imprint system can include a left footed fitting insole/imprint system, a right footed fitting insole/imprint system, or a combination thereof.
  • the insole/imprint system is provided in various sizes for use with different sized feet.
  • the sizes correspond to typical men's, women's and children's shoe sizes.
  • the sizes of insole/imprint systems disclosed herein are all purpose and can include wide, narrow, children's sizes, as well as sizes and shapes suitable for use in any number of shoe types including heels, athletic shoes, orthopedic footwear, sandals, etc. In some embodiments, sizes can range from size 3-14.
  • the insole/imprint system may include a marking/cutting guide along the perimeter of the cradle.
  • the marking/cutting guide appears on the top surface of the insole.
  • the cutting guide designates the boundaries for which further customization of fit can be achieved by trimming the edges of the insole/imprint system to accommodate sizing as well as different toe box shapes in various shoe designs.
  • the cutting guide can be printed, etched, engraved, or molded onto the surface of the insole/imprint system.
  • the kit can further include instructions for guiding the consumer to further customize the fit of an insole/imprint system by trimming the edges of the insoles relative to the cutting guide on the top surface of the imprint/insole system. Instructions also include a directive not to cut beyond the cutting guide to avoid activation of the mold-on-demand.
  • the kit can optionally include instructions to size the insole/imprint system by removing the manufacturer's insole from a shoe and using said manufacture insole as a template for trimming the insole/imprint system to optimize fit. Instructions can include directions to remove the manufacture insole, trace the outline of the manufacturer insole onto the insole/imprint system, and trim the insole/imprint system along the trace lines to fit. Instructions would further include directions to insert the trimmed insole/imprint system into the shoe prior to activation.
  • the kit includes packaging to prevent unintentional activation of the mold-on-demand insole.
  • the packaging may be a thermoformed clamshell.
  • the packaging comprises a cut-away window to provide visualization of the insole as well as an opportunity for the consumer to tactilely interact with the insole.
  • a method of forming mold-on-demand imprint insole systems is likewise contemplated.
  • the steps for producing such footbeds can include the following: materials are prepared by cutting LDPE, TPU, fabric, and transfer adhesive to the proper size required.
  • custom bubble arrays are formed by vacuum thermoforming of the film.
  • the LDPE sheeting is brought into close proximity of a high temperature heat source, kept at 275°C. Once the material begins to soften and exhibits characteristics of melting, the sheeting is then brought into contact with a custom mold that is arranged on a vacuum plate, allowing the softened material to form a net shape of the custom mold.
  • the piece is then placed into a custom holder with rigid channels between the formed bubbles, allowing the bubbles to hang freely.
  • silicone components are then loaded into the bubbles in an alternating fashion.
  • a sheet of LDPE is then laid across the loaded bubbles. Using a high temperature and high pressure pneumatic thermal press, this film is pressed into the custom bubble arrays, forcing a high pressure gradient where the rigid channel below lies, allowing the LDPE to seal to itself through the silicone contamination. This completes the formation of the silicone loaded bubble arrays.
  • the TPU sheets are then heat sealed using a custom sealing plate kept at high temperature and pressure, forming the overall shape of an insole complete with sealed partitions in specific areas of the insole to separate bubbles in certain regions of the foot. Once this seal has been created, the net shape desired for further manufacturing is then cut and the custom moldable layer of the mold-on- demand insole is finalized.
  • Certain preferred materials for use in the manufacture of a mold-on-demand imprint insole can include: a. Silicone filler material is Andisil 204-37 Parts C&D, supplied by AB Specialty Silicones b. Bubble films formed from LDPE, lOmil film thickness, supplied by SC Johnson. Film with no slip additive preferred
  • TPU sheeting is product DT-7101, 8 mil film thickness, supplied by American Polyfilms Inc.

Landscapes

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

Abstract

Des modes de réalisation de l'invention concernent un système pour article chaussant (100). Le système pour article chaussant (100) comprend une chaussure (100), une première semelle intérieure (203B, 203) et une deuxième semelle intérieure (203B, 203). La première semelle intérieure (203B, 203) est une semelle intérieure d'ajustement (203A, 203, 502A) qui présente un premier volume. Elle est placée à l'intérieur de la chaussure (100) pendant un ajustement d'un porteur potentiel de la chaussure (100). La semelle intérieure d'ajustement (203A, 203, 502A) est retirée après avoir terminé l'ajustement. La deuxième semelle intérieure (203B, 203) présente un volume sensiblement similaire au premier volume. La deuxième semelle intérieure (203B, 203) est adaptée pour être positionnée à l'intérieur de la chaussure (100) si la première semelle intérieure (203B, 203) démontre un ajustement approprié. La deuxième semelle intérieure (203B, 203) est auto-personnalisable et elle est en outre adaptée pour se conformer à l'empreinte de la plante du pied de l'utilisateur potentiel.
PCT/US2017/018006 2016-02-16 2017-02-15 Système d'ajustement et procédé pour article chaussant personnalisable WO2017142972A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US16/052,268 US20180368512A1 (en) 2016-02-16 2018-08-01 Fitting system and method for customizable footwear

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201662295826P 2016-02-16 2016-02-16
US201662295863P 2016-02-16 2016-02-16
US62/295,826 2016-02-16
US62/295,863 2016-02-16

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US16/052,268 Continuation US20180368512A1 (en) 2016-02-16 2018-08-01 Fitting system and method for customizable footwear

Publications (1)

Publication Number Publication Date
WO2017142972A1 true WO2017142972A1 (fr) 2017-08-24

Family

ID=59626276

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2017/018006 WO2017142972A1 (fr) 2016-02-16 2017-02-15 Système d'ajustement et procédé pour article chaussant personnalisable

Country Status (2)

Country Link
US (1) US20180368512A1 (fr)
WO (1) WO2017142972A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022259038A1 (fr) * 2021-06-07 2022-12-15 Sanchit Kundra Article chaussant destiné à recevoir des pieds de deux tailles différentes

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USD980589S1 (en) * 2020-12-18 2023-03-14 Peter Charles Whittington Convertible shoe

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060016103A1 (en) * 2004-07-21 2006-01-26 David Green Instant custom moldable insole
EP1623642A1 (fr) * 2004-08-06 2006-02-08 Schering-Plough Healthcare Products, Inc. Semelle intérieure amovible et chaussure avec une semelle intérieure
WO2010130283A1 (fr) * 2009-05-12 2010-11-18 M.G.S. S.R.L. Insert pour semelles, et analogue
WO2013130321A1 (fr) * 2012-03-01 2013-09-06 Spenco Medical Corporation Semelle intérieure permettant de soulager la pronation excessive et la contrainte exercée sur l'articulation du genou

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060016103A1 (en) * 2004-07-21 2006-01-26 David Green Instant custom moldable insole
EP1623642A1 (fr) * 2004-08-06 2006-02-08 Schering-Plough Healthcare Products, Inc. Semelle intérieure amovible et chaussure avec une semelle intérieure
WO2010130283A1 (fr) * 2009-05-12 2010-11-18 M.G.S. S.R.L. Insert pour semelles, et analogue
WO2013130321A1 (fr) * 2012-03-01 2013-09-06 Spenco Medical Corporation Semelle intérieure permettant de soulager la pronation excessive et la contrainte exercée sur l'articulation du genou

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
THE INSOLE STORE: "Trim to Fit Shoe Insoles, Inserts, & Arch Supports @ The Insole Store.com", 5 September 2014 (2014-09-05), XP002769824, Retrieved from the Internet <URL:https://youtu.be/7QOh1S_2x1k> [retrieved on 20170504] *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022259038A1 (fr) * 2021-06-07 2022-12-15 Sanchit Kundra Article chaussant destiné à recevoir des pieds de deux tailles différentes
GB2621291A (en) * 2021-06-07 2024-02-07 Kundra Sanchit A footwear for accommodating feet of two different size

Also Published As

Publication number Publication date
US20180368512A1 (en) 2018-12-27

Similar Documents

Publication Publication Date Title
CN104507345B (zh) 具有稳固结构的流体填充室
CN110430775B (zh) 用于鞋类物品的缓冲构件及制造方法
US10123584B2 (en) Adjustable sole support system
US20200068994A1 (en) Molded Footwear Upper And Method Of Making Same
US7762011B2 (en) Toe protection sandal
US5885500A (en) Method of making an article of footwear
US10800074B2 (en) Footwear upper components having contoured foam regions and methods of forming such components
CN101287427B (zh) 一种鞋内底和制造鞋内底的方法
US4211019A (en) Accommodative foot bed
US8567098B2 (en) Article of footwear with detachable upper and lower designs
US20060064903A1 (en) Customized footwear and process for manufacturing such footwear
US20170231320A1 (en) Fitting system and method for customizable footwear
US20080148599A1 (en) Footwear inserts, including midsoles, sockliners, footbeds and/or upper components using granular ethyl vinyl acetate (EVA) and method of manufacture
US20180368512A1 (en) Fitting system and method for customizable footwear
EP3402359B1 (fr) Structure de semelle pour un article chaussant, comportant un composant formant semelle extérieure avec un composant formant modificateur de flexion co-moulé, et procédé de fabrication de ladite structure de semelle
US20170231321A1 (en) Custom Formable Footbed and Shoe Insert
GB2358121A (en) Foam insole having areas of different density
EP2645897B1 (fr) Première installée sur mesure pour chaussure et procédé de fabrication associé
KR101060591B1 (ko) 맞춤형 신발의 형틀
KR20090067331A (ko) 발바닥의 족궁 부위를 잡아주는 열 성형 사출물 키트 및이를 이용한 맞춤 인솔의 제조방법
US7222443B2 (en) Footwear with improved insole
US10244816B2 (en) Sports shoe innerboot
JP2005074085A (ja) 履物及び履物の製造方法

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 17709227

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 17709227

Country of ref document: EP

Kind code of ref document: A1