WO2019070455A1

WO2019070455A1 - Custom sole insert for high heel shoes

Info

Publication number: WO2019070455A1
Application number: PCT/US2018/052631
Authority: WO
Inventors: Maija BENINCASA; Yonatan CHATZINOFF
Original assignee: Benincasa Brands, Llc
Priority date: 2017-10-05
Filing date: 2018-09-25
Publication date: 2019-04-11

Abstract

A sole insert designed for use in high heel shoes that includes a forward region supporting the forefoot and a hollow area disposed beneath the first metatarsal head. The hollow area provides less support to said first metatarsal head than is provided to other areas of the forward region that support the forefoot. The rear region supports the midfoot and the rearfoot including the heel, with the rear region extending from the forefoot to the back of the heel. Also disclosed are methods of making this sole insert and shoes that contain the sole insert.

Description

CUSTOM SOLE INSERT FOR HIGH HEEL SHOES

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. provisional application no. 62/568,444 filed October 5, 2017 and U.S. application no. 16/029,591 filed July 7, 2018, the entire contents of each of which are incorporated herein by reference thereto.

BACKGROUND

High heel shoes, while very fashionable, can result in significant pain for the wearer, with survey data indicating that the majority of wearers experience pain in the ball of their feet. This symptom is a direct result of the construction of typical high heel shoes and occurs for a variety of reasons. First, the angle of the sole with respect to the horizontal keeps wearer's toes plantar flexed, which reduces the cushioning effect of the fat pad underneath the metatarsals. This angle also dramatically shifts the center of pressure of the foot forward, resulting in much higher loads on the forefoot. Coupled with the tendency of feet to slide down in high heels, and the often narrow toe boxes of the shoes, these factors result in a very uncomfortable load at the first metatarsal head, which is the main weight-bearing portion of the forefoot.

Several solutions have been proposed to alleviate this discomfort. The load on the first metatarsal can be reduced by elevating some or all of the other metatarsal heads, particularly those proximate to the first metatarsal head. This solution, called a "Morton's extension" or "dancer's pad," is described in U.S. Patent No. 4,317,293. These devices redistribute the wearer's weight to be borne more evenly among all the metatarsals.

Additionally, as described in WO 2006/043923, the slope of the portion of the shoe beneath the wearer's heel may be reduced to enable the heel to carry more of the load, and to move the center of pressure dorsally.

To correctly shift weight from under the first metatarsal head, its location of must be known with some precision. Two individuals with identical heel-to-toe lengths and thus, nominally the same size shoe, can have widely varying heel to ball measurements. For example, one may have longer toes and a shorter arch respectively than the other. The first metatarsal head, which is located at the end of the arch, will thus be at different distances from the heel for these two individuals. The problem is further exacerbated by the tendency of wearers of high heels to "undersize" their shoes, as well as other anatomical variations, including different sized left and right feet. Thus, a one-size-fits all insole, simply correlated to shoe size, will fail to accurately move the center of pressure away from the first metatarsal head in all cases.

Accordingly, there is a need for improved components for high heel shoe

constructions and these as well as new high heel shoes are now provided by the present invention.

SUMMARY OF THE INVENTION

The present invention now provides a sole insert designed for use in high heel shoes comprising a forward region supporting the forefoot and comprising a hollow area disposed beneath the first metatarsal head, the hollow area providing less support to said first metatarsal head than is provided to other areas of the forward region that support the forefoot, and a rear region supporting the midfoot and the rearfoot including the heel, with the rear region extending from the forefoot to the back of the heel.

The hollow area may have an upper surface that is depressed relative to the other areas of the forefoot region, or it can be made of a softer material than the material in the other areas of the forefoot region. Preferably, the hollow area comprises a cut out portion of the forefoot region configured to accommodate the first metatarsal head, wherein the cut out region is arcuate and free of sole insert material.

The rear region comprises a heel cup configured to accommodate the heel, with the heel cup comprising a depression relative to other portions of the rear region. Also, the heel cup may comprise material that is softer than material in other portions of the rear region.

Generally, the hollow or cut out area has a boundary defined at least in part by an arc of a circle centered on the first metatarsal joint.

The invention also provides a shoe comprising a shoe body having a sole, an elevated heel, a sock liner and a sole insert as disclosed herein, wherein the sole insert is preferably present above the sole and under the sock liner. The elevated heel means a heel having a height of at least 2 inches and preferably 2 to 5 inches.

Another embodiment of the invention relates to a method of manufacturing a custom sole insert. This method comprises receiving from a client device foot impression data that includes a depth image of a foot, computing from the depth image of the foot a plurality of foot dimensions, generating from the plurality of foot dimensions 3D model data for a custom sole insert, and fabricating from the 3D model data the custom sole insert using a

manufacturing device. The custom sole insert is preferably one as disclosed herein that extends from the forefoot to the back of the heel and comprises a hollow area under the first metatarsal head of the wearer' s foot.

In this method, the computing the plurality of foot dimension data further comprises locating the most medial portion of the foot on the depth image, and determining the sesamoid height based on the location of the most medial portion of the foot on the depth image. The computing the plurality of foot dimension data also comprises selecting a landmark axis on the depth image, identifying the first metatarsal joint on the depth image, and calculating a straight line projection along the landmark axis.

Also, the identifying the first metatarsal joint on the depth image further comprises locating the approximate region of the first metatarsal joint, blurring the depth image using a filter, identifying the regional maximum of the region of the first metatarsal joint, and locating the center of the first metatarsal joint as the centroid of the regional maximum.

Generating 3D model data for the custom sole insert further comprises determining a shoe size based on the plurality of foot dimensions, selecting a basic insole having predetermined dimensions corresponding to the shoe size, forming a bounding box around the basic insole, and delimiting a boundary for the hollow area of the custom sole insert. The depth image of the foot is preferably obtained by providing a compressible material that retains its shape when deformed, pressing the wearer's foot into the compressible material such that an impression of at least the bottom of the foot is formed in the material, and scanning the impression using a scanning device comprising a range camera. The scanning device efficiently generates a depth image of the impression.

Capturing the anatomy of a foot for use in the design of a custom sole insert advantageously includes the generation of the depth image. The depth image of the impression can be used to provide a plurality of foot dimensions. This data can be used for generating from the plurality of foot dimensions 3D model data for a custom sole insert and fabricating from the 3D model data the custom sole insert using a manufacturing device. As disclosed herein in preferred embodiments, the custom sole insert extends from the forefoot to the back of the heel and comprises a hollow area under the first metatarsal head of the wearer' s foot.

This methods of the invention preferably include the additional steps of providing a high heel shoe having a shoe body, a sole and an elevated heel, and installing the custom sole insert inside the high heel shoe. Typically, a sock liner is provided and the sole insert is installed above the sole and under the sock liner. The resultant high heel shoes represent another embodiment of the invention. Another method of the invention includes providing comfort for a wearer's foot in a high heel shoe. This method includes providing a high heel shoe having a shoe body, a sole and an elevated heel, providing a sole insert comprising a hollow area under the first metatarsal head, the sole insert extending from the forefoot to the back to the heel, the sole insert supporting the midfoot and the rearfoot including the heel, with the rear region extending from the forefoot to the back of the heel, and installing the sole insert inside the high heel shoe. The preferably sole insert comprises a heel cup configured to accommodate the heel, the heel cup comprising a depression relative to other areas of the rear region. BRIEF DESCRIPTION OF THE DRAWINGS

Various advantages and features of the invention will be understood from the following detailed description taken in connection with the appended claims and with reference to the attached drawing figures in which:

Figure 1 is a schematic illustration of the steps for preparing custom sole inserts for high heel shoes according to an embodiment of the present invention;

Figures 2A and 2B are illustrations of scanned depth images of a wearer's foot for use in determining how to configure and construct the custom sole inserts according to an embodiment of the invention;

Figures 3 A is an illustration of an identification of major axes and landmark measurements made a scanned depth image of a foot according to an embodiment of the present invention;

Figure 3B is an illustration of an identification of landmark measurements made on a scanned depth image of a foot according to an embodiment of the present invention;

Figure 4 illustrates a screenshot of a software interface displaying an identification of landmark measurements on depth images of a pair of feet;

Figures 5A and 5B illustrate outlines for a basic insole;

Figure 6 illustrate a heel cup formed by a depression in the heel plate;

Figures 7A and 7B illustrates the centering of the boundary of the metatarsal hollow portion or cutout for the custom sole insert; and

Figures 8 A and 8B illustrate the metatarsal cut out and final design of the custom sole insert prior to manufacturing.

Figure 9A and 9B illustrates exemplary custom sole inserts of various shapes and sizes according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention disclose a custom sole insert for use in high heel shoes that alleviates discomfort of the wearer's foot. In particular, the custom insert provided herein shifts pressure away from the first metatarsal head and to the rest of the foot. To this end, the custom sole insert is provided with a hollow area underneath the first metatarsal head. In some embodiments, the hollow area may have an upper surface that is depressed in relation to an upper surface of the surrounding forefoot region of the custom sole insert. The hollow area may also be formed with a material softer than a material of the forefoot area such that less pressure is exerted on the first metatarsal head than the second through fifth metatarsal heads. In some embodiments, the hollow area may be a cut out area devoid of sole insert material to accommodate the first metatarsal head. The custom insert extends to the back of the heel and features a heel cup that helps lower the angle of the wearer's foot in relation to the floor. The heel cup reduces the foot's tendency to slide and down and shifts some pressure away from the forefoot and toward the heel.

Embodiments of the present invention also disclose methods for measuring a wearer's foot to design the custom sole insert, and for designing and manufacturing the custom sole insert. In particular, a physical impression of the wearer's foot is obtained with an

impression device. The impression is placed in a 3D scanning device that translates the impression into foot impression data comprising a depth image. The foot impression data is received on a computing device comprising a design software having a graphical interface. Foot dimensions are determined from the depth image and used to design a 3D model of the custom sole insert. Manufacturing data based on the 3D model is transmitted to a

manufacturing device, which uses the data to produce the custom sole insert. The custom sole insert is inserted into a high heel shoe beneath the sock liner to produce the high heel shoe with having a custom sole insert and configured to reduce pressure on the ball of foot.

Figure 1 is a schematic illustration of the steps for preparing custom sole inserts 500 for high heel shoes 600 according to the present invention. The process begins with obtaining an impression 100 of a wearer's foot. The impression 100 may be a physical impression, in some embodiments, which may be obtained using a fit kit 105 as illustrated. The foot impression 100 may be scanned or captured using an imaging device 205 to produce a three-dimensional digital image 200. The digital image 200 is transmitted to a computer system 390 having software 395 for designing the custom sole insert 500. The software 395 processes the image 200 and extracts landmarks measurements for the custom sole insert 500. The software 395 may provide various options for the operator to further design and/or customize the sole insert. After the design is complete, the resulting custom foot model data is transmitted to a manufacturing device 405 or facility configured to manufacture the sole insert according to the parameters specified in the data. The manufacturing device or facility produces the sole insert 500 based on the custom foot model data. The resulting custom sole insert 500 is installed in the wearer's shoe 600, where it provides comfort to the foot and is virtually invisible. The process described above is just one exemplary overview of the process in accordance with an embodiment of the present invention, and many of the steps are optional and/or may involve alternative devices and processes, as will be further described below.

As illustrated in Figure 1, the process of designing the custom sole insert 500 for a high heel shoe begins with obtaining an impression 100 of the wearer's foot. In some embodiments, the foot impression can be a physical impression 100. The foot impression 100 can be formed with a variety of means. For example, the impression 100 may be obtained using a plaster cast to create a positive impression mold of the foot. Alternatively, a negative impression 100 may be formed and used directly. In the embodiment shown, the impression device is a negative impression box 105. The impression box 105 typically consists of a box dimensioned to accommodate the wearer's foot. The box 105 is filed with a compressible material that deforms when the wearer's foot is pressed into it, and retains the deformed shape after the foot is removed to form an impression 100 of the foot. In some embodiments, the impression material is compressible foam. The result of obtaining an impression 100 of the foot is a physical model of the wearer's foot or foot model that accurate reflects the size, contour, and features of the foot.

Others means are provided for capturing the impression 100 of the foot. For example, a foot impression 100 and related measurements may be obtained from a photograph of the foot. In some embodiments (not illustrated), an image of the foot may be obtained by an imaging device disposed inside or associated with an enclosure where the user places the foot to be modeled. The resulting image may be processed and printed for scanning. The resulting image of the foot may also be processed and transmitted as an image file in various formats. The image file may be further processed by systems and devices downstream of the workflow to extract foot measurements.

A scanning device 205 is used to capture a three-dimensional digital image 200 of the foot model or impression 100. The scanning can be accomplished with various means that are known in the art. In some embodiments, the scanner 205 comprises a custom-built chassis to accommodate the foot model or cast. The scanning device 205 employs a depth sensor to scan the foot model 100 to provide a 3D digital representation or model of the wearer's foot. In some embodiments, the scanning sensor employs the commercially available Microsoft Kinect. The Microsoft Kinect is low cost consumer-grade 3D depth camera primarily designed for use as a peripheral device for gaming consoles. The camera has been successfully repurposed for a broad range of imaging applications in commercial and research settings due to its combination of effectiveness and low cost that provide an exceptional value and make it an attractive alternative to more expensive scanners. The Kinect sensor includes an infrared laser emitter, an infrared camera, and a color (RGB) camera. The Kinect uses these features to sense depth and generate a three dimensional imaging data using a structured or projected light method. In particular, the infrared emitter illuminates a dot pattern provided inside the camera, and the infrared sensor captures the projection pattern. Depth information is computed from the offset of each dot between the internal pattern and the captured pattern. Other methods of scanning the foot model can be employed using different devices. For example, the scanning device 205 can comprise time of flight sensors, which rely on the travel time of light between the sensor and the subject to determine the distance corresponding to each pixel. The scanning device 205 can also comprise stereoscopic sensors, which use the disparity of image captured by two adjacent cameras to resolve distance and calculate a depth map.

In some embodiments (not illustrated), the scanning device 205 may scan a printed photograph of the foot rather than a physical impression 100 of the foot. The photograph of the foot may be obtained with the process previously described above. In some

embodiments, the photograph may be a digital file from which the scanning device 205 may scan the foot impression data.

The scanned foot impression data is transmitted to a computer system 390 having software for designing the custom sole insert 500. The foot impression data may be transmitted to the computer device via a computer network or a storage media. An image processing or computer aided design application or software may be provided on the computer device 390. The application may comprise a graphical user interface for interacting with the foot impression data 200 and designing the custom sole insert 500 therefrom.

Characteristics of an exemplary computer system 390 are described further below in this specification.

Figure 2A illustrates the depth image or 3D image 200 generated by the scanning device 205 and received on the computer device or system 390 for processing. The image 200 may be processed using a graphical image interface provided on the computer device 390 running an image processing or computer aided design software 395. Referring to Figures 2A and 2B, the depth image 200 is initially preprocessed or optimized to improve quality and accuracy and provide an image suitable for determining the attributes of the wearer's foot. The image 200 may be optimized using standard image processing techniques. Figure 2B illustrates the resulting image after preprocessing. In this example, digital noise and dead pixels near the heel and the first and fifth metatarsal heads present in Figure 2A are eliminated, as are dead pixels lining the border of the image. The preprocessing also may correct for clipping, which in this example exaggerated the brightness of the heel and caused loss of detail. For example, as shown in Figure 2B, the three-dimensional details of the heel are represented with greater accuracy. Other preprocessing methods may be used to prepare the image for measurement, such as normalization of the intensity of the pixels, flattening, or artefact rejection.

Turning to Figure 3 A and 3B, landmark measurements are identified in the depth image 200. Landmark measurements are features of the image 200 that serve as reference points for calculating the relevant dimensions of the foot model in order to appropriately size and customize the sole insert. Foot impression images or depth images 200 may feature feet having various orientations reflecting the conditions of foot capture. For example, in the case of a capture using an impression box 105, users may place their feet in the box at various angles (e.g., with toes pointing straight, inward, or outward), resulting in depth images 200 with different orientations for the feet. To correct for these imperfections, anatomical markers must be identified in each image to calculate the angle of the foot and optionally normalize its orientation.

The first landmark feature may be a major axis or a set of major axes 250, 251. In some embodiments, landmark axes 250, 251 may form the axes of a coordinate system for measuring the location of landmark features. Figure 3 A illustrates the identification and use of major axes of the foot as landmark axes 250, 251. In the embodiment illustrated, a heel-to- toe axis or long axis 250 is taken from the back of the heel to an area near the middle toe such that the axis 250 generally spans the length of the foot. In additional, a short axis 251 orthogonal to the long axis 250 and bisecting the middle of the foot near the arch is identified. The combination of the long axis 250 and short axis 251 comprises the landmark axes of the illustrated foot. In some embodiments, the axes 250, 251 may be drawn on the image 200 using tools provided by the customization application's interface. In some embodiments, the software 395 may identify the axes automatically without user input. The landmark axes 250, 251 thus identified may form the coordinate system in relation to which locations of the foot's features are identified and measured.

It should be noted that the above is just one example of a landmark measurement, and that other landmark measurements can be made. For example, a landmark axis may comprise a line tangent to both the lateral heal and the fifth metatarsal, i.e., a line tangent to the outside of the wearer's foot. In another example, a line tangent to the medial heel and the first metatarsal head may serve as a landmark measurement instead. Other examples include a line bisecting the foot's width, or a line from the second toe to the heel center. Thus, any line between significant features of the image can be used as a landmark measurement or axis provided it can effectively serve as a reference for the remaining measurements. The landmark measurements can be made by the custom designer or software operator using the graphical user interface of the design software 395. In some embodiments, the design software 395 may identify the relevant features of the image 200 and draw the landmark measurements without user input. In other embodiments, the measurements may be made with combinations of user input and the software's determinations. In some embodiments, such as illustrated in Figure 3 A, the image 200 of the foot is rotated to the vertical after the major axes are identified in order to normalize its orientation and measurements.

After the landmark measurements are made, certain features of the foot are identified on the image 200. In some embodiments, the center back of the heel or heel point 210 is identified on the image 200. This can be accomplished by the operator using for example, a cursor provided on the graphical user interface of the application 395. Alternatively, the software 395 can be programmed to identify and locate the center back of the heel 210 using a variety of image processing techniques. Next, the first metatarsal joint may be located by various steps. For example, the most medial portion of the foot or ball of the foot 220 may be used as a reference for the first metatarsal joint, as illustrated in Figure 3 A. The ball of the foot 220 may be identified by the software 395 or by the operator. After the ball of the foot is identified, the feature may be projected on the heel to toe axis 250, and the sesamoid height 260 taken as the distance between the heel 210 and the projection of the ball of the foot 220 along the axis 250 - or the vertical distance 260 between the heel 210 and the ball of the foot 220.

Figure 4 illustrates a screenshot of interface of the software 395 for customizing a sole insert displaying digital images 200, 200' of a pair of feet, in accordance with an embodiment of the present invention. In the embodiment illustrated, no projection along an axis is made after the ball of the foot 220 is identified either by the application 395 or by the operator. Instead, the distance from the heel 210 to ball of the foot 220 is used directly by the application 395 as a dimension to design the sole insert. Figure 3B further illustrates the ability to custom design more than one sole insert on the application, each sole insert being custom-designed to match each foot of the wearer. Thus, the depth images 200, 200' displayed in Figure 4 have different shapes and dimensions. In particular, heel to ball of the foot distances measured according to the steps described above differ between the feet.

Figure 3B illustrates a depth image 200 of a foot with another method of obtaining landmark measurements. In some embodiments, such as illustrated in the figure, the sesamoidal height 260 may be taken by identifying the first metatarsal joint 225 instead of the ball of foot using a depth map of the foot. In particular, the metatarsal joint 225 may be identified by locating the regional maximum 226 on a depth map 200 of the first metatarsal region as with be explained below. As with the center back heel, the first metatarsal joint 225 can be identified either by the operator or by the software 395. To facilitate the identification of the first metatarsal joint 225 on the depth map 200, the image 200 may be blurred using a filter to find a locally connected regional maximum 226 on the image. A variety of filtering techniques may be used to blur the image. In the embodiment illustrated, an edge-preserving linear filter such as a Weiner filter, which reduces noise and adds some blur, was applied to the image 200.

The regional maximum 226 of the first metatarsal region highlighted in the depth image 200 of Figure 3B. A regional maximum 226 is a cluster or collection of adjacent pixels having the same intensity or depth, which is greater than the intensity of surrounding pixels. In the region of the first metatarsal joint, the regional maximum 226 represents the ball of the wearer's foot. In particular, the centroid of the regional maximum 226 is identified as the center of the first metatarsal joint. The regional maximum 226 of the first metatarsal region and the centroid of the joint may be identified by the operator or the software 395. With the heel point 210 and the center of the first metatarsal region accurately located on the image, a straight line projection along a landmark axis 250 is calculated for the center of the first metatarsal joint, as illustrated in Figure 3B. In the example shown, the landmark axis is a heel-to-toe axis 250 that includes the heel point 210. The projection of the first metatarsal joint along this axis yields the sesamoid height 260, which is the distance along the axis 250 between the heel 210 and the projection of the first metatarsal joint 225.

Projections for other features (e.g., another metatarsal joint) may be calculated as well along one or more of the landmark axes, and additional dimensions that are necessary or desirable to generate the custom sole insert, such as dimensions of the sesamoidal depression, may be calculated from the image.

Next, three-dimensional models 300 of the sole insert are created in the design software 395 from the dimensions determined in the previous steps. Referring back to Figure 4, the screenshot of the software interface 395 also includes models 300, 300' of sole inserts on the right. The soles inserts are generated based on the depth images 200, 200' on the same screen. In the embodiment described, a basic insole corresponding to the shoe size of the wearer serves as the starting point for creating the custom sole insert 500. Figures 5A-5B illustrate outlines 385 or perimeters of a basic insole 305 for a three-dimensional model 300. The shoe size of the wearer is determined from the dimensions obtained from the depth image 200, and predetermined dimensions for insoles for each standard shoe size are identified. The insole having predetermined dimensions corresponding to the shoe size of the wearer is therefore the base from which the sole insert is customized. The method modifies this basic insole 305 to fit the foot of the wearer according to the measurements obtained from the depth image 200, as well as the features identified and customizing dimensions further calculated with the design software 395.

Referring to Figure 5A, an outline 385 for a basic insole 305 corresponding to the shoe size of the wearer is created. From that outline, an inner block 386 within the basic insole 305 is formed, as illustrated in Figure 5B. The inner block 386 matches the outline 385 of the basic insole 305 but is offset from it. In some embodiments, the interior offset between the inner block and the basic insole is 3 mm wide. However, the inner block 386 may be offset from the outer perimeter 385 of the basic insole 305 by a different margin. This margin may depend of the shoe size, dimensions and specific features of the wearer's foot, or the type and make of shoe intended to house the custom sole insert 500, for example. The offset marks a region that may be variously thinned down or rounded out on the edge of the custom sole insert 500, and serves to facilitate gluing the insert to the shoe.

Figure 6 illustrates the formation of a heel cup 315 on the model 300 for the custom sole insert 500 according to an embodiments of the present invention. The heel cup 315 is a depression in the heel region of the custom sole insert or heel bed that accomplishes several functions. First, the cup 315 serves to better accommodate the bottom of the heel and therefore add stability to the heel. The heel cup 315 further serves to lower the angle of the wearer's foot with relation to the floor. Lowering the angle of the wear's foot reduces the foot's tendency to slide toward the front of the shoe, which lowers pressure on the wearer's forefoot. The lower angle further relieves the forefoot from some of weight of the wearer and eases the pressure on the forefoot by shifting the center of pressure toward the heel. The heel cup 315 can be created by removing sole insert material from the heel bed, or by reducing the material density of the heel bed such that the heel bed is depressed relative to the surrounding area when the custom sole insert is under the pressure of the wearer's foot. In some embodiments, such as illustrated in Figure 6, the heel cup 315 is formed by a depression from the heel plane. The heel plane is a plane substantially parallel to the upper surface of the custom sole insert and comprising the highest points of the medial edge and the lateral edge the heel region. The heel cup 315 may be oriented along the length of the insole.

Next, a hollow area 330 under the first metatarsal head is created. In the embodiment illustrated in Figures 8A and 8B, the depressed area 330 comprises a cut out. To create the metatarsal cut out 330, a minimum-perimeter bounding box 331 is first defined around the basic insole, as illustrated in Figure 7 A. The bounding box 331 is the smallest rectangle that can contain the outline of the insole. Next, a circle 332 is defined in the forefoot area of the insert near the first metatarsal head 320. As illustrated in Figure 7A and 7B, the circle 332 is tangent to the medial side of the minimum-perimeter bounding box 331 surrounding the basic insole 305 and may be centered on the previously identified first metatarsal joint 320. An arc of this circle provides a substantial portion of the boundary of the metatarsal cut out 330. Accordingly, the portion of the basic insole 305 inside the circle 332 comprises the cut out 330 to accommodate the ball of the foot or the first metatarsal joint 320. In some

embodiments, the cut out's boundary deviates from the arc of the circle near the edges of the cut out 330. For example, near the medial end of the cut out, the boundary may curve away from the circle such that the cut out 330 includes space outside the circle.

Figure 7B details the customization of the forefoot region 340 of the basic insole 305. In some embodiments, the lateral end of the cut out 330 may terminate before the front edge 333 of the basic insole. In particular, the lateral end of the cut out may be located on the boundary circle 332 at a point between the front edge 333 of the insole and a line 334 formed by the diameter of the circle 332 parallel to the front side of the bounding box 331. In these embodiments, the front end 335 of the custom sole insert corresponding to the second to fifth metatarsal head is drawn from this point down to the lateral end of the insole. This boundary 335 may be curved toward the heel in an arc that generally follows the arc formed by the ends of the second through the fifth metatarsal heads. In some examples, the sole insert boundary 335 corresponding to the second through fifth metatarsal heads may comprise an arc of a circle centered near the arch of the insole. In various embodiments, the edges of the custom sole insert are rounded off to tame their sharpness for wearer comfort, ease of installation, and to decrease wear and tear and improve durability. For example, the intersection of the cut out 330 and the medial edge of the sole insert may be smoothed out. Similarly, the lateral end of the cut out where it intersects with the front of the sole insert may be rounded off. Further, the perimeter of the sole insert may be filleted for comfort and to facilitate gluing.

The custom foot model 300 resulting from the above-described customization is transmitted to the manufacturing device 400. The model data 300 may be transmitted over a network or via a storage media. The manufacturing device 400 can be any device configured to generate the custom sole insert 500 based on specifications comprising dimensional parameters received from a customizing software 395. The manufacturing device may thus include various devices such as additive manufacturing machines (e.g., 3D printers), subtractive manufacturing machines (e.g., CNC machines such as laser cutters or other types of cutters), or other manufacturing equipment. For example, a 3D printer may create the custom sole insert by the successive addition of super-imposed layers of insole material. Exemplary sole insert materials include various types of plastic, nylon, foam, or gel. In an exemplary embodiment, the custom sole insert may comprise a contour-molding, shock- absorbing material such as TECHNOGEL®. The custom sole insert 500 may be formed with a single material or with a combination of materials. For example, the heel cup may be formed with a softer material than the remainder of the rear region 510 of the sole insert. Combinations of materials may be formed with layers of different materials. In addition, each layer may comprise multiple materials.

The resulting product is a custom sole insert 500 for footwear. Figures 9A-9B illustrate exemplary custom sole inserts of various sizes and shapes according to

embodiments of the invention. In particular, the custom sole insert 500 is designed to alleviate discomfort in high heel shoes. The custom sole insert 500 as designed extends down the length of the wearer's foot from the forefoot through the heel region 510, and is configured to shift the wearer's weight from the first metatarsal head or the ball of the foot 520 toward the heel 510. To that end, in the embodiment shown in Figures 9A-9B, the sole insert is provided with a cut out 530 to accommodate the first metatarsal head, whereas the second to fifth metatarsal heads are supported by the sole insert and elevated in relation to the first metatarsal head. In other embodiments, a hollow area 530 may be provided to accommodate the first metatarsal head. In such an embodiment, the area under the first metatarsal head may comprise a material providing less pressure on the metatarsal head than the material of the rest of the forefoot 540. In further embodiments, the area under the first metatarsal head may also be depressed relative to the surrounding area of the forefoot region 540 in order to accommodate, and reduce the pressure on, the first metatarsal head. The custom sole insert 500 may be further provided with a heel cup comprising a hollow area under the heel. The heel cup lowers the angle of the foot with relation to the floor, and helps shift pressure from the forefoot region 540 to the rearfoot region 510. The custom sole insert 500 thus redistributes the weight of the wearer more evenly across the bottom of the wearer's foot.

Figure 9A illustrates exemplary custom sole inserts according to embodiments of the present invention. Each sole insert 500, 500' is manufactured in accordance with principles described herein. The soles are custom-made for two different wearers having the same shoe size. Despite this common characteristic, the wearers' feet differ in shape and features. For example, the heel to ball of the foot distance for the customer with the left insole 500 is 17.92 cm, whereas the same measurement of the customer with the right insole 500' is 19.44 cm. Because each insole 500, 500' is custom-made for a particular foot, these and other differences yield two insoles of different shapes and/or sizes despite the same shoe size.

Similarly, Figure 9B illustrates an exemplary pair of custom sole inserts 500, 500' according to embodiments of the present invention. In this instance, the pair of insoles 500, 500' is manufactured for a single customer and may have the same shoe size. However, because shapes and features of the feet are different and each insole is custom-made for its corresponding foot, the insoles 500, 500' illustrated in Figure 9B have different heel to ball of the foot measurements and therefore different sizes and/or shapes.

Embodiments of the present invention further comprise a high heel shoe 600 (not illustrated) having a custom sole insert 500 as described above. The high heel shoe 600 comprises an elevated heel. The custom sole insert 500 is designed based on the dimensions of the wearer's foot as well as the configuration of the high heel shoe. The dimensions of the wearer's foot are obtained via as scanned foot impression as described above. In some embodiments, a sock liner covers the sole insert after installation in the high heel shoe, rendering the custom sole insert invisible in the shoe. The high heel shoe 600 having the custom sole insert 500 according to embodiments of the present invention alleviates pressure on the ball of the wearer's foot and provides added stability.

Each of the system, server, computing device, and computer described in this application can be implemented on one or more computer systems and be configured to communicate over a network. They all may also be implemented on one single computer system. In one embodiment, the computer system includes a bus or other communication mechanism for communicating information, and a hardware processor coupled with bus for processing information.

The computer system also includes a main memory, such as a random access memory (RAM) or other dynamic storage device, coupled to bus for storing information and instructions to be executed by processor. Main memory also may be used for storing temporary variables or other intermediate information during execution of instructions to be executed by processor. Such instructions, when stored in non-transitory storage media accessible to processor, render computer system into a special-purpose machine that is customized to perform the operations specified in the instructions.

The computer system further includes a read only memory (ROM) or other static storage device coupled to bus for storing static information and instructions for processor. A storage device, such as a magnetic disk or optical disk, is provided and coupled to bus for storing information and instructions.

The computer system may be coupled via bus to a display, such as a cathode ray tube

(CRT), for displaying information to a computer user. An input device, including

alphanumeric and other keys, is coupled to bus for communicating information and command selections to processor. Another type of user input device is cursor control, such as a mouse, a trackball, or cursor direction keys for communicating direction information and command selections to processor and for controlling cursor movement on display. This input device typically has two degrees of freedom in two axes, a first axis (e.g., x) and a second axis (e.g., y), that allows the device to specify positions in a plane.

The computer system may implement the techniques described herein using customized hard-wired logic, one or more ASICs or FPGAs, firmware and/or program logic which in combination with the computer system causes or programs computer system to be a special-purpose machine. According to one embodiment, the techniques herein are performed by the computer system in response to the processor executing one or more sequences of one or more instructions contained in main memory. Such instructions may be read into main memory from another storage medium, such as storage device. Execution of the sequences of instructions contained in main memory causes the processor to perform the process steps described herein. In alternative embodiments, hard-wired circuitry may be used in place of or in combination with software instructions.

The term storage media as used herein refers to any non-transitory media that store data and/or instructions that cause a machine to operation in a specific fashion. Such storage media may comprise non-volatile media and/or volatile media. Non-volatile media includes, for example, optical or magnetic disks, such as storage device. Volatile media includes dynamic memory, such as main memory. Common forms of storage media include, for example, a floppy disk, a flexible disk, hard disk, solid state drive, magnetic tape, or any other magnetic data storage medium, a CD-ROM, any other optical data storage medium, any physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, NVRAM, any other memory chip or cartridge.

Storage media is distinct from but may be used in conjunction with transmission media. Transmission media participates in transferring information between storage media. For example, transmission media includes coaxial cables, copper wire and fiber optics, including the wires that comprise bus. Transmission media can also take the form of acoustic or light waves, such as those generated during radio-wave and infra-red data

communications.

Various forms of media may be involved in carrying one or more sequences of one or more instructions to the processor for execution. For example, the instructions may initially be carried on a magnetic disk or solid state drive of a remote computer. The remote computer can load the instructions into its dynamic memory and send the instructions over a telephone line using a modem. A modem local to the computer system can receive the data on the telephone line and use an infra-red transmitter to convert the data to an infra-red signal. An infra-red detector can receive the data carried in the infra-red signal and appropriate circuitry can place the data on bus. Bus carries the data to main memory, from which processor retrieves and executes the instructions. The instructions received by main memory may optionally be stored on storage device either before or after execution by the processor.

The computer system also includes a communication interface coupled to bus. The communication interface provides a two-way data communication coupling to a network link that is connected to a local network. For example, the communication interface may be an integrated services digital network (ISDN) card, cable modem, satellite modem, or a modem to provide a data communication connection to a corresponding type of telephone line. As another example, the communication interface may be a local area network (LAN) card to provide a data communication connection to a compatible LAN. Wireless links may also be implemented. In any such implementation, the communication interface sends and receives electrical, electromagnetic or optical signals that carry digital data streams representing various types of information. Network link typically provides data communication through one or more networks to other data devices. For instance, network link may provide a connection through local network to a host computer or to data equipment operated by an Internet Service Provider (ISP). ISP in turn provides data communication services through the worldwide packet data communication network now commonly referred to as the "Internet." Local network and Internet both use electrical, electromagnetic or optical signals that carry digital data streams. The signals through the various networks and the signals on network link and through the communication interface, which carry the digital data to and from the computer system, are example forms of transmission media.

The computer system can send messages and receive data, including program code, through the network(s), network link and the communication interface. In the Internet example, a server might transmit a requested code for an application program through Internet, ISP, local network and the communication interface.

The received code may be executed by the processor as it is received, and/or stored in storage device, or other non-volatile storage for later execution.

It should be understood that variations, clarifications, or modifications are

contemplated. Applications of the technology to other fields are also contemplated.

Exemplary systems, devices, components, and methods are described for illustrative purposes. Further, since numerous modifications and changes will readily be apparent to those having ordinary skill in the art, it is not desired to limit the invention to the exact constructions as demonstrated in this disclosure. Accordingly, all suitable modifications and equivalents may be resorted to falling within the scope of the invention.

Thus, for example, any sequence(s) and/or temporal order of steps of various processes or methods that are described herein are illustrative and should not be interpreted as being restrictive. Accordingly, it should be understood that although steps of various processes or methods or connections or sequence of operations may be shown and described as being in a sequence or temporal order, but they are not necessarily limited to being carried out in any particular sequence or order. For example, the steps in such processes or methods generally may be carried out in various different sequences and orders, while still falling within the scope of the present invention. Moreover, in some discussions, it would be evident to those of ordinary skill in the art that a subsequent action, process, or feature is in response to an earlier action, process, or feature.

It is also implicit and understood that the applications or systems illustratively described herein provide computer-implemented functionality that automatically performs a process or process steps unless the description explicitly describes user intervention or manual operation.

It is understood from the above description that the functionality and features of the systems, devices, components, or methods of embodiments of the present invention include generating and sending signals to accomplish the actions.

It should be understood that claims that include fewer limitations, broader claims, such as claims without requiring a certain feature or process step in the appended claim or in the specification, clarifications to the claim elements, different combinations, and alternative implementations based on the specification, or different uses, are also contemplated by the embodiments of the present invention.

It should be understood that combinations of described features or steps are contemplated even if they are not described directly together or not in the same context.

The terms or words that are used herein are directed to those of ordinary skill in the art in this field of technology and the meaning of those terms or words will be understood from terminology used in that field or can be reasonably interpreted based on the plain English meaning of the words in conjunction with knowledge in this field of technology. This includes an understanding of implicit features that for example may involve multiple possibilities, but to a person of ordinary skill in the art a reasonable or primary understanding or meaning is understood.

It should be understood that the above-described examples are merely illustrative of some of the many specific examples that represent the principles described herein. Clearly, those skilled in the art can readily devise numerous other arrangements without departing from the scope as defined by the following claims.

Claims

THE CLAIMS What is claimed is:

1. A sole insert designed for use in high heel shoes comprising:

a forward region supporting the forefoot and comprising a hollow area disposed beneath the first metatarsal head, the hollow area providing less support to said first metatarsal head than is provided to other areas of the forward region that support the forefoot, and

a rear region supporting the midfoot and the rearfoot including the heel, with the rear region extending from the forefoot to the back of the heel.

2. The sole insert of claim 1, wherein the hollow area has an upper surface that is depressed relative to the other areas of the forefoot region.

3. The sole insert of claim 1, wherein the hollow area comprises softer material than the material in the other areas of the forefoot region.

4. The sole insert of claim 1, wherein the hollow area comprises a cut out portion of the forefoot region configured to accommodate the first metatarsal head, the cut out region being arcuate and free of sole insert material.

5. The sole insert of claim 1, wherein the rear region comprises a heel cup configured to accommodate the heel, with the heel cup comprising a depression relative to other portions of the rear region.

6. The sole insert of claim 1, wherein the heel cup comprises material that is softer than material in other portions of the rear region.

7. The sole insert of claim 1, wherein a boundary of the hollow area has a boundary defined at least in part by an arc of a circle centered on the first metatarsal joint.

8. A shoe comprising a shoe body having a sole, an elevated heel, a sock liner and the sole insert according to claim 1, wherein the sole insert is present above the sole and under the sock liner.

9. A method of manufacturing the custom sole insert of claim 1, the method comprising:

receiving from a client device foot impression data that includes a depth image of a foot,

computing from the depth image of the foot a plurality of foot dimensions, generating from the plurality of foot dimensions 3D model data for a custom sole insert,

fabricating from the 3D model data the custom sole insert using a manufacturing device,

wherein the custom sole insert extends from the forefoot to the back of the heel and comprises a hollow area under the first metatarsal head of the wearer's foot.

10. The method of claim 9, wherein computing the plurality of foot dimension data further comprises:

locating the most medial portion of the foot on the depth image, and

determining the sesamoid height based on the location of the most medial portion of the foot on the depth image.

11. The method of claim 9, wherein computing the plurality of foot dimension data further comprises:

selecting a landmark axis on the depth image,

identifying the first metatarsal joint on the depth image, and

calculating a straight line projection along the landmark axis.

12. The method of claim 11, wherein identifying the first metatarsal joint on the depth image further comprises:

locating the approximate region of the first metatarsal joint,

blurring the depth image using a filter,

identifying the regional maximum of the region of the first metatarsal joint, and locating the center of the first metatarsal joint as the centroid of the regional maximum.

13. The method of claim 9, wherein generating 3D model data for the custom sole insert further comprises: determining a shoe size based on the plurality of foot dimensions,

selecting a basic insole having predetermined dimensions corresponding to the shoe size,

forming a bounding box around the basic insole, and

delimiting a boundary for the hollow area of the custom sole insert.

14. The method of claim 9, wherein the depth image of the foot is obtained by: providing a compressible material that retains its shape when deformed,

pressing the wearer's foot into the compressible material such that an impression of at least the bottom of the foot is formed in the material, and

scanning the impression using a scanning device comprising a range camera, wherein the scanning device generates a depth image of the impression.

15. A method of capturing the anatomy of a foot for use in the design of a custom sole insert, the method comprising:

providing a compressible material that retains its shape when deformed,

pressing the foot into the compressible material such that an impression of at least the bottom of the foot is formed in the material, and

16. The method of claim 15, wherein the depth image of the impression is used to provide a plurality of foot dimensions, and the method further comprises:

generating from the plurality of foot dimensions 3D model data for a custom sole insert,

17. The method of claim 15 which further comprises:

providing a high heel shoe having a shoe body, a sole and an elevated heel, and installing the custom sole insert inside the high heel shoe.

18. The method of claim 17, further comprising providing a sock liner, wherein the custom sole insert is installed above the sole and under the sock liner.

19. A method of providing comfort for a wearer's foot in a high heel shoe, the method comprising:

providing a high heel shoe having a shoe body, a sole and an elevated heel, providing a sole insert comprising a hollow area under the first metatarsal head, the sole insert extending from the forefoot to the back to the heel, the sole insert supporting the midfoot and the rearfoot including the heel, with the rear region extending from the forefoot to the back of the heel, and

installing the sole insert inside the high heel shoe.

20. The method of claim 19, further comprising providing a sock liner, wherein the sole insert is installed above the sole and under the sock liner, and wherein the sole insert comprises a heel cup configured to accommodate the heel, the heel cup comprising a depression relative to other areas of the rear region.