Patent ID: 6485661
Filing Date: 2002-11-26
Classification: A43B,B29C,B29D,B29K,Y10S,Y10T

Abstract:
A method for forming a blank for an orthotic insert, said method comprising the steps of:forming a fiberglass-resin base layer having a heel end, a forefoot end, and medial and lateral sides; forming at least one graphite fiber-resin reinforcement layer; positioning said graphite fiber-resin reinforcement layer on said fiberglass-resin base layer so that medial and lateral edges of said reinforcement layer will be spaced inwardly from finished medial and lateral edges of said blank so as to form clear borders of said fiberglass-resin base layer between said medial and lateral edges of said graphite fiber-resin reinforcement layer and said medial and lateral edges of said blank, said clear borders each having a width sufficient to prevent microcracks formed in trimming of said fiberglass-resin base layer from reaching and propagating into said graphite fiber-resin reinforcement layer; bonding said fiberglass-resin base layer and said graphite fiber-resin reinforcement layer so that resin matrixes thereof join together and said layers form a unitary structure for engaging a plantar surface of a person's foot; and trimming said fiberglass-resin base layer along said edges thereof so as to form said finished medial and lateral edges of said blank.