Customizable footwear inserts and methods for using same

Systems and methods for customizable footwear inserts having a plurality of removable sections. Removable sections may be permanently bonded to adjacent layers of the inserts to eliminate or minimize the tendency of removable sections surrounding the removed sections to fall out or migrate into the cavity created by the removed sections. In some aspects, multiple layers are provided to increase the comfort, support, and/or fit provided to the wearer of the insert. Further, some embodiments include a removable backing that, when removed, exposes an adhesive that may be utilized to, inter alia, adhere an original insole of footwear to the top of the footwear insert such that the user's foot is still in contact with the original insole when wearing the footwear.

BACKGROUND OF THE INVENTION

Embodiments of the present invention generally relate to systems and methods for customizable footwear inserts. More specifically, the present invention relates to systems and methods for customizable footwear inserts having a plurality of removable sections.

Shoe insoles or inserts are commercially available devices that may be used to increase the comfort of various types of footwear. Some such insoles may also be designed to relieve painful conditions, such as bunions, hammer-toes, nerve pain or other painful conditions of the foot. Insoles, sold over-the-counter, are relatively inexpensive but can provide limited relief of many conditions since they are not customizable. Doctor prescribed, custom-designed orthotics can provide relief, but are expensive, inconvenient to replace and are typically relatively non-adjustable. As such, there is a need for insoles that are inexpensive, widely-available, easily adjustable and provide pain relief for a wide range of painful and/or damaging foot conditions

BRIEF SUMMARY OF THE INVENTION

In one embodiment of the invention, a footwear insert is provided. The footwear insert comprises a first layer having an upwardly facing surface and a downwardly facing surface, at least one removable section, the removable section having an upwardly facing surface coupled to the first layer downwardly facing surface via a permanent bond.

In another embodiment of the invention, the footwear insert is comprised of: a first layer having an upwardly facing surface and a downwardly facing surface; a second layer having an upwardly facing surface and a downwardly facing surface, the second layer upwardly facing surface is coupled to the first layer downwardly facing surface via a first bond; and a third layer having an upwardly facing surface and a downwardly facing surface, the third layer upwardly facing surface is coupled to the second layer downwardly facing surface via a second bond; and at least one removable section having an upwardly facing surface coupled to the third layer downwardly facing surface via a third bond.

In another embodiment of the invention the footwear insert comprises: a first layer having an upwardly facing surface and a downwardly facing surface; a second layer having an upwardly facing surface and a downwardly facing surface, the second layer upwardly facing surface coupled to the first layer downwardly facing surface via a first bond; a third layer having an upwardly facing surface and a downwardly facing surface, the third layer upwardly facing surface coupled to the second layer downwardly facing surface via a second bond; a fourth layer having an upwardly facing surface and a downwardly facing surface, the fourth layer upwardly facing surface coupled to the third layer downwardly facing surface via a third bond; and at least one removable section having an upwardly facing surface coupled to the fourth layer downwardly facing surface via a fourth bond.

In yet another embodiment, a method of using a footwear insert comprises the steps of: creating a customized footwear insert by tearing at least one removable section of the footwear insert to remove a substantial portion of the removable section from the footwear insert, wherein the footwear insert includes a first layer having an upwardly facing surface and a downwardly facing surface, and at least one removable section, the removable section upwardly facing surface coupled to the first layer downwardly facing surface via a permanent bond; and the customized footwear insert is insert into footwear.

DETAILED DESCRIPTION OF THE INVENTION

Certain terminology may be used in the following description for convenience only and is not limiting. The words “lower” and “upper” and “top” and “bottom” designate directions in the drawings to which reference is made. The terminology includes the words above specifically mentioned, derivatives thereof and words of similar import.

Furthermore, the subject application references certain processes which are presented as series of ordered steps. It should be understood that the steps described with respect to those processes are not to be understood as enumerated consecutive lists but could be performed in various orders while still embodying the invention described herein.

Where a term is provided in the singular, the inventors also contemplate aspects of the invention described by the plural of that term. As used in this specification and in the appended claims, the singular forms “a”, “an” and “the” include plural references unless the context clearly dictates otherwise, e.g., “a layer” may include a plurality of layers. Thus, for example, a reference to “a method” includes one or more methods, and/or steps of the type described herein and/or which will become apparent to those persons skilled in the art upon reading this disclosure.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods, constructs and materials are now described. All publications mentioned herein are incorporated herein by reference in their entirety. Where there are discrepancies in terms and definitions used in references that are incorporated by reference, the terms used in this application shall have the definitions given herein.

Disclosed herein are systems and methods for creating and using customizable footwear inserts. Such inserts may be worn in various types of footwear including, without limitation, standard and specialty shoes, boots, orthopedic braces and apparatus, and postoperative shoes. The customizable footwear inserts may be customized by the user to shift force (when one is walking or standing) away from targeted areas of the feet that may be painful, injured or otherwise damaged, to other targeted areas of the foot. This may sometimes be referred to as “off-loading.” In some aspects of the present invention, the footwear insert allows the creation of one or more “offloading zone(s)” to minimize the forces and pressure experienced by targeted areas of the feet during walking and standing (e.g., to protect injuries from force and stress, and to reduce pain).

Referring toFIG. 1, depicted is a bottom view of a footwear insert100shaped in the form of a standard footwear insole in accordance with one embodiment of the present invention. An insert sized in this manner may be used with zero, or minimal, trimming of the exterior edges of the insert (i.e., the insert may simply be slid into the shoe as is). In the depicted embodiment, the insert has a length I1of approximately 10.25 inches and widths W1and W2of approximately 3.5 and 2.5 inches, respectively, however, alternate dimensions may be substituted without departing from the scope hereof.

As may be best seen in the cross-sectional view ofFIG. 2, insert100includes a first layer106having a first layer upwardly facing surface116and a first layer downwardly facing surface118and a plurality of removable sections112. Removable section upwardly facing surfaces120are coupled to first layer downwardly facing surface118via a bond110.

In the depicted embodiment, first layer106is microfiber, specifically Alcantara®, which has a blend of approximately 68% polyester and approximately 32% polyurethane. First layer106has an approximate thickness of one (1) millimeter (“mm”), however alternate thicknesses may be substituted without departing from the scope hereof. Alternate materials may be substituted without departing from the scope of the present invention including, without limitation, a single or double-sided adhesive material (i.e., a flat material that has adhesive applied on both of its major surfaces).

One such alternate is depicted inFIG. 5, which has a cross-section that is substantially identical to the cross-section of footwear insert100as depicted inFIG. 2and as described herein, with the exception of first layer106. As seen inFIG. 5, in lieu of first layer106, footwear insert500includes a single-sided adhesive material, wherein the material506is fabric that has an adhesive508applied to the upwardly facing surface522thereof. The depicted embodiment also includes a removable backing504atop adhesive508. Similar to first layer106of footwear insert100material506and its associated adhesive508and optional backing504are coupled to removable sections512via bond520. Removable sections512are defined by cuts514similar to cuts114as described in greater detail herein.

In an embodiment similar to that shown inFIG. 5, a double-sided adhesive fabric could be substituted for the single-sided adhesive fabric. In such embodiments, bond520is not required as the adhesive applied to the downwardly facing surface524of the material506may be utilized to adhere removable sections512to material506. In such embodiments, the removable sections may be able to be reattached to material506after initial removal thereof, but the integrity of bond520is likely to be significantly lesser than that described herein with respect to footwear insert100. Each of these embodiments has its own advantages and disadvantages and the elements of the various footwear inserts may be interchanged in order to meet the specific needs of each user/product.

Referring back toFIG. 1, footwear insert100includes removable sections112across the entire downwardly facing surface of footwear insert100(i.e., there is no portion of the downwardly facing surface of footwear insert100that does not initially have a removable section112prior to customization by a user). In the depicted embodiment, the removable sections112are foam such as a memory-resistant polyurethane foam (e.g., PORON®). However, alternate materials and/or alternate types of foam may be substituted without departing from the scope hereof.

Also, removable sections112have an approximate thickness of five (5) mm, however, alternate thicknesses may be substituted without departing from the scope hereof. Similarly, removable sections112are shown as being approximately one-half (½) inch squares (or portions thereof at points at which the squares are cut by the exterior shape of the insert100) arranged in a grid pattern, however, alternate shapes and alternate patterns may be substituted without departing from the scope of the present invention. For example, sections112may be substantially diamond, substantially rectangular, substantially triangular, substantially circular, and combinations thereof. Also, although the depicted embodiment includes sections112having nearly identical shapes and sizes, in some embodiments of the present invention, the shapes and/or sizes of the individual sections112in a specific insert may vary from the other shapes and/or sizes of the other sections112of the specific insert. Also, sections112do not need to be arranged in a pattern in order to meet the goals of the present invention. Also, in some embodiments of the present invention, some areas of the downwardly facing surface of footwear insert100do not have removable sections112.

Footwear insert100includes a bond110that is a permanent bond. In some embodiments, these bonds are formed via a reactive polyurethane and polychloroprene solvent-based adhesive system, however, other types of bonds and/or other methods of creating the bonds may be substituted without departing from the scope hereof. Embodiments of the present invention are also envisioned that include non-permanent bonds.

In embodiments of the present invention that incorporate a permanent bond, the permanent bond facilitates the removal of one or more individual removable sections112without degrading the integrity of the bond between the first layer106and the surrounding removable sections112(i.e., the surrounding removable sections112are those sections112that are located adjacent one or more sections112that are/have been removed by the user). The use of a permanent bond allows the individual removable sections112to be removed by tearing the material of sections112without affecting the integrity of the bond between the first layer106and the surrounding removable sections212. Although bond110is depicted inFIG. 2as having a specific thickness, this thickness is not meant to illustrate an amount of bonding material to be utilized for bond110. The amount of the bonding material may be varied without departing from the scope hereof.

As depicted inFIGS. 1 and 2, substantially vertical cuts114define individual removable sections112in order to facilitate the individual removal thereof without damage to the remainder of the footwear insert. In some embodiments of the present invention, removable sections112are removed by tearing the material of the removable section112in a location proximal to bond110but not necessarily at bond110. Substantially vertical cuts114allow the piece to be removed when the tear intersects with all of the substantially vertical cuts114defining the removable section112, thereby allowing the majority of the removable section112to be removed from the footwear insert. For example, in the embodiment depicted inFIGS. 1 and 2, removable sections112may be removed by tearing the material of removable section112along a tear line such as tear line128without damage to the remainder of the footwear insert because, in part, the amount of tear force required to tear the removable section112is significantly lower than the pull strength of bond110(bond110which binds the removable sections112and the surrounding removable sections112to first layer106). Also, such removable section tear force is lower than the amount of force required to tear the material of first layer106These relative strengths facilitate removal of individual removable sections112without damage to first layer106or bond110. This is particularly important for the portion of the bond110that secures surrounding removable sections112to the first layer106as it minimizes or eliminates the potential for surrounding removable sections112(i.e., removable sections located adjacent the cavity132caused by the removed sections130) to unintentionally fall out, for example, due to wear and tear on the footwear insert caused by removal of the removed sections or use of the customized footwear insert. This bond110also helps to prevent surrounding removable sections112from “migrating” into cavity(ies)132while the user is wearing the insole, which can sometimes occur if the bond between the surrounding removable sections112and the first layer106is not strong enough to prevent such migration.

In some embodiments of the present invention, the footwear inserts are manufactured via a process with the following steps: 1) each of the layers is adhered to its adjacent layers, each layer having a size larger than the size of the footwear insert being created, and the layer of material that will become the removable sections is initially provided as a solid piece with no cuts therein; 2) the exterior shape of the footwear insert is cut through all of the adhered layers; 3) substantially vertical cuts114are cut into the solid layer of removable section material to create individual removable sections112. In the embodiment of the present invention depicted inFIGS. 1 and 2, substantially vertical cuts114extend throughout ninety-nine (99) percent of the thickness of the removable section layer but do not penetrate the bond110or the first layer106. However, alternate embodiments of the present invention are envisioned in which the substantially vertical cuts114extend through a lesser extent of the removable section layer of material and/or the cuts114penetrate bond110and/or first layer106.

In some embodiments of the present invention in which the top layer is a microfiber type material, the footwear inserts are manufactured via a process with the following steps: 1) the microfiber is laid flat on a flat surface and prepped for bonding; 2) microfiber layer and foam or foam-type material layer is pretreated with a catalyst, microfiber is treated on the downwardly facing surface only whereas the foam is treated on both sides; 3) a catalytic-cured adhesive is applied to the pretreated side of the microfiber layer and to one side of the foam or foam-type material; 4) the adhesive is dried mechanically or otherwise; 5) the downwardly facing side of the microfiber layer is applied to the upwardly facing side of the foam or foam-type materials layer; 6) if additional layers of foam or foam-type materials are to be included, the additional layers are applied to each other, and to the foam or foam-type material layer coupled to the microfiber; 7) all layers are pressed together; 8) the exterior shape of the footwear insert is cut through all of the adhered layers; and 9) substantially vertical cuts are cut into the solid layer of removable section material to create individual removable sections to the extent desired.

The footwear inserts of the present invention may be utilized to create customized footwear inserts. To create these customized footwear inserts, the user simply removes the desired removable sections by tearing or the like. After all desired removable sections have been removed, the user inserts the footwear insert into the desired footwear. In some uses of the present invention, the user removes an original insole (i.e., the insole that is typically sold or otherwise provided with the footwear) from the footwear into which the insert will be inserted prior to inserting the footwear insert therein. Optionally, thereafter, the user may reinsert the original insole atop the upwardly facing surface of the customized footwear insert. However, reinsertion is not required as the user's foot may also rest comfortably upon the customized footwear insert.

In embodiments of the present invention that incorporate an adhesive backing on the upwardly facing surface of the footwear insert such as those shown inFIGS. 5 and 8, the adhesive backing may be removed from the footwear insert upwardly facing surface to expose the adhesive located below the backing. This step may be done prior to reinsertion of the original insole. Thereafter, the downwardly facing surface of the original insole may be adhered to said footwear insert upwardly facing surface via the adhesive.

After the footwear insert has been customized by removing removable sections in locations that correspond with locations of the feet at which offloading is desired, the insert is then placed in footwear as is depicted inFIG. 3. When one is walking or standing while the insert is in his or her shoe, the areas of the foot122at which the removable sections have been removed will not contact the bottom surface inside the shoe or boot, and therefore will not transmit force to those locations of the foot. The forces involved with walking and standing will therefore be transmitted to the surrounding removable sections and other removable sections that have not been removed. In this manner, customization of the footwear insert via removal of specific removable sections creates one or more off-loading zone(s) to minimize the forces and pressure experienced by targeted areas of the feet during walking and standing.

Further embodiments of the present invention are envisioned in which the size and shape of the footwear insert is such that the footwear insert may be cut to a custom shape in order to fit any type of footwear. An example of one such insert shaped and sized for custom sizing is shown inFIG. 7. The overall size and shape of the insert700is larger than that of a typical insole, thereby allowing the user to cut the insert700as needed to fit the size of the footwear into Which it will be inserted. In the depicted embodiment, the insert has a length I1of approximately 12.5 inches and widths W1and W2of approximately 4.75 and 3.25 inches, respectively, however, alternate dimensions may be substituted without departing from the scope hereof. The shape of insert700facilitates cutting of a custom size by the user by including a relatively standard heel section736having a substantially semicircular end728that will require minimal modification in order to meet the desired heel shape. Similarly, insert700includes relatively standard arch shapes732on both sides of insert700to allow the insert700to be easily modified to fit left or right footwear, again with relatively minor modification. Arch shapes732gradually enlarge as they extend from the heel section736of insert700to the enlarged toe section734of insert700. Toe section734includes rounded edges738to facilitate fitting without cutting into a rounded toe section of footwear. Some or all of these sections of the insert700will be cut by the user as desired to create the exterior shape desired by the user.

Further embodiments of the present invention are envisioned in which the footwear insert is oblong such as the insert depicted inFIG. 4. Such a shape provides maximum coverage for use in any type of footwear. In the depicted embodiment, the insert has a length I1of approximately 5.75 inches and a width W1of approximately 4.75 inches, respectively, however, alternate dimensions may be substituted without departing from the scope hereof.

Turning now toFIGS. 6 and 8, depicted are two potential cross-sections for the footwear insert700depicted inFIG. 7. However, it should be noted that the cross-sections ofFIGS. 6 and 8can be utilized with a footwear insert having virtually any external shape including, without limitation, those shapes shown inFIGS. 1 and 4without departing from the scope hereof.

Referring now to the cross-sectional view ofFIG. 6, insert600includes a first layer605, a plurality of removable sections610, a plurality of intermediate layers612and622, and a material layer624, wherein all of the layers are coupled to each other via a plurality of bonds620,616,618,626.

In the depicted embodiment, first layer605is similar to first layer106as described in greater detail herein. First layer605includes a first layer upwardly facing surface640(upon which objects may be placed such as a foot, an original insole, etc.) and a first layer downwardly facing surface642. Downwardly facing surface642is coupled to the uppermost intermediate layer612via bond620. In the depicted embodiment, bond620,616,618, and626are as described herein for bond110. However, bonds may be permanent or non-permanent without departing from the scope hereof. Also, bonds620,616,618, and626may all be identical or may vary from each other without departing from the scope hereof.

In the depicted embodiment, uppermost intermediate layer612is a foam such as a memory-resistant polyurethane foam (e.g., PORON®) having an approximate thickness of three (3) mm. Intermediate layer612also has a different density than intermediate layer622and removable sections610in order to provide additional comfort and/or support to the user. For example, in the depicted embodiment, intermediate layer612is a PORON® Slow Rebound Material having model no. SRVFMA 15118 with antimicrobial properties. However, alternate non-foam materials and/or alternate types of foam may be substituted without departing from the scope hereof. Also, alternate thicknesses may be substituted without departing from the scope hereof.

Uppermost intermediate layer612has a downwardly facing surface644, which is coupled to intermediate layer622via bond616. In the depicted embodiment, intermediate layer622is a foam such as a memory-resistant polyurethane foam (e.g., PORON®) having an approximate thickness of two (2) mm. In the depicted embodiment, intermediate layer622is a PORON® Performance material having model no. FMA with antimicrobial properties. However, alternate non-foam materials and/or alternate types of foam may be substituted without departing from the scope hereof. Also, alternate thicknesses may be substituted without departing from the scope hereof.

Intermediate layer622has a downwardly facing surface646, which is coupled to material layer624via bond626. In the depicted embodiment, intermediate layer622is a fabric having an approximate thickness of one-half (0.5) mm. For example, the fabric may be a classic backing in mixed cotton having a weight of approximately 200 g/m2. However, alternate non-fabric materials may be substituted without departing from the scope hereof. Also, alternate thicknesses may be substituted without departing from the scope hereof.

Material layer624has a downwardly facing surface648, which is coupled to the upwardly facing surfaces650of the plurality of removable sections610via bond618. In the depicted embodiment, removable sections610are defined by cuts614and extend across the entire downwardly facing surface of footwear insert600(i.e., there is no portion of the downwardly facing surface of footwear insert600that does not initially have a removable section610prior to customization by a user). In the depicted embodiment, the removable sections610are foam such as a memory-resistant polyurethane foam, for example, PORON® Performance material having model no. FMA with antimicrobial properties. However, alternate materials and/or alternate types of foam may be substituted without departing from the scope hereof.

Also, removable sections610have an approximate thickness of nine and one-half (9.5) mm, however, alternate thicknesses may be substituted without departing from the scope hereof. Similarly, removable sections610are shown (as best seen inFIG. 7) as being approximately one-half (½) inch squares (or portions thereof at points at which the squares are cut by the exterior shape of the insert700or the exterior shape thereof as customized by a user) arranged in a grid pattern, however, alternate shapes and sizes may be substituted without departing from the scope of the present invention as discussed in greater detail with reference toFIGS. 1 and 2.

In embodiments of the present invention that incorporate a permanent bond, the permanent bond facilitates the removal of one or more individual removable sections610without degrading the integrity of the bond between the material layer624and the surrounding removable sections610for the reasons discussed in greater detail herein with respect to first layer106and removable sections112ofFIGS. 1 and 2. The material layer624further acts to prevent any damage to intermediate layers612and622during customization of the footwear insert600by the user (e.g., tearing of removable sections610from insert600). That is, material layer624acts as a barrier that eliminates or minimizes tearing of intermediate layers612and/or622when pressure is applied to removable sections610during the tearing of same. In some embodiments of the present invention, removable sections610are removed by tearing the material of the removable section610in a location proximal to bond618but not necessarily at bond618. Substantially vertical cuts614allow the piece to be removed when the tear intersects with all of the substantially vertical cuts614defining the removable section610, thereby allowing the majority of the removable section610to be removed from the footwear insert. For example, in the embodiment depicted inFIGS. 6 and 7, removable sections610may be removed by tearing the material of removable section610along a tear line such as tear line652without damage to the remainder of the footwear insert because, in part, the amount of tear force required to tear the removable section610is significantly lower than the pull strength of bond618(bond618which binds the removable sections610and the surrounding removable sections610to material layer624). Also, such removable section tear force is lower than the amount of force required to tear the material of material layer624. These relative strengths facilitate removal of individual removable sections610without damage to material layer624, bond618, or any of the intermediate layers or bonds located above material layer624. This is particularly important for the portion of the bond618that secures surrounding removable sections610to the material layer624as it minimizes or eliminates the potential for surrounding removable sections610(i.e., removable sections located adjacent the cavity630caused by the removed sections632) to unintentionally fall out, for example, due to wear and tear on the footwear insert caused by removal of the removed sections or use of the customized footwear insert. This bond618also helps to prevent surrounding removable sections610from “migrating” into cavity(ies)630while the user is wearing the insole, which can sometimes occur if the bond between the surrounding removable sections610and the material layer624is not strong enough to prevent such migration.

It should be noted that the cross-section ofFIG. 8is substantially identical to the cross-section ofFIG. 6as described herein with the exception of first layer605. As seen inFIG. 8, in lieu of first layer605, footwear insert700includes a single-sided adhesive material, wherein the material706is fabric that has an adhesive708applied to the upwardly facing surface740thereof. The depicted embodiment also includes a removable backing704atop adhesive708. Similar to first layer605of footwear insert600, material706and its associated adhesive708and optional backing704are coupled to removable sections710via a plurality of bonds720,716,718,726and intermediate layers712,722, and724which are substantially identical to bonds620,616,618,626and intermediate layers612,622, and624, respectively, as described herein. Removable sections710are defined by cuts714similar to cuts114as described in greater detail herein. Removable sections710may be removed by tearing the material of removable section710along a tear line such as tear line752as described in greater detail herein. The bond718that secures surrounding removable sections710to the material layer724minimizes or eliminates the potential for surrounding removable sections710(i.e., removable sections located adjacent the cavity730caused by the removed sections750) to unintentionally fall out, for example, due to wear and tear on the footwear insert caused by removal of the removed sections or use of the customized footwear insert. This bond718also helps to prevent surrounding removable sections710from “migrating” into cavity(ies)730as described in greater detail herein.