Abstract:
A molding device is disclosed. In one aspect, the molding device includes a foam layer, a gel layer placed over the foam layer, and a flexible cover configured to enclose the foam layer and the gel layer, wherein the flexible cover comprises a movable portion and an intermediate portion placed below the movable portion, wherein the intermediate portion is placed between a portion of the gel layer and a portion of the foam layer, and wherein the flexible cover includes a surface that contacts a top of the gel layer, wherein the gel layer is configured to elastically support the shoe insole via the surface of the flexible cover, and wherein the movable portion is configured to move the portion of the gel layer between a first position where the movable portion contacts the intermediate portion and a second position where the movable portion is separated from the intermediate portion.

Description:
RELATED APPLICATIONS 
       [0001]    This application is related to i) the U.S. patent application entitled “Moldable Footwear Insole” (Attorney Docket No. ZGI.002A) and ii) the U.S. patent application entitled “System and Method for Reproducing Molded Insole” (Attorney Docket No. ZGI.004A) concurrently filed with this application, both of which are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    1. Field 
         [0003]    The described technology generally relates to a molding device and a method of use thereof to produce a custom molded insole. 
         [0004]    2. Description of the Related Technology 
         [0005]    A shoe insole or insole refers to an insert with a cushion layer which is fitted into a shoe. Insoles are widely used to provide support and comfort for a user&#39;s foot. To provide optimized comfort to a specific foot, custom-made insoles have been developed that conform to the unique and specific shape of a user&#39;s foot. In general, custom insoles can be made by molding insoles using a person&#39;s feet. These customized insoles are generally more comfortable than mass produced insoles. 
       SUMMARY 
       [0006]    The apparatuses and systems of the present disclosure have several features, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of the described technology as expressed by the claims which follow, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description,” one will understand how the features of this disclosure provide several advantages over current insole molding technologies. 
         [0007]    In one aspect, a molding device includes a foam layer, a gel layer placed over the foam layer, and a flexible cover configured to enclose the foam layer and the gel layer, wherein the flexible cover includes a movable portion and an intermediate portion placed below the movable portion, wherein the intermediate portion is placed between a portion of the gel layer and a portion of the foam layer, and wherein the flexible cover includes a surface that contacts a top of the gel layer, wherein the gel layer is configured to elastically support the shoe insole via the surface of the flexible cover, and wherein the movable portion is configured to move the portion of the gel layer between a first position where the movable portion contacts the intermediate portion and a second position where the movable portion is separated from the intermediate portion. 
         [0008]    Another aspect is a method of custom molding a shoe insole including placing the insole on a molding device, wherein the molding device includes a foam layer, a gel layer, and a flexible cover, first pressing the insole between a user&#39;s foot and a surface of the molding device with the molding device in a first position, wherein the surface contacts a top of the gel layer; and second pressing the insole between the user&#39;s foot and the surface of the molding device with the molding device in a second position different from the first position. In some aspects the method further includes heating the insole to a temperature in the range of approximately 120° C. and approximately 140° C. for between about three minutes and about five minutes; 
         [0009]    Another aspect is a shoe insole molded by the above method. 
         [0010]    Another aspect is a molding device for molding a shoe insole including a gel layer and a flexible cover configured to enclose the gel layer, wherein the flexible cover includes a surface that contacts a top of the gel layer, wherein the gel layer is configured to elastically support the shoe insole via the surface of the flexible cover. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The above mentioned and other features of this disclosure will now be described with reference to the drawings of several embodiments of the present molding device and method of use thereof. The illustrated embodiments of the apparatuses and methods are intended to illustrate but not to limit the disclosure Like reference numerals refer to like elements throughout the detailed description. The drawings contain the following figures: 
           [0012]      FIG. 1  is a conceptual drawing that illustrates a method for custom molding an insole using a molding device according to one embodiment. 
           [0013]      FIGS. 2A and 2B  show top and bottom views, respectively, of a pair of example insoles that can be molded to conform to the specific shape of a user&#39;s foot with example molding devices and methods described herein according to one embodiment. 
           [0014]      FIGS. 3A and 3B  show perspective views of an example molding device including a moveable portion in a first position and a second position, respectively, according to one embodiment. 
           [0015]      FIGS. 3C and 3D  show side views of the molding device of  FIGS. 3A and 3B  with the movable portion in the first position and the second position, respectively. 
           [0016]      FIG. 3E  shows a top view of the molding device of  FIGS. 3A and 3B  with a movable portion shown in the first position. 
           [0017]      FIG. 4  depicts example interior layers of the molding device according to one embodiment. 
           [0018]      FIG. 5  is a side view of the molding device that illustrates the placement of each of the internal layers within the cover according to one embodiment. 
           [0019]      FIG. 6A  shows an example molding stand including two molding devices, according to one embodiment. 
           [0020]      FIG. 6B  is a cross-sectional view of the molding stand of  FIG. 6A  and illustrates the placement of the molding devices within the molding stand. 
           [0021]      FIG. 7  is a flowchart depicting an example method of using a molding device as described herein to custom mold a moldable insole according to one embodiment. 
           [0022]      FIGS. 8A through 8C  illustrate comparison of a user&#39;s foot to a selected insole to determine whether a properly sized insole has been selected. 
           [0023]      FIG. 9  illustrates an example heater configured to heat the insoles according to one embodiment. 
           [0024]      FIGS. 10A through 10C  illustrate proper and improper insertion of moldable insoles into the heater according to one embodiment. 
           [0025]      FIG. 11  illustrates an example of the relative positioning of a user, a heated moldable insole, and a molding device in preparation for molding the moldable insole according to one embodiment. 
           [0026]      FIG. 12  provides a detailed view of the alignment of a heated moldable insole on a molding device according to one embodiment. 
           [0027]      FIGS. 13A and 13B  illustrate the use of an example heel alignment guide on the moldable insole to properly align the user&#39;s foot relative to the moldable insole during the molding process according to on embodiment. 
           [0028]      FIG. 14  illustrates an example positioning of a user with weight shifted to his or her heels during some portions of the molding process according to one embodiment. 
           [0029]      FIG. 15  illustrates an example positioning of a user and the molding device with a movable portion in the second position during some portions of the molding process according to one embodiment. 
           [0030]      FIGS. 16A and 16B  illustrate the use of an example quality control tool to check that the heel portion of a molded insole is properly aligned and level according to one embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    Embodiments will be described with respect to the accompanying drawings. Like reference numerals refer to like elements throughout the detailed description. In this disclosure, the term “substantially” includes the meanings of completely, almost completely or to any significant degree under some applications as understood by those skilled in the art. 
         [0032]      FIG. 1  is a conceptual drawing that illustrates a method  10  for molding a non-molded insole  100  (hereinafter to be interchangeably used with non-molded insoles  100 ) to produce a custom molded insole  100 ′ using a molding device  300  according to one embodiment. The method  10  the uses non-molded insoles  100 , a heater  200 , and the molding device  300  to mold the non-molded insoles  100  to conform to the unique shape of a user&#39;s foot  5 . 
         [0033]    The method  10  begins at step  15  with selection of a pair of non-molded insoles  100 , one for each of a user&#39;s feet  5 . Each of the insoles  100  may include at least one rigid layer that becomes pliable upon heating. At step  15 , the selected non-molded insole  100  is inserted into the heater  200  and heated until the at least one rigid layer becomes pliable. 
         [0034]    At step  20 , the heated insole  100  is removed from the heater  200  and placed on a top surface of the molding device  300 . The user&#39;s foot  5  is then placed on top of the heated insole  100 . As the foot  5  presses the heated insole  100  into the molding device  300 , the heated insole  100  substantially conforms to the specific musculoskeletal shape of the foot  5 . As shown in step  20 , the molding device  300  includes a moveable portion  310  resting on top of a fixed portion  320 . This position of the movable portion  310  of the molding device  300  is referred to as the first position throughout this application. The molding device  300  can mold at least the rearfoot and/or midfoot portion of the insole  100  in the first position. In some embodiments, the user leans back, placing his or her weight on her heels to mold a portion of the insole  100  with the movable portion  310  of the molding device  300  in the first position. 
         [0035]    At step  25 , the movable portion  310  of the molding device  300  is moved into a second position as shown. When the movable portion  310  is in the second position, the moveable portion  310  can be pulled up away from the fixed portion  320  and toward a user&#39;s shin. The molding device  300  includes a handle  350  attached to a distal end of the moveable portion  310  that can be gripped to move the moveable portion  310  into the second position as described. The molding device  300  can mold at least a forefoot and/or midfoot portion of the insole  100  with the movable portion  310  in the second position. 
         [0036]    Step  25  can be performed substantially close in time to step  20 , either before or after. In some embodiments, step  25  follows immediately after or precedes immediately before step  20  such that the heated insole  100  remains substantially pliable during step  20  and step  25 . Moreover, in some embodiments, the foot  5  is not repositioned on the heated insole  100  or molding device  300  between step  20  and  25  (other than the movement of the insole  100  and foot  5  as the movable portion  310  of the molding device  300  is moved from the first position to the second position, or vice versa). 
         [0037]    Method  10  concludes at step  30 , where the now molded insole  100 ′ is removed from between the user&#39;s foot  5  and the molding device  300  and allowed to cool. As the rigid layer of the molded insole  100 ′ cools, it returns to its substantially rigid state and holds its newly molded shape. Accordingly, method  10  allows a user to mold a non-molded insole  100 , with a general shape, into a molded insole  100 ′ with a specific shape that conforms substantially to the unique shape of the user&#39;s foot  5 . 
         [0038]    In some embodiments, the method  10  is repeated for each of a user&#39;s feet  5 . A single insole  100  (for example, for the right foot) can be heated, molded to the user&#39;s foot  5  with the movable portion  310  of the molding device  300  in the first position and in the second position, and allowed to cool, and then the process can be repeated again for the other insole  100  (for example, for the left foot). In some embodiments, both insoles  100  (left and right) are heated together and molded separately. For example, both insoles  100  can be heated at the same time, one insole  100  can be molded using the molding device  300  with the movable portion  310  in the first and second positions, and then the other insole  100  can be molded using the molding device  300  in the first and second positions. In some embodiments, the insoles  100  are heated and molded together, for example, using a single molding device  300  wide enough to simultaneously accommodate both of a user&#39;s feet  5 , or two narrower molding devices  300  placed side by side. The specific details and devices of method  10  will now be discussed in greater detail below. 
         [0039]      FIGS. 2A and 2B  show top and bottom views, respectively, of a pair of example insoles  100  that can be molded to conform to the specific shape of a user&#39;s foot  5  with embodiments of the molding devices  300  and methods described herein according to one embodiment. The following description of  FIGS. 2A and 2B  is applicable to insoles  100  in both a molded or non-molded state. 
         [0040]    Each pair of insoles  100  includes a right and a left insole  100 , each shaped generally with a profile configured to substantially follow the shape of a user&#39;s left and right foot, respectively. Each insole  100  includes a rearfoot or heel area  101 , midfoot or arch area  103 , and a forefoot or toe area  105  as shown. In some embodiments, the insoles  100  are made from one or more layers. For example, as shown in  FIGS. 2A and 2B , the insoles  100  are made from four layers. Each of the insoles  100  includes a cover layer  110  placed on top of a foam layer  120 , a rigid layer  130 , formed of a heat-moldable material, placed below the foam layer  120 , and a base layer  140  covering the rigid layer  130 . In some embodiments, the cover layer  110  and the foam layer  120  extend under the entirety of the user&#39;s foot  5 , for example, from the rearfoot area  101  to the forefoot area  105 . In some embodiments, the rigid layer  130  and the base layer  140  extend only under the rearfoot area  101  and at least a portion of the midfoot area  103  (or, in other words, in some embodiments, the rigid layer  130  and base layer  140  do not extend under the toe area  105  of the insole  100 ). 
         [0041]    The rigid layer  130  of the insole  100  can be made from a heat-formable or thermoplastic material, such as a glycol-modified polycyclohexylenedimethylene terephthalate copolymer (PCTG), ABS, PVC, A-PET, PETG, or another suitable material that is (1) substantially rigid throughout a range of temperatures at which the insole  100  will be used, for example, the range of temperatures typical within a user&#39;s shoe, and (2) substantially pliable or moldable throughout a range of temperatures that will be used during the molding process, for example, temperatures in the range of about 120 to about 140° C. In some embodiments, the material of the rigid layer  130  is pliable at temperatures which allow the heated insole  100  to be pressed against a user&#39;s foot  5  while still in a pliable state without burning or injuring the user. In some embodiments, the foam layer  120  and the cover layer  130  provide sufficient insulation to protect a user&#39;s foot  5  during molding. 
         [0042]    In some embodiments, as shown in  FIG. 2A , the cover layer  110  also includes one or more heel alignment guides  111 , configured to aid a user in correctly locating his or her heel relative to the insole  100  during molding. Moreover, additional alignment guides  113  are present on the cover layer  111  which may be used to help align the insole  100  relative to the molding device  300  during the molding process. However, some or all of the elements  111  and  113  can be omitted. 
         [0043]    A detailed description of an example moldable insole that can be used with the devices and methods described herein is provided in the U.S. patent application entitled “Moldable Footwear Insole” (Attorney Docket No. ZGI.002A) that is concurrently filed herewith and is incorporated herein by reference. It should be noted, however, that the molding devices and methods described herein may be usable with other types of moldable insoles. 
         [0044]      FIGS. 3A through 3E  show various views of an example molding device  300  according to one embodiment. Specifically,  FIGS. 3A and 3B  show perspective views of the molding device  300  including a moveable portion  310  in a first position and a second position, respectively.  FIGS. 3C and 3D  show side views of the molding device  300  shown with the movable portion  310  in the first position and the second position, respectively.  FIG. 3E  shows a top view of the molding device  300  with a movable portion  310  shown in the first position. Depending on the specific embodiments, certain elements may be removed from or additional elements may be added to the molding device  300  illustrated in  FIGS. 3A through 3E . Furthermore, two or more elements may be combined into a single element, or a single element may be realized as multiple elements. 
         [0045]    The molding device  300  shown in  FIGS. 3A and 3B  includes a body  301  shaped as a rectangular prism, although other shapes may be used without departing from the scope of this disclosure. The body  301  is configured to support the insole  100  and the foot  5  during the molding process. The insole  100  can be placed on a top surface  305  of molding device  300  and the foot  5  is placed on top of the insole  100 . 
         [0046]    The body  301  of the molding device  300  may include one or more internal layers of gel and one or more internal layers of foam, as will be described below, placed within a flexible cover  360 . Accordingly, as a user steps onto the top surface  305  of the molding device  300 , the user&#39;s foot presses into the body  301  of the molding device  300 , and the top surface  305  of the molding device  300  conforms substantially to the specific shape of the bottom surface of the user&#39;s foot  5 . The insole  100 , pressed between the foot  5  and the molding device  300 , is therefore molded to conform to the shape of the foot  5 . 
         [0047]    A front or distal portion  302  of the body  301  of the molding device  300  is divided between a moveable portion  310  and a fixed portion  320  separated by a gap  315 . The movable portion  310  can be configured as a flap and attached to the rest of body  301  at a proximal end of the movable portion  310  at a hinge region  313 . A handle  350  can be provided at a distal end of the movable portion  310  and configured such that a user can grip the handle  350  and pull the movable portion  310  up away from the fixed portion  320 , thereby increasing the size of gap  315 . In some embodiments, the movable portion  310  connects to the fixed portion  320  at approximately the location where the ball of a foot is placed during molding. In some embodiments, the length of the moveable portion  310  is approximately one-third the total length of the molding device  300 . 
         [0048]      FIGS. 3A and 3C  show the molding device  300  with the movable portion  310  in the first position. In the first position, the moveable portion  310  rests substantially on top of and is supported by the fixed portion  320 , and the gap  315  is substantially small. In some embodiments, a lower surface of the movable portion  310  rests directly on top of a top surface of the fixed portion  320  such that the gap  315  is substantially closed. With the movable portion  310  in the first position, the top surface  305  of the molding device  300  has a substantially horizontal planar shape. Accordingly, in this position, the molding device  300  provides a flat molding surface. 
         [0049]      FIGS. 3B and 3D  show the molding device  300  with the movable portion  310  in the second position. In the second position, the moveable portion  310  is pulled up and away from the fixed portion  320  and the gap  315  is substantially open. Because the moveable portion  310  is attached to the body  301  at the hinge region  313 , in the second position, the moveable portion  310  is substantially positioned at an angle relative to the plane of the top surface  305  in the first position. In some embodiments, the moveable portion  310  curves up and away from the body  301 . The molding device  300 , with the movable portion  310  in the second position, provides a molding surface configured to conform to the shape of a user&#39;s foot  5  with the toes in extension. 
         [0050]    As shown in  FIG. 3C , the molding device  300  may have an overall thickness T. In some embodiments, the overall thickness T is between approximately 30 mm and approximately 200 mm. In some embodiments, the overall thickness T is approximately 100 mm. For a front or distal portion  302  of the molding device  300 , the overall thickness T is divided between the thickness of the moveable portion  310 , T m , and the thickness of the fixed portion  320 , T f . In some embodiments, the thickness T m  is substantially half or less than half the thickness of T f . For example, in some embodiments, T m  is approximately 30 mm and T f  is approximately 70 mm. However, the described technology is not limited to the above ranges and other thicknesses for T, T m , and T f  are possible. As will be explained below, the thicknesses of T m  and T f  may correspond to the thicknesses of the individual layers that make up the internal structure of the molding device  300 . 
         [0051]    The molding device  300  has an overall length L and an overall width W as shown in  FIG. 3E . The length L and width W define the overall shape of the molding device  300 . As shown, the molding device  300  may be substantially rectangular, although other shapes are possible as long as the shape provides adequate space for an insole  100  and user&#39;s foot  5  to be received thereon. In some rectangular embodiments, each of the length L and the width W may be in the range of approximately 150 mm and approximately 400 mm. However, other lengths and widths are possible, for example, as long as the length L and width W are sufficient to accommodate the entire length of a user&#39;s foot  5  and provide some clearance space (for example, at least 10 mm) around the foot  5 . The width W can be configured such that the molding device  300  is suitable for use with only a single foot  5  at a time. The width W can further be configured such that the molding device  300  is suitable for use with both feet  5  at the same time. 
         [0052]    In some embodiments, as shown in  FIG. 3E , the top surface  305  of the molding device  300  includes one or more alignment guides  307  that aid a user in placing the insole  100  correctly on the molding device  300 . The alignment guides  307  may be markings corresponding to other alignment guides (for example, front alignment guides  113  as seen in  FIG. 2A ) on the cover layer  130  of the insole  100 . For example, in some embodiments, the user may be instructed to align front alignment guides  113  on the cover layer  110  with the alignment guides  307  on the top surface  305  of the molding device  300 . This may help ensure that the insole  100  is correctly aligned on the molding device  300  so as to correctly be molded when the movable portion  310  of the molding device  300  is in the second position. 
         [0053]    In some embodiments, as shown in  FIG. 3E , the handle  350  of the molding device  300  includes one or more holes  351  extending through the handle  350 . The holes  351  can be configured to make the handle  350  easier to grip. 
         [0054]    In some embodiments, as seen in  FIGS. 3A and 3B , the molding device  300  includes a cover  360  configured to surround the internal components of the molding device  300 . The cover  360  can be made from any typical flexible fabric, such as flexible cloth. In some embodiments, the cover  360  is made from a thin, elastic cloth, for example Spandex. The particular shape of the cover  360  will become apparent as the internal components of the molding device  300  are described below. 
         [0055]    The cover  360  may be configured to be removable. As seen in  FIG. 3A , in some embodiments, the cover  360  includes a zipper  365  extending around a back surface of the molding device  300 . The cover  360  may use other closure mechanisms. For example, the cover  360  may include one or more openings that use Velcro, buttons, snaps, toggles, magnets, zippers, or any other suitable closure mechanism. In some embodiments, the cover  360  includes openings that do not use any closure mechanism. For example, the cover  360  may include an opening that includes overlapping flaps. In some embodiments, the cover  360  does not include any opening and may not be removable. In some embodiments, no cover is used. 
         [0056]      FIG. 4  depicts example interior layers of the molding device  300  according to one embodiment. In the embodiment shown, the molding device  300  includes two layers: a gel layer  370  and a foam layer  380 . 
         [0057]    The gel layer  370  is placed directly below the top surface  305  of the molding device  300 . Accordingly, the gel layer  370  is the structure within the molding device  300  that allows the molding device  300  to accurately mold the insoles  100  to the specific shape of a user&#39;s foot  5 . In some embodiments, the gel layer  370  provides a liquid pressure effect against the bottom and sides of the foot during molding. That is, in some embodiments, the gel layer  370  provides a substantially or significantly uniform pressure around the sides of the foot, as well as on the bottom of the foot. The gel layer  370  may allow a more accurate molding of a heel cup region of the insole  100  by providing uniform molding pressure around the heel as high as 2 cm to about 4 cm above the bottom of the insole  100 . Similarly, the gel layer  370  may allow for a higher formed arch and a more generally contoured molded insole  100 . The gel layer  370  may be made from a gel or foam material with a density and/or hardness comparable to the hardness of muscle tissue. For example, in some embodiments, the gel layer  370  is formed from a silicon rubber or other suitable material with a Shore hardness of in the range of about 00-40 and about 00-05. In some embodiments, the gel layer is formed from Ecoflex® Supersoft 0010, Ecoflex® Supersoft 0020, or Ecoflex® Supersoft 0030 available from Smooth-On, Inc., of Macungie, Pa. 
         [0058]    The foam layer  380  is placed below the gel layer  370 . The foam layer  380  supports the gel layer  370 , for example, by providing a sturdy, compressible base for the molding device  300 . The foam layer  380  can be made from a stiff, deformable viscoelastic foam, such as memory foam. In some embodiments, the foam layer  380  is made at least partially from a polyurethane material that has viscoelastic property. Preferably, in some embodiments, the foam layer  380  should be just pliable to enough to allow the gel layer  370  to contour to the bottom of the user&#39;s foot  5  when the user stands on the molding device  300 . Preferably, in some embodiments, the foam layer  380  is as stiff as possible while still allowing deformation sufficient to allow the gel layer  370  to contour to the entire bottom surface of a user&#39;s foot  5  and at least a portion of the side surface of the foot. In some embodiments, the foam layer  380  may deform in the range of between about 0.1 inches to about 1.0 inch when a user stands on the molding device  300 . In some embodiments, the combined deformation of the gel layer  370  and the foam layer  380  is sufficient to allow the top surface  305  to conform to the shape of the arch of the foot  5  when the user stands on the molding device  300 . In some embodiments, each of the gel layer  370  and/or the foam layer  380  includes one or more layers. 
         [0059]    Each of the gel layer  370  and the foam layer  380  can be configured in size and shape to fit within the cover  360 . Accordingly, the gel layer  370  and the foam layer  380  may each have a length and a width that correspond to the overall length L and width W of the molding device  300  described above in reference to  FIG. 3E . Moreover, the thicknesses of gel layer  370  and the foam layer  380  may correspond to the thicknesses of the moveable portion  310 , T m , and the fixed portion  320 , T f , respectively. 
         [0060]      FIG. 5  is a side view of the molding device  300  that illustrates the placement of each of the internal layers  370 ,  380  within the cover  360  according to one embodiment. As shown, the cover  360  is configured to substantially surround the gel layer  370  and the foam layer  380 . At the distal end  302 , the molding device  300  is divided into the moveable portion  310  and the fixed portion  320  as described above. The cover  360  includes a movable pocket  361  and a fixed pocket  363  as shown. The foam layer  380  may be inserted into the bottom portion of the cover  360  and a distal end of the foam layer  380  may be placed within the fixed pocket  363 , forming the fixed portion  310 . Similarly, the gel layer  370  may be inserted into the top portion of the cover  360  above the foam layer  370 . A distal end of the gel layer  370  may be placed within the moveable pocket  361  of the cover  360 , forming the movable portion  310 . Accordingly, a top portion of the fixed pocket  363  and a bottom portion of the moveable pocket  361  are located between the distal ends of the foam layer  380  and the gel layer  370 . The proximal ends of the foam layer  380  and the gel layer  370 , in some embodiments, are placed directly on top of each other. 
         [0061]    A portion of the gel layer  370  may be placed within the fixed pocket  363 . For example, the distal end of the gel layer  370  is split with a top portion placed within the moveable pocket  361  and a bottom portion placed within the fixed pocket  363 . Or, for example, the gel layer  370  includes two or more layers, with a top layer placed within the moveable pocket  361  and a bottom layer placed within the fixed pocket  363 . Similarly, a portion of the foam layer  380  may be placed within the movable pocket  361 . For example, the distal end of the foam layer  380  is split with a top portion with a top portion placed within the moveable pocket  361  and a bottom portion placed within the fixed pocket  363 . Or, for example, the foam layer  380  includes two or more layers, with a top layer placed within the moveable pocket  361  and a bottom layer placed within the fixed pocket  363 . 
         [0062]    The layers placed within the movable pocket  361 , that accordingly include the movable portion  310  of the molding device  300 , are sufficiently pliable to allow movement of the movable portion  310  of the molding device  300  between the first and second positions as described above. The movable portion  310  allows the molding device  300  to more accurately mold the forefoot and/or midfoot portions of the insole  100 . 
         [0063]      FIG. 6A  shows an example molding stand  400  including two molding devices  300  according to one embodiment. The molding stand  400  includes a base  405  configured to rest on the ground and support one or more molding devices  300  therein. In some embodiments, the base  405  includes one or more recesses  410  formed in a top surface of the base  405 . The base  405  can include a single recess  410  configured to hold a single molding device  300  or two (or more) molding devices  300  side by side. The base  405  may include more than one recess  410 , each recess configured to hold a single molding device  300 . The base  405  may support one or more molding devices  300  above the ground such that a user may easily step up and onto the molding devices  300  in the base  405  of the molding stand  400 . 
         [0064]    A vertical support  415  can extend upward from the base  405  and provide a handle  420  that users can use to support and balance themselves during the molding process. In some embodiments, the vertical support  415  extends up and away from an outer edge of the base  405  such that the handle  420  is positioned substantially in front of a user standing on the molding stand  400 . The handle  420  can be positioned between three and four feet above the base  405 . In some embodiments, the vertical support  415  is adjustable, such that the height of the handle  420  can be adjusted to accommodate users of different heights. 
         [0065]      FIG. 6B  is a cross-sectional view of the molding stand  400  of  FIG. 6A  and illustrates the placement of the molding devices  300  within the molding stand  400 . As shown, the molding device  300  rests within the recess  410  of the base  405 . In some embodiments, the movable portion  310  is placed substantially above the top surface of the base  405 . This may facilitate use of the molding device  300 . For example, it may make it easier to grab the handle  350  and move the movable portion  310  of the molding device  300  from the first position to the second position. In some embodiments, however, the top surface  305  of the molding device  300  may be level with (or even below) the top surface of the base  300 . 
         [0066]      FIG. 7  is a flowchart depicting an example method  700  of using a molding device  300  as described herein to custom mold an insole  100  according to one embodiment. Method  700  describes in detail the molding method  10  discussed at a conceptual level above in reference to  FIG. 1 . Depending on the specific embodiment, additional steps may be added, others removed, or the order of the steps changed in the method  700 . The method  700  will now be described in detail with reference to  FIG. 7  as well as the specific examples and embodiments illustrated in  FIGS. 8A-16B . 
         [0067]    The method  700  may be performed in a retail establishment, for example, a sporting goods store, runner specific athletic store, or other shoe store. Accordingly, in some embodiments, the user may be customer visiting a retail establishment to obtain a pair of custom molded insoles  100 . An employee or clerk of the retail establishment may assist the user in custom molding a pair of insoles  100  using the method  700  described herein. In another embodiment, a medical professional, for example a doctor or physical therapist, may assist the user in custom molding a pair of insoles  100 . 
         [0068]    At block  704 , a non-molded insole  100  is selected to be custom molded to conform to the specific shape of the user&#39;s foot  5 . In some embodiments, selection of the insole  100  involves consideration of several factors. For example, the selection can be made based on the size of the user&#39;s foot  5 , the weight of the user, or the anticipated use of the insole  100 . 
         [0069]      FIGS. 8A through 8C  illustrate comparison of a user&#39;s foot  5  to a selected insole  100  to determine whether a properly sized insole  100  has been selected.  FIG. 8A  illustrates an example of a properly sized insole  100  as compared to the user&#39;s foot  5 .  FIG. 8B  provides an example of an insole  100  that is too small when compared to the user&#39;s foot  5 . The toes of the user&#39;s foot  5  fall on top of, over, or across the outline of the toe edge of the insole  100 . When comparison of the insole  100  and the foot  5  indicates that the selected insole  100  is too small, a larger sized insole  100  should be chosen.  FIG. 8C  illustrates an example of an insole  100  that is too large as compared to the user&#39;s foot  5 . For example, as shown in  FIG. 8C , if there is more than one half-inch space between the end of the user&#39;s toes and the toe edge of the insole  100 , the selected insole  100  is too large and a smaller sized insole  100  should be selected. 
         [0070]    Returning to  FIG. 7 , the selection of the insole  100  performed at block  704  may be made, in part, based upon a user&#39;s weight. For example, a thicker, or more rigid, insole  100  may be selected to accommodate a heavier user. In some embodiments, the selection of the insole  100  also may consider, in part, the intended use of the insole  100 . For example, one type of insole  100  may be provided for distance runners, another type of insole  100  may be provided for general athletes, and another type of insole  100  may be provided for general non-athletic use. 
         [0071]    At block  706 , the selected insole  100  is heated. The insole  100  can be heated to a temperature in the range of about 120° C. to about 140° C. (for example, about 127° C.) for a range of about three to five minutes (for example, about four minutes). In some embodiments, the insole  100  is heated in a heater  200 . 
         [0072]      FIG. 9  illustrates an example of a heater  200  configured to heat the insoles  100  according to one embodiment. The heater  200  includes a slot  203  into which the insoles  100  can be inserted into an interior region of the heater  200 . The heater  200  includes a heating element (not shown) within the interior region of the heater  200 . In some embodiments, the heating element is a resistive wire heater. In some embodiments, the heating element is similar to that used in a traditional oven. The heating element may be positioned above and/or below the insoles  100 . In some embodiments, the heating element includes a heated plate that is pressed against the insoles  100 . A single heated plate may be positioned above and/or below the insoles  100 . In some embodiments, the heated plate is positioned below the insoles  100  and a pillow positioned above the insoles  100  presses the insoles  100  into the heated plate. The heater  200  may also include an on/off switch  205 , one or more heater controls  210 , and a display  215 . The one or more heater controls  210  may allow a user to select between one or more preset heating cycles, or to adjust the heating temperature and/or heating time manually. The display  215  can be configured to display the desired heating temperature, the current internal temperature of the heater  200 , and/or the heating duration. It will be appreciated that the heater  200  shown in  FIG. 9  is merely one embodiment that can be used with the method  700 . A person skilled in the art will understand that other types of heaters or methods for heating the insole  100  may be used with method  700  without departing from the scope of this disclosure. 
         [0073]      FIGS. 10A through 10C  illustrate proper and improper insertion of the insoles  100  into the heater  200  according to one embodiment. In some embodiments, proper heating of the insoles  100  involves heating only the portion of the insole  100  that includes the heat moldable rigid layer  130 . For example, only the rearfoot area  101  and the midfoot area  103  of the insole  100  are inserted into the heater  200 .  FIG. 10A  illustrates an example where the insoles  100  are inserted into the heater  200  only as far as necessary. As shown, the forefoot area  101  and a very small portion of the midfoot area  103  are positioned outside of the heater  200 . The remainder of the midfoot area  103  and the rearfoot area  101  are inserted into the heater  200 . Accordingly, only the portions of the insole  100  that include the heat moldable rigid layer  130  are heated.  FIG. 10B  illustrates an example where the insole  100  is not sufficiently inserted into the heater  200 . As shown, a large portion of the midfoot area  103 , including a portion of the rigid layer  130 , is not inserted into the heater  200 . When this occurs, a portion of the rigid layer  130  is not heated and thus cannot be properly molded to the user&#39;s foot  5 .  FIG. 10C  illustrates an example where too much of the insole  100  is inserted into the heater  200 . As shown, only a small portion of the forefoot area  105  of the insole  100  is extending out of the heater  200 . This may be problematic because the heater  200  is heating portions of the insole  100  that do not require heating. 
         [0074]    Returning to  FIG. 7 , at block  708 , the heated insole  100  is positioned on the top surface  305  of the molding device  300  in preparation for molding.  FIG. 11  illustrates an example of the relative positioning of the user, the user&#39;s foot  5 , the heated insole  100 , and the molding device  300  in preparation for molding. As shown, two molding devices  300  (one for each foot) are placed in a molding stand  400 . The user stands with his or her left foot  5  on the left molding device  300  and his or her right foot  5  lifted above the top surface  305  of the right molding device  300 . The right heated insole  100  is placed on the top surface  305  of the right molding device  300  below the user&#39;s foot  5 . Although  FIG. 11  illustrates an example where a user is preparing to mold a right-footed insole  100 , it will be understood that the example can be reversed and applied to the positioning for molding a left-footed insole  100 . 
         [0075]      FIG. 12  provides a detailed view of the alignment of the heated insole  100  on top of a molding device  300  and below the user&#39;s foot  5 . Front alignment guides  113  on the cover layer  110  of the insole  100  (also shown in  FIG. 2A ) are aligned with the alignment guides  307  (also shown in  FIG. 3E ) on the top surface  305  of the molding device  300 . In some embodiments, this ensures that the heated insole  100  is positioned correctly on the molding device  300  so as to properly be molded when the movable portion  310  of the molding device  300  is in both the first and second positions. The heel alignment guide  111  on the top surface of the insole  100  is positioned below the heel. 
         [0076]    Once the heated insole  100  and user have been properly positioned relative to the molding device  300 , the user&#39;s foot  5 , is placed into contact and aligned with the insole  100 . At block  710 , the user&#39;s foot  5  can be correctly positioned by aligning the heel of the user&#39;s foot  5  with the heel alignment guides  111  on the insole  100 , and then ensuring that the user&#39;s foot  5  is centered along the width of the insole  100 . 
         [0077]      FIGS. 13A and 13B  illustrate the use of an example heel alignment guide  111  on the moldable insole  100  to properly align the user&#39;s foot  5  relative to the moldable insole  100  during the molding process  700  according to on embodiment. As shown in  FIG. 13A , an employee or other person assisting the user, may place the thumb of one hand at the bottom of the circles of the heel alignment guide  111 . The thumb may provide a backstop against which the user&#39;s foot  5  will be positioned. As shown in  FIG. 13B , the employee or other person assisting the user uses his or her other hand to guide the placement of the user&#39;s foot  5  onto the heated insole  100 . The user&#39;s heel is placed against the employee&#39;s thumb, and the employee ensures that foot  5  is centered on the insole  100  across the insole&#39;s width. 
         [0078]    Returning again to block  710  of the method  700  illustrated in  FIG. 7 , once the user&#39;s foot  5  is aligned and placed onto the heated insole  100  with the user&#39;s weight applying downward pressure, the heated insole  100  begins to conform to the unique shape of the user&#39;s foot  5 . In some embodiments, after the foot  5  is properly placed and aligned on the insole  100 , the user stands with weight distributed evenly on both feet  5 , looking straight ahead, for example, for approximately ten seconds to allow time for the insole  100  to mold to the user&#39;s foot  5 . In some embodiments, during this step the user may stand with weight evenly distributed between each foot  5 , looking straight ahead, for example, for between about five and about thirty seconds. 
         [0079]    At block  712 , the molding device  300  is used with the movable portion  310  in the first position to mold a portion of the insole  100 . In some embodiments, with the movable portion  310  in the first position, the user shifts his or her weight to his or her heels and distributes the weight equally between each foot  5 . That position may be held, for example, for approximately ten seconds, while continuing to look straight ahead. In some embodiments, this is accomplished by having the user grip the handle  420  of the molding stand  400  and lean backward, placing weight onto his or her heels, for example as shown in  FIG. 14 . After shifting weight to the heels for, for example, ten seconds, the user is directed to return to an upright position with weight distributed equally. In some embodiments the user may shift weight to the heels, for example, for between about five and about thirty seconds before returning to an upright position. 
         [0080]    At block  714 , the movable portion  310  of the molding device  300  is adjusted to the second position to mold a portion of the insole  100 .  FIG. 15  illustrates an example positioning of a user and the molding device  300  with the movable portion  310  in the second position. As shown, an employee or other person assisting the user, uses one hand to grab the handle  350  on the distal end of the moveable portion  310  and pulls the moveable portion  310  straight back towards the user&#39;s shin, pulling the toes of the user&#39;s foot  5  back and up. With his or her other hand, the employee or other person assisting the user can hold the user&#39;s ankle or lower leg to ensure that the user&#39;s ankle and foot alignment remains neutral throughout the molding process. This positioning is held for, for example, approximately ten seconds to allow the insole  100  to conform to the shape of a user&#39;s foot  5 . In some embodiments, this position is held for, for example, between about five and about thirty seconds. After the designated time, the movable portion  310  of the molding device  300  is returned to the first position by lowering the handle  350  until the movable portion  310  rests on top of the fixed portion  320 . This allows the user&#39;s toes to come back down to a normal standing position. At this point, the user lifts his or her foot off the insole  100  and the insole  100  is removed and allowed to cool. As the insole  100  cools, the rigid layer  130  hardens and retains the newly molded shape. 
         [0081]    At block  716 , the now molded insole  100  is checked for quality. In some embodiments, this involves visually inspecting the molded insole  100 , placing the insole  100  in a user&#39;s shoe to check for comfort, and/or checking the molded insole against a quality control tool. 
         [0082]      FIGS. 16A and 16B  illustrate the use of an example quality control tool  800  to check that the heel portion  101  of a molded insole  100  is properly aligned and level according to one embodiment. The quality control tool  800  includes a semicircular body  801  with one or more parallel lines  805  inscribed on an inside wall of the body  801 . Each of the interior lines  805  may be a different color to allow a user to easily follow each single interior line  805 . The heel area  101  of the molded insole  10  can be inserted into the interior region of the body  801  and the compared against the plurality of lines  805  to determine whether the heel area  101  is properly aligned and level. In some embodiments, as shown in  FIG. 16A , the edge of a properly aligned and level heel area  101  of the molded insole  100  generally follows the interior lines  805  of the quality control tool  800 . This indicates that the heel cup is level.  FIG. 16B  shows an improperly molded insole  100  compared against the quality control tool  800 . When the edge of the heel area  101  crosses through several of the interior lines  805  of the quality control tool  800 , this indicates that the insole  100  has not been properly molded. 
         [0083]    If the quality of the molded insole  100  is determined to be insufficient, the molded insole  100  may discarded and the method  700  may begin again with a new non-molded insole  100 . If the quality of the molded insole  100  is determined to be sufficient, method  700  ends. 
         [0084]    The toe edge of the molded insole  100  may be trimmed before use. This may be done by placing the molded insole  100  on top of or below the insole from the user&#39;s shoe. The user or employee assisting the user can then trim the toe edge of the molded insole with scissors using the insole from the user&#39;s shoe as a template. It may not be necessary to trim the heel edge of the molded insole  100 . The molded insole  100  is then ready for insertion into a user&#39;s shoe and is ready for use. 
         [0085]    According to at least one of the disclosed embodiments, an insole  100  can be efficiently and accurately molded by a molding device  300 . The molding device  300  include a movable portion  310  that is movable between a first position, useful for molding at least a rearfoot and/or midfoot portion of the insole  100 , and a second position, useful for molding at least a forefoot and/or midfoot portion of the insole  100 . 
         [0086]    While the above description has pointed out features of various embodiments, the skilled person will understand that various omissions, substitutions, and changes in the form and details of the device or process illustrated may be made without departing from the scope of the appended claims.