Abstract:
A removable and adjustable insert for footwear has slots placed in the insole and/or midsole of the shoe to allow access to the arch and/or metatarsal and/or heel regions of the insole and/or midsole. In an embodiment, an insert placed into the arch insert slot that establishes how much the arch protrudes above the remainder of the top surface of the insole. One or more inserts are provided having different thicknesses so that the height of the arch can be varied by the user or at the direction of a third party, such as a doctor or a trainer.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 11/701,090, filed on Jan. 31, 2007, entitled “Adjustable Arch Insole” which is hereby incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention relates to footwear, including shoes, boots, sandals, etc. In particular, the invention relates to systems and methods for allowing a user to adjust the amount of support in the metatarsal, arch and heel portion of the insole or midsole of footwear. 
       BACKGROUND OF THE INVENTION 
       [0003]    Different people need different amounts of support in the footwear they wear. In addition, an individual wearer&#39;s need for support can vary such that occasionally more or less support may be desirable. For example, in some situations, it may be beneficial to have additional arch support for the wearer, while the support in the heel would be minimized. Alternatively, the wearer may desire to have no support in the heel portion of the sole, but a greater varus angle in the metatarsal region. To accomplish these variations in support and angles, the wearer would be required to purchase footwear configured to each situation or purchase several insoles configured to each situation. Furthermore, some footwear inserts are not held in place, and move out of position causing discomfort to the user. 
         [0004]    Another challenge of footwear design is the need to accommodate a wide variety of foot shapes and dimensions, which vary from person to person, while providing a product that is economical. Human feet tend to encompass a wide variety of characteristics including volume, length, arch height, toe dimensions, and various protrusions. The variance in these characteristics causes people&#39;s feet to differ significantly from one another and sometimes from foot to foot. To properly provide optimal support characteristics, it is necessary for the article of footwear to correspond as closely as possible to the unique dimensions of a user&#39;s foot. An improperly-fitting article of footwear will likely cause pain, injury and damage to a user&#39;s foot, leg(s), back, and neck. Therefore, various systems and methods are used to facilitate selecting and/or adjusting existing footwear for a user. 
         [0005]    In order to accommodate a wide variety of foot shapes and dimensions, the seller of the footwear or the insole would be required to carry a large inventory having multiple variations of arch support, metatarsal support and heel support of the footwear or insole because these support regions could not be adjusted by the user or at the direction of a third party (such as a doctor or a trainer), which would significantly increase the cost and inventory of the seller and subsequently the consumer. 
         [0006]    Thus, there is a need for an adjustable sole support system, in the midsole or in the insole, which allows the user to individually adjust the support in the metatarsal, arch and heel regions. Furthermore, there is a need for an adjustable sole support system, in the insole and the midsole, which allows the user to adjust these regions for use in different activities. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    The present invention overcomes the problems of the prior art by providing an insole, which may be removable, and is configured to accept inserts or angled inserts into slots in the metatarsal, arch and/or heel portions of the insole. A plurality of inserts are provided such that the user may choose to use an insole without any inserts, provide inserts to one portion of the insole or provide several inserts to several portions of the insole. The user may also vary the thickness and angle of the inserts by using a plurality of inserts in the insole slots. Additionally, because the insole contains slots for the inserts, which are shaped to accept the inserts, the inserts remain correctly positioned in the insole during use. 
         [0008]    In some configurations, the midsole of a shoe is configured to accept padding or angled inserts into slots in the metatarsal, arch and/or heel portions of the midsole. 
         [0009]    In some configurations, a cover is provided to prevent debris and/or particulates from entering the slots in the midsole of the shoe or insole. 
         [0010]    The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon consideration of the following detailed description of the invention, taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  illustrates a side elevation view of the insole without inserts; 
           [0012]      FIG. 2  is a plain view of an arch wedge insert and a metatarsal insert; 
           [0013]      FIG. 3  is a medial elevation side view of the insole with arch and metatarsal inserts. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]      FIGS. 1 ,  2  and  3  depict specific embodiments of the present invention.  FIGS. 1 ,  2  and  3  illustrate different embodiments of the present invention that may be both left and right forms of an insole and inserts and include insoles and inserts designed to fit a man, a woman, or both. The insole of the invention may have a shoe size according to any international shoe size designation. Alternatively, the insole may be fixed to a shoe or sandal while maintaining access to an adjustable insole support system within the insole of the shoe or sandal. Alternatively, the inserts may be inserted into the midsole of a shoe rather than into the insole. 
         [0015]    Referring to the drawings,  FIG. 1  shows an adjustable insole support system that includes an insole  100  which is configured to fit within a shoe, boot or other type of footwear. The insole  100  has a bottom surface layer  112  which is generally planar and rests on the bottom of the footwear upper (top of the outersole—not shown) when the insole is inserted into the footwear. The insole has a top surface  104  which may be generally planar and is parallel with the bottom surface  112  over the entire insole  100 . The top surface  104  and the bottom surface  112  may be attached to each other at various locations on the insole  100 . The top surface  104  and the bottom surface  112  may be attached by heat mold, gluing, VELCRO®, embossed seams, welded seams, bonded seams, adhesive seals, stitched seams, or a combination thereof. The top surface  104  and the bottom surface  112  may be attached so as to allow insert slots as discussed below. Other methods to form a metatarsal insert slot, an arch insert slot and/or heel insert slot are discussed in greater detail below. 
         [0016]    In another embodiment, the top surface  104  of the insole  100  may contain a protruding semi-circular arch  106  along its central medial edge  120 . As will be more fully explained later, the arch  106  in the insole  100  is less than the arch normally provided in footwear. The foot of a user rests on top of the top surface  104  of the insole  100  with the arch  106  extending upwardly against the user&#39;s foot. 
         [0017]    The insole  100  preferably is molded from a polyurethane foam or similar material to provide an appropriate combination of support and comfort to the user, however, the insole  100  may be leather, canvas, rubber, EVA, polyester, nylon, nylon textiles, thermoplastic polyurethane or any other suitable material. Furthermore, the insole  100  may contain additional materials or material layers for antimicrobial or antifungal protection, or fragrances. These materials or layers may be located on the top surface  104  of the insole  100 , on the bottom surface  112  of the insole  100  or between the top surface  104  and the bottom surface  112  of the insole  100 . The additional layers may be attached to the insole  100  by any suitable means, including, but not limited to, heat mold, gluing, VELCRO®, embossed seams, welded seams, bonded seams, adhesive seals, stitched seams, or a combination thereof. The additional layers may be removable so that they may be replaced by the user. Furthermore, the additional layers may span the entire width and length of the insole  100 , or may cover only a portion of the insole  100 . 
         [0018]    Optional holes  125  may also be located on either the top surface  104  of the insole  100  or the bottom surface  112  of the insole  100  and may extend through the entire thickness of the insole  100 . The holes  125 , may reduce the weight of the insole  100 . Alternatively, the holes  125  may provide breathability of the insole  100 . 
         [0019]    Located in the insole  100  between the top surface  104  and bottom surface  102  under the arch  106  is an arch insert slot  108 . The arch insert slot  108  may be any suitable shape, but preferably is semi-circular and underlies the entire arch  106 . As illustrated in  FIG. 1 , the arch insert slot  108  opens out of medial edge  120  of the insole  100 .  FIG. 1  illustrates the arch insert slot  108  near the bottom of the medial edge  120  of the insole  100 , but may also it could be located at different locations along the medial edge  120  as desired. In one embodiment, when no inserts are placed into the metatarsal slot, the top surface  104  of the insole  100  and the bottom surface  112  of the insole  100  come into contact with each other or the one or more of the additional layer(s) as described above. 
         [0020]    In another embodiment where no arch inserts are used, it is possible for the arch  106  to provide some arch support to the user. 
         [0021]    In another embodiment, the slot is located on the lateral edge of the insole. In this embodiment, the inserts may be inserted such that they are substantially flush with the medial edge of the insole in the arch region. 
         [0022]    In another embodiment of the invention, the arch insert slot extends from the medial edge to the lateral edge, allowing the user to introduce the inserts from either the medial edge or the lateral edge. 
         [0023]    In another embodiment, the arch insert slot is accessible from the bottom of the insole, such that no slot exists on either the medial or lateral edge of the insole. 
         [0024]    In another embodiment, the arch insert slot extends on the bottom of the insole, the medial edge of the insole and/or the lateral edge of the insole. A cover may be included in any of the previously described embodiments, to cover the arch insert slot to prevent debris and particles from entering the arch insert slot. 
         [0025]    Located in the insole between the top surface  104  and the bottom surface  102  under the metatarsal region of the insole  100  is the metatarsal insert slot  122 . The metatarsal insert slot  122  may be any suitable shape, but preferably is substantially trapezoidal in shape, though the metatarsal insert slot  122  could be rectangular or semi-circular and underlies a substantial portion, if not the entire, metatarsal region. As illustrated in  FIG. 1 , the metatarsal insert slot  122  opens out of medial edge  120  of the insole  100 . In one embodiment, when no inserts are placed in the metatarsal slot, the top surface  104  of the insole  100  and the bottom surface  112  of the insole  100  come into contact with each other or additional layer(s), as described above. In the embodiment illustrated in  FIG. 1 , the metatarsal slot is centrally located between the top surface  106  and the bottom surface  112  of the insole, but may be within either the top surface  104  or the bottom surface  112  of the insert as desired. In another embodiment, the metatarsal insert slot is located on the lateral edge of the insole. In this embodiment, the inserts are inserted such that they are substantially flush with the medial edge of the insole in the metatarsal region. In another embodiment of the invention, the metatarsal insert slot extends from the medial edge to the lateral edge, allowing the user to introduce the inserts from either the medial edge or the lateral edge of the insole. In another embodiment, the metatarsal insert slot is accessible from the bottom of the insole, such that no slot exists on either the medial or lateral edge of the insole. In another embodiment, the metatarsal insert opening is positioned on the bottom of the insole, the medial edge of the insole and/or the lateral edge of the insole. A cover may be included in any of the previously described embodiments, to cover the metatarsal insert slot to prevent debris and particles from entering the metatarsal insert slot. 
         [0026]    In one configuration, the insole contains cutouts near the metatarsal region so as to allow less padding due to the insole. This configuration is useful for transferring power between the user and, for example, a bicycle pedal. In this configuration, rigid inserts may be used with the insole such that the insole sufficiently holds the insert in place, though with minimal or no padding between the user and the top surface of the insole and/or between the bottom surface of the insole and the top surface of the insole. 
         [0027]    Though not illustrated in  FIG. 1 , the insole may contain a heel insert slot located in the insole between the top surface and the bottom surface under the heel region of the insole. The heel insert slot may be any suitable shape, but preferably is substantially circular, though could be rectangular or semi-circular and underlies a substantial portion, if not the entire, heel region of the insole. The heel insert slot may open through the back edge of the insole. In one embodiment, when no inserts are placed into the heel slot, the top surface of the insole and the bottom surface of the insole come into contact with each other or additional layer(s), as described above. In one embodiment the heel slot is generally located near the center of the medial edge of the insole but it may be higher or lower in the elevation profile as desired. In another embodiment, the heel insert slot is located on the lateral edge of the insole. In another embodiment, the heel insert is located on the medial edge of the insole. In another embodiment, the heel insert slot is accessible from the bottom of the insole, such that no slot exists on either the medial, back edge or lateral edge of the insole. In another embodiment, the heel insert slot exists on the bottom of the insole, the back edge of the insole, the medial edge of the insole and/or the lateral edge of the insole. A cover may be included in any of the previously described embodiments, a cover may be used over the heel insert slot to prevent debris and particles from entering the heel insert. 
         [0028]    The metatarsal insert slot, arch insert slot and heel insert slot can be formed in the insole in several different ways. In one embodiment, a top surface of the insole and a bottom surface of the insole may be joined together, leaving openings for the metatarsal insert slot, the arch insert slot and/or the heel insert slot. The top surface of the insole and the bottom surface of the insole are joined together using any suitable means to secure the top surface to the bottom surface. By way of example, the top surface and the bottom surface may be attached by, heat mold, gluing, VELCRO®, embossed seams, welded seams, bonded seams, adhesive seals, stitched seams, or a combination thereof. In another embodiment, the insole is formed out of one continuous material to form a top surface and a bottom surface. The metatarsal insert slot, the arch insert slot and/or the heel insert slot may be formed using a slider to create an opening in the insole. A slider, as defined herewith, is a portion of the mold that is inserted during an injection molding process that allows the area of the insert to be absent of material. Once the cycle time of the material being molded is met, the slider can be removed so that the part can be removed from the mold. In some embodiments, the insole is poured into a mold to create the opening. In another configuration, the material is injected into a mold to create an opening. In another configuration, the inserts are cut out of the continuous insole after the insole is formed. The metatarsal insert slot, the arch insert slot and/or the heel insert slot may be formed using similar methods in the midsole. 
         [0029]    In some embodiments, the metatarsal insert slot, the arch insert slot and/or the heel insert slot are substantially similar in shape to the inserts, which aids in holding the inserts in place during use. 
         [0030]    The adjustable insole support system may include any combination of the metatarsal insert slot, arch insert slot or heel insert slot, or all of these insert slots. 
         [0031]    The adjustable insole support system may also include a plurality of inserts, which may be chosen by the user to adjust the level of support in the metatarsal, arch and heel regions. In a preferred embodiment, the inserts generally have the same shape as the insert slot that they fit into so that they can be inserted into the slot and substantially fill the slot in order to provide support and comfort for the user. The inserts may be used individually, or they may be stacked with other inserts to vary the thickness of the inserts. The inserts may be any suitable material, but are preferably a substantially pliable material, such as a foam, including a ethylene vinyl acetate foam or other open cell foams or cork or other polymer materials. The inserts may also be made of rubber, canvas, leather, EVA, nylon, polyester, nylon textiles, thermoplastic polyurethane, composites, laminates or other suitable structural material or combinations thereof. The insert(s) may be colored, or may be translucent. In certain embodiments, it is preferable for the inserts to be substantially rigid so as to transfer power, for example, while the user is pedaling a bicycle. In this configuration, the inserts may be a substantially rigid material, including but not limited to a polymer, a metal or wood. Furthermore, the inserts may contain additional materials or material layers for antimicrobial or antifungal protection, or fragrances. 
         [0032]      FIG. 2  illustrates embodiments of the metatarsal and heel inserts of the present invention. Metatarsal insert  204  has generally the same shape as the metatarsal insert slot that it fits into. The metatarsal insert  204  may have a substantially constant thickness from the metatarsal insert medial edge  205  to the metatarsal insert lateral edge  206 . In another embodiment, the metatarsal insert medial edge  205  may be thicker than the metatarsal insert lateral edge  206 . For purposes of this application when an insert is said to have a specific thickness it refers to its maximum thickness. In another embodiment, the thickness may be substantially constant from the top edge  207  of the metatarsal insert  204  to the bottom edge  208  of the metatarsal insert  204 . In another embodiment, both the thickness from the top edge  207  of the metatarsal insert  204  to the bottom edge  108  of the metatarsal insert  204  and the thickness from the medial edge  205  to the lateral edge  206  vary. In a preferred embodiment, the insert  204  has a variable thickness where the maximum thickness at the medial edge  205  is no more than approximately ⅕ of an inch (approximately 5 mm). Preferably, when a metatarsal insert  204  is in the metatarsal insert slot its medial edge  205  is flush with the medial side of the insole. Though the inserts will be at a set thicknesses, the thickness of the inserts can be varied in the insole by combining multiple inserts and inserting them into the metatarsal insert slot of the insole. 
         [0033]      FIG. 2  also illustrates the arch insert  212 . Though the right arch insert is illustrated in  FIG. 2 , as explained above, the present invention may be both left and right forms of an insert. In a preferred embodiment, the insert  212  is the thickest at the center of the medial edge  216  and the thinnest at its periphery  215 . In the embodiment illustrated in  FIG. 2 , the arch insert  212  has a semi-circular center portion where the thickness varies gradually and a semi-annular outer section where the thickness varies rapidly. For purposes of this application when an insert is said to have a specific thickness it refers to its maximum thickness. Preferably when an insert is in the slot its outer edge  216  is flush with the medial side of the insole. Though the insert may be any suitable thickness, in the preferred embodiment, the thickness is no more than approximately ⅜-⅗ of an inch (approximately 12 mm or 1.2 cm). Though the inserts will be at a set interval range of thicknesses, the thickness of the inserts can be varied in the insole by combining multiple inserts and inserting them into the arch insert slot of the insole. In one embodiment, the insole is sized such that when the insert  212  with a thickness of approximately 3/16 of an inch (approximately 5 mm) and the arch of the insole are used, the total arch thickness is approximately ⅜-⅗ of an inch (approximately 10 mm-15 mm). By adding additional inserts  212  to this configuration, the size of the arch is increased above its normal size. By decreasing the size of the insert  212  below approximately 3/16 of an inch (approximately 5 mm), the size of the arch is decreased below this thickness. Though thicker and thinner inserts  212  may be used, generally the thickness will vary between approximately 0.15-0.35 inch (approximately 4 mm-8 mm). 
         [0034]    A heel insert may be used in the adjustable insole support system. As described above, the heel insert may be any suitable shape, but preferably is circular, though could be rectangular or semi-circular and underlies a substantial portion, if not the entire, heel region of the insole. Similar to the metatarsal inserts and the arch inserts, the heel inserts will be available in a variety of different sizes and can be combined to create the correct amount of cushion and support as determined by the user. 
         [0035]    As described above, the several inserts may be combined to make the appropriate size insert as determined by the user.  FIG. 3  illustrates the insole  300  containing several metatarsal and arch inserts. As illustrated in  FIG. 3 , the insole  300  comprises a metatarsal insert slot  322  and an arch insert slot  308  between the top surface  304  and the bottom surface  312  of the insole  300 . Three metatarsal inserts  301 ,  302  and  303  are shown within the metatarsal insert slot  322  and are substantially flush with the medial edge  320  of the insole  300 . Though three metatarsal inserts  301 ,  302  and  303 , are illustrated in  FIG. 3 , it is understood that any number of inserts may be used. The optional arch  306  is also illustrated in the insole  300 . Two arch inserts  305  and  307  are illustrated in this embodiment. Though two arch inserts  305  and  307  are illustrated in  FIG. 3 , it is understood that any number of inserts may be used. 
         [0036]    The adjustable insole support system allows a shoe to have variable arch, metatarsal and/or heel support that is adjustably sized to work for the particular user without having to use multiple insoles, each sized for different applications. In addition, the arch, metatarsal and/or heel support can be changed to address problems that might occur or the need for more support in the insole. Furthermore, in some embodiments, the insole is compatible with different shoes. 
         [0037]    In one embodiment, the inserts may be incorporated directly into the midsole of the footwear, such as a shoe, boot or sandal. Though in some embodiments, the insole attaches directly to the footwear, in other embodiments, the inserts are incorporated into the midsole of the footwear. In some embodiments, the midsole of the footwear may contain a midsole capable of accepting inserts into the midsole of the footwear. In some embodiments, the metatarsal insert slot, the arch insert slot and the heel insert slot contain a cover, which substantially protects the respective slots from receiving particles or debris. Other embodiments may include an arch insert slot within the midsole and/or a metatarsal insert slot and/or a heel insert slot. Each of these slots may contain a cover to protect the insert slots from receiving debris or particles. 
         [0038]    In some embodiments, the adjustable support system, including the insole and inserts, are combined as a kit. The kit may include the insole (as described in several embodiments above), and one or more inserts (as described in several embodiments above) for use in the insole. Depending upon the insole insert slots present in the insole (i.e. metatarsal insole slot, arch insole slot and heel insert slot), the kits may be tailored to include several inserts of varying thickness for use with the insole. In other configurations, the inserts (as described in several embodiments above) are combined as a kit, with variable thicknesses of inserts, for use in either the insole and/or the midsole. 
         [0039]    The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.