Patent Publication Number: US-2019166948-A1

Title: Toe protector

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to shoe inserts and, more particularly, to shoe inserts that protect a wearer&#39;s toes. 
     BACKGROUND 
     Playing contact sports such as basketball poses many hazards. One well-known hazard is the risk of foot injury. Injuries from twisting or over extension (e.g., ankle sprains, turf toe, Achilles tendonitis) are the most common types of sports-related foot injuries. Injuries resulting from an impact on the top of the foot, particularly on the toes, can be just as debilitating, however. This type of injury can also occur in an industrial work environment, such as when heavy boxes or other objects are accidentally dropped on a worker&#39;s foot. 
    
    
     
       DRAWINGS 
       The features of the present techniques may be best understood from the following detailed description taken in conjunction with the accompanying drawings of which: 
         FIG. 1  is a transparent perspective view of a shoe insert, according to an embodiment. 
         FIG. 2  is top view of outer piece of a shoe insert according to an embodiment (in an unfolded configuration). 
         FIG. 3  is top view of an outer piece of a shoe insert according to an embodiment (with a wearer&#39;s foot inserted, but without a shoe). 
         FIG. 4  is a side view of a shoe insert on a wearer&#39;s foot according to an embodiment (with a wearer&#39;s foot inserted, but without a shoe). 
         FIG. 5A  is a front view of an inner piece of a shoe insert according to an embodiment. 
         FIG. 5B  is a bottom view of an inner piece of a shoe insert according to an embodiment. 
         FIG. 5C  is a side view of an inner piece of a shoe insert according to an embodiment. 
     
    
    
     DESCRIPTION 
     In various embodiments: A shoe insert (“insert”) provides protection (e.g., protection from the impact of a heavy weight) for the toes of a user (also referred to herein as a “wearer”). The insert compartmentalizes each toe like a glove and can be worn on top of or underneath socks. The insert distributes the impact of weight dropped onto the toes by spreading the force to other parts of the shoe&#39;s structure, thereby lowering the total force on the toes (by two thirds in some implementations). The insert may be produced in multiple sizes (e.g., small, medium, and large). 
     Turning to  FIGS. 1-5C , a shoe insert according to an embodiment is shown. The shoe insert, generally labelled  10 , is configured to be inserted into a shoe so that it protects a wearer&#39;s foot  11  when the wearer&#39;s foot  11  is inside the insert  10 . The insert  10  includes an outer piece  12  and an inner piece  14 . The outer piece  12  has first surface  13  and a second surface  15 . The outer piece  12  is generally flat and includes one or more layers of material between the first surface  13  and the second surface  15 . The outer piece  12  has a generally curvilinear quadrilateral shape with a concave edge  16 , a convex edge  18 , a left lateral side  20 , and a right lateral side  22 . On the left lateral side  20  are a left upper tab  24  and a left lower tab  26 . On the right lateral side  22  are a right upper tab  28  and a right lower tab  30 . The outer piece  12  also has a series of padded portions  32 , which help protect the wearer&#39;s toes. Each padded portion  32  is thicker than an area of the outer piece  12  surrounding the padded portion  32 , and at least some of the padded portions  32  is disposed on a location of the outer piece  12  that corresponds to a respective toe of the wearer. For example, one padded portion  32  sits above the big toe, another padded portion  32  is sits above the second portion  32 , etc. Other padded portions  32  are disposed on the respective tabs  24 ,  26 ,  28 , and  30 . 
     As shown in  FIG. 4 , when the insert  10  is in use, the right lower tab  30  and the right upper tab  28  each partially cover a lateral right side  40  of the foot  11  and are positioned such that the right lower tab  30  is located closer to the end  42  of the foot  11 . Similarly, though not depicted in  FIG. 4 , the left lower tab  26  and the left upper tab  24  each partially cover a lateral left side of the foot  11  and are positioned such that the right lower tab  30  is located closer to the end  42  of the foot  11 . 
     Turning to  FIG. 5A ,  FIG. 5B , and  FIG. 5C , in an embodiment, the inner piece  14  includes a shield  50  and a series of dividers  52  extending from the shield  50 . The dividers are configured so that, during use, when the inner piece  14  is positioned on top of the wearer&#39;s toes, the dividers  52  at least partially separate the wearer&#39;s toes. For example, one divider may be positioned between the wearer&#39;s first toe (“big toe”) and second toe, one divider may be positioned between the wearer&#39;s second toe and third toe, one divider may be positioned between the wearer&#39;s third toe and fourth toe, and one divider may be positioned between the wearer&#39;s fourth toe and fifth toe (“pinkie toe”). As the wearer engages in physical activity, the inner piece  14  houses and protect the toes, provides stability, and acts as both a cushion and as a splint to keep the toes stable. 
     According to an embodiment, the insert  10  is constructed so that the outer piece  12  folds back onto itself so that a first portion  13   a  of the first surface  13  faces a second portion  13   b  of the first surface  13  so that the outer piece  12  covers the inner piece  14 . 
     In an embodiment, to use the insert  10 , a wearer places the insert  10  into a shoe and then inserts a foot into the insert so that the wearer&#39;s toes are at least partially separated (e.g., at least one gap is created between each adjacent pair of toes by a divider). The wearer repeats this procedure with the other shoe. The outer piece  12  consequently covers the end of the wearer&#39;s foot in addition to covering the second piece  14 . 
     According to an embodiment, the inner piece  14  is made of a medium stiffness silicone. 
     In an embodiment, one or both of the outer piece  12  and the inner piece  14  are made of a thermoplastic elastomer. 
     According to an embodiment, the insert  10  is made of two different types of plastics—a stiffer material for the inner piece  14  than for the outer piece  12 . The two different pieces go through separate processes until their final shapes are manufactured. After that, they are joined (e.g., with an adhesive) to form a finished insert. 
     In an embodiment, the insert  10  is manufactured as follows. The material for the insert is shipped in from an external factory. The shipment may be silicone in a pellet state for the inner piece  14  and a foam type thermoplastic elastomer in pellet form for the outer piece  12 . Once the pellets have been heated they become liquid. Each piece is then molded into its respective shape and taking to a settling station. 
     According to an embodiment, once both pieces are taken to the settling station they will be put in the joining area. The parts will be joined by an epoxy. The epoxy will then be allowed to dry and the insert will be taken to a packaging machine. The operator will place the finished insert inside of a thin plastic package with both sides open on it. The operator will then use the packaging machine by placing the ends inside the machine. Once in position the machine clamps down and seals both ends by heating them and compressing. The package itself will have a hole in it to allow air to flow through it to allow the epoxy to cure. After packaging, the insert will be taken to a storage area to be place in boxes and prepared for shipping. 
     Forming the Inner Piece  14   
     According to various embodiments, the first piece can be made by, for example, injection molding or compression molding. 
     Injection Molding 
     Injection molding is a type of molding in which the polymer is heated until it is in a highly plastic state and then forced, using high pressure, to flow into a mold cavity where it solidifies. The mold is then pulled apart leaving the cooled product. The process takes anywhere from ten seconds up to a minute. Because the inner piece  14  is smaller, it may take closer to 10 seconds to cool and solidify. 
     According to an embodiment, the material for the inner piece  14  is first placed into a feed hopper and then subsequently allowed to flow into an injection unit, where it is forced through a nozzle. A nonreturn valve keeps the material from flowing backwards in the machine. From the nozzle, the material is forced into a mold. The material is then allowed to cool and the mold (which is made of two separate pieces) is opened up, thereby allowing the piece to be removed. 
     In an embodiment, the mold used for the inner piece  14  is a two-plate mold. The two plate mold includes two halves that have a cavity in them in the shape of the inner piece  14 . The mold may also include a cooling system that allows for water to flow through the mold but not come in contact with the inner piece  14 , thereby allowing it to cool faster. 
     Compression Molding 
     Another type of forming process that can be used is compression molding. To carry out compression molding, the raw material (a “charge”) is placed into a mold. The charge itself can be in a liquid, powder, or pellet form and is inserted in a measured amount to make sure that the density and composition is constant. The mold is made of two halves—a lower half and an upper half. The upper half is lowered onto the lower half and compresses the material to take the shape of the cavity in the mold. The mold is then heated, allowing the charge to polymerize and then cure as it cools. Once cool, it will have the shape of the cavity. The mold will then be opened up the part removed. 
     Forming the Outer Piece  12   
     In an embodiment, the outer piece  12  is a thin walled hollow piece that takes the shape of the front half of a shoe. In various embodiments, the outer piece  12  is made by blow molding or by rotational molding. 
     Blow Molding 
     Blow molding works as follows: one starts with a tube of molten plastic known as a parison and the tube is inflated to fit the desired shape. 
     Rotational Molding 
     Rotational molding uses gravity to cause the material to take the form of the cavity. This process is also known as rotomolding. Rotomolding is used to form more complex external geometries and may be used to take the shape of a foot. To carry out this process, a predetermined amount of polymer powder is loaded into the cavity. The mold is then heated and rotated on two perpendicular axis so that the powder covers the internal surfaces of the molding. This will cause it to form a layer of uniform thickness. The mold will then be opened and the piece taken out 
     Settling the Inner Piece  14   
     In an embodiment, the settling process for the inner piece  14  begins while the piece is still in the machine. The material is permitted to cool in order to allow it to be handled without warping taking place. The machine itself will either blow air on the mold or run water through the mold to facilitate cooling. Once the piece has cooled to a temperature that will allow it to be taken out of the machine without warping (e.g., room temperature), it will be ready for pre-joining. 
     Settling the Outer Piece  12   
     In an embodiment, the outer piece  12  is put through a cooling process that is similar to that of the inner piece  14 . Once the outer piece  12  reaches room temperature it will be ready for pre-joining. 
     Pre-Joining the Outer Piece  12  and the Inner Piece  14   
     According to an embodiment, both pieces are taken from the cooling area and placed into a bin to be taken to the joining stage. 
     Joining the Outer Piece  12  and the Inner Piece  14   
     In an embodiment, the pieces will be joined by an extra bit of the material left on the inside piece  14 . A pea size piece of epoxy is applied to the inner piece  14  and the inner piece  14  is then pushed into the outer piece  12  and the combined pieces (i.e., the assembled insert  10 ) is allowed to cool. According to an embodiment, the epoxy is a thermoplastic polymer that chemically transforms into a rigid structure when cooled. When the epoxy has dried the finished part will be transported to the packaging area. 
     Packaging and Storage 
     In an embodiment, once an insert has arrived at the packaging area it will be put into a packaging machine. The machine encloses the part in plastic and then an operator will place the part into the shipping box. The shipping box will then be taken into a storage area where it will wait until it is picked up by a shipping company. 
     The particular implementations shown and described herein are illustrative examples and are not intended to otherwise limit the scope of the disclosure in any way. The steps of all methods described herein are performable in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on scope. Numerous modifications and adaptations will be readily apparent to those skilled in this art without departing from the spirit and scope of the disclosure.