Patent ID: 12256810

It should be noted that the figures are not drawn to scale and that elements of similar structures or functions are generally represented by like reference numerals for illustrative purposes throughout the figures. It also should be noted that the figures are only intended to facilitate the description of the preferred embodiments. The figures do not illustrate every aspect of the described embodiments and do not limit the scope of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Since currently-available shoe stretchers are incapable of adjusting shoes with accuracy, apparatuses and methods for adjusting shoes that can overcome the drawbacks as set forth above can prove desirable and provide a basis for a wide range of applications, such as customizing shoes for anyone, breaking in new sports footwear for athletes, improving comfort level for people in professions that require wearing numerous new shoes (for example, runway models). This result can be achieved, according to one embodiment disclosed herein, by an apparatus100for adjusting a shoe as illustrated inFIG.1.

The apparatus100is shown inFIG.1as including a platform140.FIG.1further shows an optional model foot200for being at least partially disposed within a shoe202. The shoe202is shown as resting on the platform140. Stated somewhat differently, a bottom of the shoe202is at least partially in contact with the platform140.

In one embodiment, the model foot200can be supported in a predetermined (preferably fixed) position and/or manner. The platform140can engage the shoe202and move (for example, rocking repeatedly back and forth or in any preselected pattern and/or manner) relative to the model foot200to mimic actual human steps and thus break in the shoe202.

FIG.1shows the apparatus100as further including an optional coupling structure120configured to be connected to the model foot200. The coupling structure120can be in a predetermined position relative to the platform140. In one embodiment, the model foot200can be releasably attached to the coupling structure120. Stated somewhat differently, the coupling structure120can be a part of the apparatus100while the model foot200can be removable from the coupling structure120and/or customized. For example, the coupling structure120can be connected to, integrated with, be a part of, be in place of, and/or function as, the top assembly180. Additionally and/or alternatively, the coupling structure120can be at least partially integrated with the model foot200. For example, the coupling structure120can be an extension of the model foot200. Additionally and/or alternatively, a portion of the coupling structure120can be a part of the apparatus100and another portion of the coupling structure120can be integrated with the model foot200.

The apparatus100can include an optional platform control system300for controlling the platform140. The platform control system300can be configured to control a position and/or motion of the platform140relative to the coupling structure120. Stated somewhat differently, when the model foot200is connected with the coupling structure120, the platform control system300can control a position and/or motion of the platform140relative to the model foot200. When the platform140moves relative to the model foot200wearing the shoe202and contacts the shoe202, the model foot200can apply pressure to the shoe202. The model foot200can thus adjust or stretch the shoe202. Adjusting the shoe202can include stretching, and/or changing a shape of the shoe202. The shoe202can include a sole208and an upper portion201that collectively hold the model foot200in the shoe202. In some embodiments, the internal surface of the upper portion201can be stretched to better accommodate a natural foot.

In one embodiment, the natural foot can have a foot deformation (or foot abnormality). Exemplary foot deformations can include a deformed toe, bunions, etc. An exemplary deformed toe can be misaligned with all other toes. Such deformed toes can include a hammer toe, a claw toe, a mallet toe, a curled toe, or a combination thereof. The model foot200can exactly replicate the foot deformation and stretch the toe box at the upper portion201of the shoe202, so the toe box can accommodate the deformed toe without applying strong force on the deformed toe. Similarly, the shoe202can accommodate the bunion. The natural foot can avoid getting blisters on the deformed toe, bunion or other foot deformation that can be incurred during a shoe break-in process.

Advantageously, the model foot200can be a surrogate to a natural foot (or a biological foot, or a human foot) in adjusting the shape of the shoe202. Upon the shoe202being adjusted, the natural foot can wear the shoe202with comfort. The natural foot does not need to break in the shoe by prolonged wearing. Painful symptoms from breaking the shoe202, such as blisters, can be eliminated.

AlthoughFIG.1one shows model foot200for adjusting one shoe202for illustrative purposes only, a plurality of uniform and/or different model feet200can be used for adjusting uniform and/or different model feet200in parallel and/or series in the apparatus100. The plurality of model feet200can share a common coupling structure120, use respective coupling structures120, or a combination thereof.

Turning toFIG.2, an exemplary method400for adjusting the shoe202is shown. The model foot200can optionally be attached, at410, to the coupling structure120. The model foot200can wear the shoe202. In one embodiment, the model foot200can be attached to the coupling structure120and the shoe202can be put on the model foot200. In another embodiment, the shoe202can be put on the model foot200and the model foot200wearing the shoe can be attached to the coupling structure120. In yet another embodiment, the model foot200can remain attached to the coupling structure120and wear a plurality of uniform and/or different shoes202sequentially to adjust each of the shoes202one at a time.

A relative movement can be generated, at420, between the platform140and the model foot200, such that the platform140can contact the shoe202and the model foot200can adjust the shoe220via the relative movement. During the relative movement, because the platform140is in contact with the shoe202, the model foot200can move within the shoe202and apply pressure to the shoe202. Selected location(s) on the shoe202can be stretched under the pressure to conform the shape of the selected locations to the shape of the model foot200, and thus ultimately to the foot of the shoe wearer. The selected locations can be, for example, on the toe, heel, vamp, welt and/or the sole of the shoe202.

The relative movement can include any suitable motion for the model foot200to press on the platform140and enabling sliding and/or bending of the model foot200in the shoe202. In one embodiment, the relative movement can include a simulated walking motion. Stated somewhat differently, the model foot200can walk on the platform140while wearing the shoe202. For example, the model foot200can be stationary or static, and the platform140can press against a heel220(shown inFIG.3A) of the model foot200and then press against toes240(shown inFIG.3A) of the model foot200. To simulate an actual human walk, the pressing motion can include the platform140rolling against the heel220and/or the toes240to imitate motion of a natural foot rolling against ground when making a step. Advantageously, the model foot200can stretch the shoe202in a manner similar to human walk.

In another embodiment, the relative movement can include a vibrating motion. Stated somewhat differently, the model foot200can vibrate against the platform140while wearing the shoe202. The vibration can be in any selected directions model foot200including, for example, up and down, side to side, front to back. For example, the model foot200can be stationary or static and the platform140can press against a bottom of the shoe202(shown inFIG.1) while vibrating. The vibration can result in sliding and/or rubbing motion of the model foot200against the shoe202and achieve adjustment of the shoe202.

Turning toFIG.3A, an exemplary model foot200is shown. The model foot200can have a shape, size, and/or dimension that at least partially simulates a shape, size, and/or dimension of a natural foot. When the model foot200wears the shoe202(shown inFIG.1), the model foot200can push against at least a portion of an internal surface (not shown) of the shoe202, such that the portion being pushed can be stretched or expanded. In one embodiment, the model foot200can include at least a heel220and/or a plurality of toes240that respectively simulate a heel and/or toes of the natural foot. A heel (not shown) and a toe box (not shown) of the shoe202, when new or unstretched, are most likely to cause discomfort. Advantageously, stretching of the heel and the toe box of the shoe202can be ensured.FIG.3Ashows the model foot200as having an appearance of an entire natural foot.

The model foot200can be at least partially made using a method for replicating a sample foot (not shown). An exemplary sample foot can be a natural foot or any man-made surrogate object for simulating a natural foot. Additionally and/or alternatively, the sample foot can be a virtual foot, or an electronic image of a foot in two- or three-dimensions.

In one embodiment, the sample foot can be based on a natural foot of a person. Thus, the model foot200can be at least partially an exact replica of the natural foot, so the shoe202can be stretched to fit the natural foot. Stated somewhat differently, the model foot200can include at least one modeling portion and the modeling portion can be any portion that exactly replicates the shape of at least a part of the natural foot.

In one embodiment, the model foot200can include a modeling portion exactly replicating the shape of toes and/or heel of the natural foot. For example, the modeling portion can be a first foot portion211(shown inFIGS.4A,25and27A). Additionally and/or alternatively, the model foot200can include a modeling portion exactly replicating the shape of a part of the natural foot that is not the toes or heel (such as the top or dorsum of the natural foot). For example, the modeling portion can be a second foot portion212(shown inFIG.4A). In another embodiment, the model foot200can include one modeling portion exactly replicating the shape of the entire natural foot. Advantageously, the person can experience great comfort when wearing the stretched shoe202. However, even if a different person wears the shoe, he/she may still experience comfort because the shoe202has been stretched in the apparatus100and the stretching can be more effective than conventional stretching methods.

In selected embodiments, an exemplary method can include three-dimensional (3D) printing (or additive manufacturing), casting (for example, life casting), or a combination thereof.

In an exemplary 3D printing process, the sample foot, or an equivalent thereof, can be scanned. A 3D printer can build the model foot200under computer control and based on images from scanning the sample foot. The 3D printing process can include, for example, extrusion deposition binder jetting, directed energy deposition, material jetting, powder bed fusion, sheet lamination, vat photopolymerization, stereolithography, or a combination thereof.

An exemplary model foot200can be at least partially made of an elastic material. Exemplary elastic material can include rubber, silicone, and/or the like. Thus, the model foot200can fit in the shoe202and, when inside the shoe202, push against an interior region and/or interior surface the shoe202. Advantageously, the model foot200can simulate the mechanical characteristics of the natural foot. In one embodiment, the model foot200can make movements within the shoe202, including spreading and/or compressing under pressure from the platform140(shown inFIG.1), traveling within the shoe202, or a combination thereof. Such movements, which are in conjunction with the relative movement between the model foot200and the platform140can stretch the shoe202effectively and simulate how the natural foot stretches the shoe202.

In one embodiment, the model foot200can be made using one method, and/or made of a uniform material. In one example, the model foot200can be made using 3D printing. An exemplary model foot200can be made of rubber. In another example, the model foot200can be made using casting. An exemplary model foot200can be made of silicone.

In one embodiment, the model foot200can be made using life casting. An exemplary life casting process can include casting a mold250(shown inFIGS.3C-3E) from the natural foot. The mold250can be made of any suitable molding material. An exemplary molding material can include Alja-Safe™ alginate, available from Smooth-On, Inc., located in Macungie, Pennsylvania. Additionally and/or alternatively, an exemplary molding material can include gypsum plaster or plaster of Paris. Additionally and/or alternatively, an exemplary molding material can include Body Double™ Silk mold rubber, available from Smooth-On, Inc. An exemplary mold250can be soft enough to be detached from the natural foot without being damaged.

A casting material can be placed into the mold250. Exemplary casting material can include a silicone rubber. Optionally, the second foot portion212(shown inFIG.27A) can be inserted into the casting material and locked in place in the mold (by any suitable tools, jigs, rigs, for example) before placing, or curing, of the casting material of the first foot portion211(shown inFIG.27A). Thus, the second foot portion212can be fixedly embedded in the first foot portion211upon curing and/or solidification of the casting material. Optionally, openings (not shown) can be cut through selected locations on the mold250before placing, or curing, of the casting material, such that suitable mechanical structure (such as nuts, bolts, brackets, molds, etc.) can be fixed at the locations during curing of the casting material. Thus, upon curing of the casting material, the attachment point260(shown inFIG.16) can be defined on the model foot200and attachments, such as attachment point loop262(shown inFIG.17), can be connected to the model foot200.

Turning toFIG.3B, the model foot200is shown as exactly replicating the shape of the entire natural foot. The model foot200is shown as including first, second and third sub-portions251-253. The first and third foot sub-portions251,253include the toes240and the heel220, respectively. The second sub-portion252can include the remaining portion (or mid portion) of the model foot200.

In one embodiment, the first and third foot sub-portions251,253can be made of a first material. The second sub-portion252can be made of a second material. The first material can be stronger (or denser, or harder) than the second material. Thus, the toes240and/or the heel220can mimic bones of the foot and withstand rubbing against the shoe202(shown inFIG.1). The second material can be softer (and/or more compliant) than the first material. Thus, the model foot200can be compressed to fit in the shoe202and can expand to rub against the shoe202as a natural foot does. Additionally and/or alternatively, the second sub-portion252can compress with pressure from the platform140(shown inFIG.1). Such compression can result in a spreading motion that simulates spreading of the natural foot when the natural foot fully rests on a surface.

In one embodiment, the first material can have a Shore hardness ranging from25A to45A, a tensile strength ranging from 550 psi (pound-force per square inch) to 700 psi, an 100% modulus ranging from 60 psi to 120 psi, an Elongation (@) Break ranging from 300% to 750%, a Die B Tear Strength ranging from 104 pli (pounds per lineal inch) to 110 pli. The second material can have a Shore hardness ranging from5A to20A, a tensile strength ranging from 400 psi to 500 psi, an 100% modulus ranging from 15 psi to 50 psi, an Elongation (@) Break ranging from 800% to 1200%, a Die B Tear Strength ranging from 100 to 103 pli. For example, the first material can include a silicone, such as Sorta Clear™ 37, available from Smooth-On, Inc. The second material can include a silicone, such as Dragon Skin™ 10 Medium, available from Smooth-On, Inc.

The sub-portions251-253can be made using any suitable methods. In one example, the sub-portions251-253can be formed individually and, after the formation, be bonded together. In another example, each of the sub-portions251-253can be connected or bonded during the formation.

AlthoughFIG.3Bshows the model foot200as including the first, second and third foot sub-portions251-253for illustrative purposes only, the model foot200can include, and/or be partitioned into, any number of uniform and/or different sub-portions, without limitation, and each of the sub-portions can be made of a suitable material and/or process to mimic property of the natural foot.

FIGS.3C-3Eshow the mold250during an exemplary process for making the model foot200(shown inFIG.3B). Turning toFIG.3C, the mold250is shown as defining a bottom254that forms an angle B with a level surface600. The angle B can be, for example, 90 degrees. The first material can be placed into the mold250to reach a first level L1 such that the first material can form the first foot sub-portion251that includes the toes240(shown inFIG.4A).

Turning toFIG.3D, the angle B can be smaller than the angle B shown inFIG.3C. The second material can be placed into the mold250to reach a second level L2 such that the second material can form the second foot sub-portion252that includes a middle portion of the bottom204(shown inFIG.4A) of the model foot200. The second material can be placed into the mold250when the first foot sub-portion251is partially cured. For example, the second material can be placed into the mold250when the first foot sub-portion251has been cured for half the time needed for full curing. Advantageously, the first foot sub-portion251can be sufficiently solidified to remain in shape and still be able to bond with the second foot sub-portion252.

Turning toFIG.3E, the angle B can be smaller than the angle B shown inFIG.3D. For example, the angle B can be 0 degrees. The first material can be placed into the mold250to reach a third level L3 such that the first material can form the third foot sub-portion253that includes the heel220. The first material can be placed into the mold250when the second foot sub-portion252is partially cured. For example, the first material can be placed into the mold250when the second foot sub-portion252has been cured for half the time needed for full curing. Advantageously, the second foot sub-portion252can be sufficiently solidified to remain in shape and still be able to bond with the third foot sub-portion253. By adjusting the angle B, the model foot200can advantageously be made with sub-portions of different materials in a simple manner.

Although the first and third foot sub-portions251,253are set forth above as being made of the first material for illustrative purposes only, the first and third foot sub-portions251,253can be made of uniform and/or different materials, without limitation. AlthoughFIGS.3C-3Eshow the first, second and third foot sub-portions251-253as being made sequentially for illustrative purposes only, the first, second and third foot sub-portions251-253can be made in any suitable sequence, without limitation.

Turning toFIG.3F, the third level L3 is shown as being lower than the second foot sub-portion252when the model foot200stands on the ground600. The third level L3 is thus lower than the third level L3 shown inFIG.3E. The third level L3 can be selected within a range from a minimum height to a maximum height. At the minimum height, the third foot sub-portion253can be formed to include at least the heel220. The maximum height can be equal to the height of the model foot200. Stated somewhat differently, the third level L3 is not necessarily higher than the second foot sub-portion252and can be selected base on certain factors including, for example, the type of shoe202(shown inFIG.1) and/or cost of manufacturing.

Turning toFIG.4A, the model foot200is shown as including first and second foot portions211,212. The first and second foot portions211,212can be made using uniform and/or different methods. Additionally and/or alternatively, the first and second foot portions211,212can be made using uniform and/or different materials. When the first and second foot portions211,212are made of different materials, the first and second foot portions211,212can have different properties and/or manufacturing cost. Advantageously, the model foot200can be further customized to fit a great variety of needs of stretching the shoe202(shown inFIG.1).

FIG.4Ashows the first foot portion211as including the toes240, the heel220and a bottom204of the model foot200that is between the toes240and the heel220. The second foot portion212is shown as including a top (or dorsum)206adjacent to an ankle (not shown). Stated somewhat differently, the first foot portion211can be distal from the ankle and the second foot portion212can be proximal to the ankle.

In one embodiment, the first foot portion211can be made of rubber using 3D printing. The second foot portion212can be made of any suitable material (for example, plastic or wood) and have a generic or un-customized shape that can be used in combination with a variety of first foot portions211. The 3D printed first foot portion211can be attached to the second foot portion212. Advantageously, the rubber can allow the model foot200to be flexible enough to fit into the shoe202. The cost of 3D printing can be reduced while customized stretching by the heel220and the toes240can still be achieved.

In another embodiment, the first and second foot portions211,212can be made to have a customized shape by, for example, using casting and/or 3D printing. In one example, the first foot portion211can be made of a first silicone. The second foot portion212can be made of a second silicone. The first silicone can be stronger than the second silicone. Thus, the toes240and/or the heel220can withstand rubbing against the shoe202. The second silicone can be softer than the first silicone. Thus, the model foot200can be compressed to fit in the shoe202and can expand to rub against the shoe202as a natural foot does. In another example, the first foot portion211can be softer than the second foot portion212.

Turning toFIG.4B, the first foot portion211is shown as including the first, second and third sub-portions251-253. The first and third foot sub-portions251,253include the toes240and the heel220, respectively. The second sub-portion252can include the remaining portion of the first foot portion211.

In one embodiment, similar to the model foot200as set forth inFIG.3B, the second sub-portion252can be softer (and/or more compliant) than the first and third foot sub-portions251,253. Thus, the toes240and/or the heel220can mimic bones of the foot and withstand rubbing against the shoe202(shown inFIG.1). The second sub-portion252can spread under pressure from the platform140(shown inFIG.1) to simulate spreading of the natural foot when the natural foot fully rests on a surface.

Turning toFIG.5, a detail drawing of a selected alternative embodiment of the model foot200ofFIG.4is shown. The first foot portion211is shown as wrapping the second foot portion212(shown in dashes). Stated somewhat differently, the first foot portion211can be a shell and the second foot portion212can be a core or filler wrapped in the shell. A thickness of the first foot portion211can be selected to adjust property and/or manufacturing cost of the model foot200. Stated somewhat differently, the second foot portion212can be at least partially disposed in the first foot portion211.

Turning toFIG.6, another exemplary embodiment of the apparatus100is shown. The coupling structure120is shown as including at least one arm122. The arm122can have a first end region121proximal to the platform140and configured to connect to the model foot200(shown inFIG.1). The arm122can have a second end region126distal from the platform140and connected to a top assembly180. The apparatus100is shown as including a support frame160. The support frame160and the top assembly180can collectively provide a framework for at least partially containing the platform control system300, the coupling structure120and/or the platform140.

The platform control system300is shown as including a motor340driving a rocker spindle342separated from the model foot200by the platform140. The platform control system300further includes at least two rotary members344A,344B each coupled to two opposite end regions of the shaft342. Each of the rotary members344A,344B is shown as having an egg shape, or an oval shape with one axis of symmetry. Stated somewhat differently, each of the rotary members344A,344B can have a maximum radius opposite to a minimum radius, optionally with a smooth transition therebetween. In other words, each of the rotary members344A,344B has a wide half and a narrow half located opposite to the wide half.

The rotary members344A,344B are shown as being oriented with a selected phase difference. Stated somewhat differently, when the wide half of the rotary member344A is in contact with the platform140, the wide half of the rotary member344B is not in contact with the platform140. Thus, when the motor340drives the rocker spindle342to rotate, the rotary members344A,344B can alternately raise the platform140such that the platform140can tilt in an alternate manner. In one embodiment, the phase difference can be, for example, 180 degrees. Stated somewhat differently, when the wide and narrow halves of the rotary member344A are respectively proximal to and distal from the platform140, the narrow and wide halves of the rotary member344B are respectively proximal to and distal from the platform140. Optionally, the platform control system300can include a controller320for providing instruction to the motor340.

Turning toFIG.7, the top assembly180is shown as defining at least one coupling structure slot182. The coupling structure120can be connected at a selected location on the top assembly180via the assembly slot182. For example, the arm122can be connected to the top assembly180in any suitable manner including, for example, via a fastener, such as a bolt. Additionally and/or alternatively, the arm122and the top assembly180can be joined via a mechanical connection such as cooperating detents including any combination of mating elements, such as blocks, tabs, pockets, slots, ramps, locking pins, cantilevered members, support pins, and the like, that may be selectively or automatically engaged and/or disengaged to couple or decouple the arm122and the top assembly180.

In one embodiment, the arm122can be fixedly coupled to the top assembly180. In another embodiment, a connection between the arm122and the top assembly180can be at least partially spring-loaded. When pressure is applied to the arm122by the platform140, the spring (not shown) of the connection can absorb some of the pressure. The arm122can have small or negligible movement relative to the platform140. Advantageously, damage to the arm122, the top assembly180, and/or the connections thereof, can be prevented.

In one embodiment, the arm122can be fixedly coupled to the model foot200(shown inFIG.1). In another embodiment, a connection between the arm122and the model foot200can be spring-loaded. When pressure is applied to the model foot200by the platform140, the spring at the connection can absorb at least some of the pressure. The arm122and the model foot200can have small or negligible movement relative to a movement of the platform140. Damage to the arm122, the model foot200, and/or the connections thereof, can be prevented.

Turning toFIG.8, the top assembly180is shown as including a rectangular plate having four corner regions each connected with a top assembly support member182. The top assembly support member182is shown as being elongated and defining a column of position selection holes188. A position selector184is shown as being an elongated pin that can pass through two selected position selection holes188of two adjacent top assembly support members182.

The support frame160is shown as including four support frame receiving members162. Each support frame receiving member162is shown as being elongated and defining a positioning slot164. The position selector184can be positioned to pass through the two position selection holes188of the two adjacent top assembly support members182. At the same time, the position selector184can be positioned in the positioning slots164of two adjacent support frame receiving member162. By selecting the position selection hole188to accommodate the position selector184, a distance between the top assembly180and the platform140can be selected. Advantageously, even if the arm122or the platform control system300remain unchanged, the apparatus100can have greater flexibility in adapting to a great variety of shoes202(shown inFIG.1) and adjusting a pressure of the platform140on the model foot200.

Turning toFIG.9A, the apparatus100is shown as being in a resting state. The rotary members344A,344B are shown as being oriented to be detached from the platform140. In the resting state, the platform140platform140can apply pressure, or apply no pressure, to both the heel220and the toes240.

Turning toFIG.9B, the apparatus100is shown as being in a heel-press state. The rotary member344A is shown as pressing up the platform140. The platform140can thus press on the heel220. Stated somewhat differently, the wide half of the rotary member344A can be in contact with, and press up, the platform140. The heel-press state can simulate a motion of a heel presses on the ground when a natural foot starts a step.

AlthoughFIG.9Bshows the toes240as being in contact with the platform140for illustrative purposes only, the toes240does not necessarily contact or press on the platform140.

Turning toFIG.9C, the apparatus100is shown as being in a toe-press state. The rotary member344B is shown as pressing up the platform140. The platform140can thus press on the toes240. Stated somewhat differently, the wide half of the rotary member344B can be in contact with, and press up, the platform140. The toe-press state can simulate a motion of the toes presses on the ground when a natural foot completes a step.

The apparatus100can repeat a cycle that sequentially includes the heel-press state, the resting state and the toe-press state to simulate a step. Advantageously, when the model foot200wears the shoe202(shown inFIG.1), the model foot200can stretch the shoe202in a manner similar to the natural foot walking in the shoe202, so the shoe202can be stretched more accurately.

AlthoughFIG.9Cshows the heel220as being in contact with the platform140for illustrative purposes only, the heel220does not necessarily contact or press on the platform140.

Additionally and/or alternatively, the motor340can introduce a vibration motion when the rotary member344A and/or the rotary member344B presses on the platform140. The vibration can make the model foot200move within the shoe202and stretch the shoe202. For example, the motor340can include a vacuum motor (not shown). A rotor (not shown) of the motor340can be connected with the shaft342via a hose clamp. The vacuum motor can place the shaft342off balance and achieve vibration.

Turning toFIG.10A, another exemplary apparatus100is shown. The coupling structure120is shown as including a predetermined number of arms122. The platform control system300is shown as including at least two actuators360A,360B each being configured to alternately raise two opposite end regions of the platform140. Stated somewhat differently, the actuator360A can be configured to raise and/or lower an end region of the platform140proximal to the heel220. The actuator360B can be configured to raise and/or lower an end region of the platform140proximal to the toes240.

The actuators360A,360B can each include suitable motors for respectively moving pressure components366A,366B under a control signal including, for example, electric current, hydraulic fluid pressure, or pneumatic pressure. The actuators360A,360B can respectively drive the pressure components366A,366B via worm gears, for example. Exemplary actuators360A,360B can include electric motor, pneumatic motors, and/or hydraulic motors.

The platform control system300is shown as including a controller320configured to generate programming instruction that can control speed, frequency, and/or intensity of movement generated by the actuators360A,360B. The controller320can include a computer that is programmed to instruct the actuators360A,360B. The platform control system300is shown as including an optional interface unit322configured to convert electrical power of standard computer interface output (for example, such as the Universal Serial Bus, Ethernet or RS-232) to power required by the actuators360A,360B. The interface unit322can provide power and pulses of the actuators360A,360B. Software running on the controller320can trigger the interface unit322. The interface unit322can send signals, such as pulses, to the actuators360A,360B.

The actuators360A,360B can be instructed to move the pressure components366A,366B with a selected phase difference. Stated somewhat differently, when the pressure component366A raises the platform140, the pressure component366B does not raise the platform140. When the pressure component366B raises the platform140, the pressure component366A does not raise the platform140. Thus, the pressure components366A,366B can alternately raise the platform140such that the platform140can tilt in an alternate manner. In one embodiment, the phase difference can be, for example, 180 degrees. Stated somewhat differently, when the pressure component366A raises the platform140, the pressure component366B lowers the platform140. When the pressure component366B raises the platform140, the pressure component366A lowers the platform140.

The apparatus100is shown as including a stabilizing member364configured to support and/or stabilizing the platform140. The stabilizing member364is shown as including a structure fixed to the support frame160that is connected to the platform140. The stabilizing member364can be rotatably connected to a center region of the platform140. Advantageously, when the platform140is only supported by the stabilizing member364, the platform140can be parallel to the ground.

The apparatus100is shown as including optional sensors362A,362B respectively configured to sense a height of the pressure components366A,366B. For example, when a height of the pressure components366A reaches a selected value, the sensors362A can communicate with the controller320, so the controller320can instruct the actuator360A to stop raising or lowering the pressure components366A. Exemplary sensors362A,362B can include gear tooth sensors.

AlthoughFIG.10Ashows the apparatus100as including two actuators360A,360B and two pressure components366A,366B for illustrative purposes only, the apparatus100can include any predetermined number of uniform and/or different actuators360and any preselected number of uniform and/or different pressure components366, without limitation.

In one embodiment, the pressure components366A,366B can be located along a center line of the model foot200. Stated somewhat differently, the model foot200can, similar to a natural foot, be in a neutral position on the platform140. In the neutral position, the model foot200does not roll to a left or a right side of the model foot200. Additionally and/or alternatively, the pressure components366A,366B can be shifted to a right and/or left of the center line such that the model foot200, during operation of the apparatus100, can roll to the right and/or the left side. Advantageously, the model foot200can simulate pronation and/or supination of a natural foot and the stretching of the shoe202(shown inFIG.1) can be further customized. In one embodiment, additional actuators360and/or pressure components366can be used for increased flexibility of simulating more complex gait (or push and roll) of a natural foot. For example, two pressure components366can be respectively located on the left and right sides of the model foot200.

Turning toFIG.10B, the apparatus100is shown as including a toe flexing device146disposed between the toes240and the platform140. The toe flexing device146is shown as having a wedge shape and can force the toes240to flex distally from the platform140to a great extent.

In one embodiment, in a toe-press state (shown inFIG.12C, for example), the toes240may flex by a limited amount on a planar-shaped platform140. By inserting the toe flexing device146beneath the toes240, the toes240can be forced to bend more in the shoe202(shown inFIG.1). The toe-pressing state can thus better simulate actual walking motion and result in effective stretching of the shoe202.

AlthoughFIG.10Bshows the toe flexing device146is used on the platform140that is controlled by the actuators360for illustrative purposes only, the toe flexing device146can be implemented on the platform140controlled in any other manners (for example, as shown inFIG.1), without limitation.

Turning toFIG.11, the top assembly180is shown as defining at least one coupling structure slot182. Each arm122can be connected at a selected location on the top assembly180via the assembly slot182. For example, the arm122can be connected to the top assembly180and/or the connected to the model foot200in a manner similar to the manner as described herein with reference toFIG.7.

FIG.11shows the arms122as being parallel and arranged in a straight line in the coupling structure slot182for illustrative purposes only, the arms122can be arranged in any locations relative to each other. Although the coupling structure slot182is shown as having a shape of a cross for illustrative purposes only, the coupling structure slot182can have any shape, without limitation.

Turning toFIG.12A, the apparatus100is shown as being in a resting state. The pressure components366A,366B can evenly support the platform140. In the resting state, the platform140can apply pressure to both the heel220and the toes240.

Turning toFIG.12B, the apparatus100is shown as being in a heel-press state. The pressure component366A is shown as pressing up the platform140. The platform140can thus press on the heel220of the model foot200. The heel-press state can simulate a motion of a heel first presses on the ground when a natural foot starts a step.

AlthoughFIG.12Bshows the toes240as being in contact with the platform140for illustrative purposes only, the toes240does not necessarily contact, or press on, the platform140.

Turning toFIG.12C, the apparatus100is shown as being in a toe-press state. The pressure component366B is shown as pressing up the platform140. The platform140can thus press on the toes240. The toe-press state can simulate a motion of the toes pressing on the ground when the natural foot completes a step.

The apparatus100can repeat a cycle that sequentially includes the heel-press state, the resting state and the toe-press state to simulate a step. Advantageously, when the model foot200wears the shoe202(shown inFIG.1), the model foot200can stretch the shoe202in a manner similar to the natural foot walking in the shoe202, so the shoe202can be stretched more accurately.

AlthoughFIG.12Cshows the heel220as being in contact with the platform140for illustrative purposes only, the heel220does not necessarily contact, or press on, the platform140.

Additionally and/or alternatively, the actuator360A and/or the actuator360B can be configured to generate a vibrating motion such that the pressure component366A and/or the pressure component366B vibrates the platform140. The vibration can make the model foot200move within the shoe202and stretch the shoe202. For example, the motor340can include a vibration motor (not shown) to generate micro-motions in the platform140.

Turning toFIG.13, an exemplary apparatus100is shown. The coupling structure120is shown as including three arms122. The platform control system300is shown as including a roller382separated from the model foot200by the platform140. The roller382is shown as having a circular cross section when viewed at the side of the model foot200. Exemplary roller382can be cylindrical, spherical, or the like. The roller382is shown as including a roller shaft381defining a central axis of the circular cross section of the roller382. The apparatus100is shown as including a roller rail386that accommodates the roller shaft381. Thus, when the roller382rotate about the roller shaft381, the roller382can roll on the platform140between the heel220and the toes240repeatedly along a track defined by the roller rail386. The roller382can thus press the platform140alternately on the heel220and the toes240.

The platform control system300is shown as including a motor380and at least one roller translator384each being driven by the motor380and configured to rotate the roller382. The roller translator384can include any device and/or structure that can make a movement under control of the motor380and convert the movement into rotation and/or translation motions of the roller382. Exemplary roller translator384can include a gear, worm gear, sprocket, chain, or a combination thereof. Optionally, the platform control system300can include the controller320(shown inFIG.10A) and/or the interface unit322(shown inFIG.10A) for providing instruction to the motor380.

Turning toFIG.14, a detail drawing of an exemplary roller translator384is shown. The roller translator384is shown as including sprockets388A-388C each meshing with, and enclosed by, a chain (or track, belt)383. The sprocket388C can be fixedly connected to the roller382at a center of the circular cross section of the roller382. When the motor380drives the sprocket388A to rotate, the sprocket388A can drive the chain383to move. The chain383can thus drive the sprockets388B,388C. Accordingly, the sprocket388C can drive the roller382to rotate and translate along the roller rail384. When the motor380reverses a driving direction, the chain383can move in an opposite direction and the roller382can reverse direction of rolling.

Turning toFIG.15A, the apparatus100is shown as being in a resting state. The roller382is shown as being at a middle of the platform140. In the resting state, the platform140can apply pressure to both the heel220and the toes240.

FIG.15Ashows the apparatus100as including the stabilizing member364for limiting a moving range of the roller382. The stabilizing member364can include one or more structures slidingly coupled to the support frame160and configured to block the roller382from moving out of the support frame160. The stabilizing member364is shown as triangular plates surrounding the roller382for illustrative purposes.

Turning toFIG.15B, the apparatus100is shown as being in a heel-press state. The roller382is shown as rolling to be proximal to the heel220and pressing up the platform140against the heel220. The heel-press state can simulate a motion of a heel first presses on the ground when a natural foot starts a step.

AlthoughFIG.15Bshows the toes240as being in contact with the platform140for illustrative purposes only, the toes240does not necessarily contact or press on the platform140.

Turning toFIG.15C, the apparatus100is shown as being in a toe-press state. The roller382is shown as rolling to be proximal to the toes240of the model foot200and pressing up the platform140against the toes240. The toe-press state can simulate a motion of the toes presses on the ground when a natural foot completes a step.

The apparatus100can repeat a cycle that sequentially includes the heel-press state, the resting state and the toe-press state to simulate a step. Advantageously, when the model foot200wears the shoe202(shown inFIG.1), the model foot200can stretch the shoe202in a manner similar to the natural foot walking in the shoe202, so the shoe202can be stretched more accurately.

AlthoughFIG.15Cshows the heel220as being in contact with the platform140for illustrative purposes only, the heel220does not necessarily contact or press on the platform140.

Additionally and/or alternatively, the motor380can introduce a vibration motion when the roller382presses on the platform140. For example, the motor380can reverse direction at a selected frequency, so the roller382can roll back and forth within a small distance and at the frequency. The vibration can make the model foot200move within the shoe202and stretch the shoe202. For example, the motor380can include the vacuum motor (not shown). The rotor (not shown) of the vacuum motor can be connected with the roller shaft381(shown inFIG.13) via the hose clamp, and/or in any suitable manner coupled with one or more of the sprockets388A-388C. The vacuum motor can place the roller shaft381, and/or the sprockets388A-388C, off balance and achieve vibration.

Turning toFIG.16, the model foot200is shown as including a predetermined number of attachment points260. Each attachment point260can include a location, and any structure attached thereon, on the model foot200for connecting the model foot200to the coupling structure120(shown inFIG.1) or the arm122(shown inFIG.6). Each attachment point260is shown as defining a concaved slot on the model foot200and any optional device (not shown) located in the slot. As shown inFIG.16, the slot can be made by cutting dent into the model foot200. Advantageously, the slot can accommodate the device while does not increase a size of the model foot200.

In one embodiment, each attachment point260can be connected to one arm122. Exemplary attachment point260can be connected to the arm122via fastening, bolting, cooperating detents, or a combination thereof.

AlthoughFIG.16shows three attachment points260arranged in a row for illustrative purposes only, the model foot200can include one attachment point260or any number of uniform and/or different attachment points260, without limitation. The attachment point(s)260can be located on any suitable position(s) on the model foot200and arranged in any manner, without limitation. The attachment points260be uniform and/or different in shape, size and/or dimension.

Turning toFIG.17, the attachment point260is shown as including an attachment point loop262. The attachment point loop262can be used as an anchor point for the coupling structure120(shown inFIG.1) or the arm122(shown inFIG.6). For example, the arm122can include a hook (not shown) at the end region of the arm122for engaging the attachment point loop262.

Turning toFIG.18A, the arm122can include two expansion members124at the end region of the arm122. The expansion members124can be spring loaded. When the arm122is not pressed against the model foot200, the expansion members124can be located close to each other, or in a closed configuration.

Turning toFIG.18B, the expansion members124are shown as being in a spreading configuration, similar to a pair of bird wings, when pressed against the model foot200. Advantageously, the spread expansion members124can apply force to a broader area of the model foot200, improve balance of the model foot200, and prevent damage of the model foot200.

AlthoughFIGS.18A and18Bshow two expansion members124as being oppositely arranged for illustrative purposes only, the arm122can include any number of uniform and/or different expansion members124, without limitation. The expansion members124can be arranged in any selected manner, without limitation.

Turning toFIG.19, the model foot200is shown as being viewed from the arm122. The expansion member124is shown as having an end region having a spherical shape. The end region can be configured to roll during spreading of the expansion member124. Advantageously, damage of the model foot200can be prevented.

Turning toFIG.20, the model foot200is shown as including two attachment points260. The attachment point260is shown as defining a fastening point264on the model foot200. The fastening point264can be made by cutting grooves into the model foot200. The arm122can be connected to the model foot200via fastening by bolting, screwing, or the like. Advantageously, the attachment point260does not increase a size of the model foot200.

Turning toFIG.21, the model foot200is shown as including a foot core280connecting the heel220and the toes240. The arm122and the foot core280are shown to be connected via a pivot member128. The pivot member128can be fixedly connected to the foot core280and pivotably connected to the arm122.

The pivot member128can pivot about the end region of the arm122. An angle (not shown) between the foot core280and the platform140can thus be adjusted. Stated somewhat differently, the foot core280can be in a non-parallel position relative to the platform140in the resting state (shown inFIG.9A). Advantageously, the model foot200can wear the shoe202(shown inFIG.1) with a high heel and the pivot member128can raise the heel220to fit in the shoe202. Further, when the rocker spindle342rotates, the shoe202with the high heed does not constrain movement of platform140.

Turning toFIG.22A, the apparatus100viewed from the toes240to the heel220. Springs346A,346B can be respectively positioned under right and left sides of the model foot200for applying pressure to the model foot200via the platform140.

FIG.22Bshows that the model foot200is in a neutral position. The model foot200is shown as including a big toe241and a pinky toe245. In the neutral position, the model foot200does not roll inward (proximally to the big toe214and distally from the pinky toe245). Stated somewhat differently, the model foot200does not pronate. Further, in the neutral position, the model foot200does not roll outward (distally from the big toe214and proximally to the pinky toe245). Stated somewhat differently, the model foot200does not supinate.

FIG.22Cshows that the model foot200as rolling outward or as supinating. In one embodiment, in the apparatus100(shown inFIG.22A), a pressure applied to the platform140(shown inFIG.22A) by the spring346A (shown inFIG.22A) can be greater than the pressure applied to the platform140by the spring346B (shown inFIG.22A). The apparatus100can thus simulate supination. Additionally and/or alternatively, the springs346A,346B can apply equal pressure on the platform140while the model foot200can be aligned so as to tilt outward to simulate supination.

FIG.22Dshows that the model foot200as rolling inward or as having pronation. In one embodiment, in the apparatus100(shown inFIG.22A) a pressure applied to the platform140(shown inFIG.22A) by the spring346A (shown inFIG.22A) can be weaker than the pressure applied to the platform140by the spring346B (shown inFIG.22A). The apparatus100can thus simulate pronation. Additionally and/or alternatively, the springs346A,346B can apply equal pressure on the platform140while the model foot200can be aligned so as to tilt inward to simulate pronation.

Turning toFIG.23, the pivot member128is shown as pivoting about the end region of the arm122. The foot core280is shown as being moved to be non-parallel to the platform140and non-parallel to the toes240. Thus, the model foot200can lift the heel220away from the platform140and simulate posture of the natural foot when wearing the shoe202(shown inFIG.1) that has a high heel.

Turning toFIG.24, a detail drawing of an exemplary model foot200is shown. The model foot200is shown as including a toe connector282fixedly coupled to the toes240(shown inFIG.21). The foot core280is shown as including a first core connector284coupled to the toe connector282, a second core connector284coupled to the first core connector284, and a heel connector288coupled to the second core connector284. The heel220(shown inFIG.21) can be fixedly coupled with the heel connector288.

The foot core280is shown as including a toe pivot joint281rotatably coupled to the first core connector284and the toe connector282. The foot core280can pivot about the toe pivot joint281, so the model foot200can bend at the toe pivot joint281and simulate the natural foot when wearing the shoe202(shown inFIG.1) with high heel.

Exemplary first core connector284can define holes, such as #10-32 threaded holes. The holes can be used to attach the model foot200to the pivot member128(shown inFIG.21).

Exemplary second core connector286can have an adjustable length for adapting to shoes202(shown inFIG.1) of different sizes (or lengths). For example, the second core connector286can have threads such as # 7/16-20 threads/inch, and a 1 plus ⅝ inch adjustment range.

Exemplary heel connector288can optionally be configured to adjust the length of the model foot200. For example, the heel connector288can have threads such as # 7/16-20 threads/inch. In one embodiment, the heel connector288can make fine length adjustment and the second core connector286can make coarse length adjustment.

Turning toFIG.25, a detail drawing of an exemplary model foot200is shown. The toes240are shown as including the second foot portion212and the first foot portion211that covers the second foot portion212as a shell. The first foot portion211can be made using 3D printing. The second foot portion212can be made of potting compound and can fill within the first foot portion211. Advantageously, the cost of 3D printing can be reduced while customized stretching by the toes240can still be achieved.

In one embodiment, the toe connector282and the toes240can be aligned, manually and/or by using a fixture. Advantageously, the toes240and the foot core280can be appropriately aligned relative to the arm122(shown inFIG.21) and the platform140(shown inFIG.21).

The model foot200is shown as including a nut283that can be configured to turn to push and/or pull the heel220forward and/or backward when the heel220is in the shoe202(shown inFIG.1). The nut283can optionally be threaded. Being able to retract the heel220toward the toe240, the model foot200can be more easily placed inside the shoe202.

Turning toFIG.26, a detail drawing of an exemplary model foot200is shown. The heel220is shown as including the second foot portion212and the first foot portion211that covers the second foot portion212as a shell. The first foot portion211can be made using 3D printing. The second foot portion212can be made of potting compound and can fill within the first foot portion211. Advantageously, the cost of 3D printing can be reduced while customized stretching by the heel220can still be achieved.

In one embodiment, the heel connector288and the heel220can be aligned, manually and/or by using a fixture. For example, the heel220can be placed in a fixture. The fixture can hold the nut283and the heel220in proper alignment before filling the potting compound in the first foot portion211. Advantageously, the heel220and the foot core280can be appropriately aligned relative to the arm122(shown inFIG.21) and the platform140(shown inFIG.21).

Turning toFIG.27A, an exemplary model foot200is shown as including the first foot portion211with the second foot portion212embedded therein. The first foot portion211can replicate an external shape of the entire natural foot. The second foot portion212can be an endoskeleton or core of the model foot200. The second foot portion212can include a foot segment216including first and second end regions218,213distal from and proximal to the heel220of the first foot portion211, respectively. The second foot portion212can include a leg segment215including a first leg end region217joining with the second foot end region213and a second leg end region219attached to an end region of the coupling structure120.

In one embodiment, the second foot portion212can be more rigid than the first foot portion211. Advantageously, the second foot portion212can simulate stiffness of an internal bone structure of the natural foot. Additionally and/or alternatively, the second foot portion212can distribute any force applied to the model foot200throughout the first foot portion211to achieve accurate compression of the first foot portion211.

The coupling structure120can include a post that can have an elongated shape. The coupling structure120can define one or more slots123arranged in a column for attaching to the top assembly180(shown inFIG.28, for example). Advantageously, the slots123can achieve adjustable distance between the model foot200and the top assembly180.

Turning toFIG.27B, another exemplary alternative embodiment of the coupling structure120is shown. The coupling structure120ofFIG.27Bcan include a U-shaped post that can have an elongated shape and that defines a slot123for attaching to the top assembly180(shown inFIG.28, for example) via a clip125. Advantageously, the plurality of slots123can achieve adjustable distance between the model foot200and the top assembly180by adjusting position of the clip125in the slot123. The coupling structure120can include a connector plate127for bonding to the model foot200.

Turning toFIG.28, an exemplary detail drawing illustrating an alternative embodiment of the apparatus100is shown. The apparatus100is shown as including two platforms140, including platforms140A,140B. The apparatus100is shown as including the top assembly180that can be connected directly and/or indirectly to one or more model feet200(shown inFIG.1). In one embodiment, each of the platforms140can be moved relative to a selected model foot200in uniform and/or different manners, respectively. Advantageously, the apparatus100can be used for adjusting a plurality of shoes202(shown inFIG.1). For example, one apparatus100can be used for adjusting a pair of shoes202simultaneously.

Turning toFIG.29, the top assembly180is shown as including one or more bars186each defining a slot181. The coupling structure120(shown inFIG.27A) can be fixed to the bars186by clamping using a bolt and/or nut via the slot181and the slot123(shown inFIG.27A). The bars186can be connected to the support frame160(shown inFIG.28) via any suitable locking mechanism including, for example, nuts, bolts, pins springs, latches and/or cooperating detents.

Turning toFIG.30, the platform140is shown as being connected to a base member110. The base member110can be a part of the support frame160(shown inFIG.28). Three actuators360A-360C can be attached to the base member110, optionally at mutually orthogonal positions. Exemplary actuators360A-360C can each include a rotary actuator. For example, the rotary actuator can include a rotational servo. The actuators360A-360C can control movement of the pressure components366A-366C. Each of the pressure components366A-366C are shown as including a crank linkage with one or more links and can be connected to the platform140via a pivotable joint (not shown). An exemplary pivotable joint can include a ball joint.

The actuators360A-360C can be configured to generate rotational and/or translational movements of the platform140relative to the model foot200(shown inFIG.1) about one or more axes. In one embodiment, the platform140can rotate about x axis to reach selected pitch position(s) to simulate dorsiflexion and plantarflexion of the model foot200. Additionally and/or alternatively, the platform140can rotate about y axis to reach selected roll positions to simulate pronation and supination of the model foot200. Additionally and/or alternatively, the platform140can translate in z axis to reach selected heave positions to accommodate a height of the heel of the shoe202(shown inFIG.1) and/or ease the process of attaching the model foot200to the apparatus100.

Stated somewhat differently, the platform140can be configured to function in the form of a Stewart and/or Stewart-like platform. The apparatus100can comprise a traditional six degrees-of-freedom Stewart platform and preferably can simulate a walking motion by using three, or fewer, degrees of freedom. In various embodiments, the platform140can simulate the walking motion by using any suitable number of degrees of freedom that is less than, and/or equal to, six. In one embodiment, the apparatus100can comprise a Stewart and/or Stewart-like platform for simulating a walking motion by using three, two, or one selected degrees of freedom.

Additionally and/or alternatively, one or more of the actuators360A-360C to introduce the vibration motion when the pressure components366A-366C press on the platform140. The vibration can make the model foot200move within the shoe202and stretch the shoe202. For example, a vibration motor (not shown) can be connected to the platform140to generate micro-motions in the platform140.

Turning toFIG.31, a surface layer142is shown as being disposed on the platform140and proximal to the shoe202(shown inFIG.1). The surface layer142can be removable, fixed to the platform140, and/or integrated as a part of the platform140. The surface layer142can simulate texture and/or mechanical properties of a floor or ground upon which the shoe202may walk. Advantageously, the apparatus100can simulate conditions for actual usage of the shoe202. When the surface layer142is removable, a plurality of different surface layers142can be changed. Exemplary surface layers142can be wood, artificial or natural turf, carpet, concrete, dance or sport floor, rough and/or uneven surface to simulate rough and/or uneven terrain, and/or the like.

Turning toFIG.32, two actuators360A,360B are shown as being attached to the base member110. The actuators360A,360B can each include a linear and/or rotary actuator. The actuators360A-360C can control movement of the pressure components366A,366B, respectively. Each of the pressure components366A,366B can be connected to the platform140via the pivotable joint (not shown).

The actuators360A,360B can be attached to the base member110optionally at mutually orthogonal positions. The actuators360A,360B can be configured to generate rotational movements of the platform140relative to the model foot200(shown inFIG.1) about one or more axes. In one embodiment, the actuator360B can move a side144B of the platform140in z direction, so that the platform140can rotate about x axis to reach selected pitch position(s) to simulate dorsiflexion and plantarflexion of the model foot200. Additionally and/or alternatively, the actuator360A can move a side144A of the platform140in z direction, so that the platform140can rotate about y axis to reach selected roll positions to simulate pronation and supination of the model foot200. Stated somewhat differently, the platform140can function as a Stewart platform but using two degrees-of-freedom to simulate a walking motion. In one embodiment, the actuators360A,360B can drive the platform140to simultaneously cycle through a plurality of pitch positions and a plurality of roll positions.

Additionally and/or alternatively, one or more of the actuators360A,360B can introduce the vibration motion when the pressure components366A,366B press on the platform140. The vibration can make the model foot200move within the shoe202(shown inFIG.1) and stretch the shoe202.

Turning toFIG.33, the model foot200is shown as wearing a sock230. The sock230is shown as covering at least the heel220, the toes240, or a combination thereof. The sock230can be more slippery against the shoe202(shown inFIG.1) than the model foot200is. Stated somewhat differently, a friction between the shoe202and the model foot200can be greater than a friction between the shoe202and the sock230. Exemplary sock230can made of silk, natural and/or engineered spider silk, satin, nylon, polyester, polyester and spandex, or a combination thereof.

The sock230can increase sliding and/or slipping of the model foot200against the shoe202and prevent the model foot200from sticking to the shoe202. Advantageously, the model foot200can slide in the shoe202during operation of the apparatus100(shown inFIG.1) and stretch the shoe202. Additionally and/or alternatively, the model foot200wearing the sock230can slip easily into the un-stretched shoe202.

The model foot200is shown as defining three attachment point openings232each being shaped to expose one of the attachment points260. As shown inFIG.33, the attachment point openings232can define a hole cut in the sock230. Advantageously, the attachment points260can be connected to the coupling structure120(shown inFIG.1).

Turning toFIG.34, the sock230is shown as including a sock base234. The sock base234is shown as being shaped to define an opening238to expose a plurality of attachment point openings232. The sock230is shown as including a closure236between two adjacent attachment point openings232. The closure236can include an elongated piece of material that spans across the opening238and have two end regions configured to attach to the sock base234. Advantageously, the sock base234can more completely cover the model foot200to increase slipping and, at the same time, the attachment points260can be exposed. The sock base234with the closure236can adapt to the model foot200that have different numbers and arrangements of attachment points260.

Turning toFIG.35, a stretching enhancer500is shown. The stretching enhancer500can include a material that can moisten, soften, and/or weaken a material of the shoe202(shown inFIG.1) to increase efficacy of, or expedite, the stretching. Exemplary stretching enhancer500can include a liquid, a gel, or a combination thereof. Exemplary gel can include an alcohol gel and/or a leather stretch liquid.

The stretching enhancer500can be sprayed on the model foot200. Additionally and/or alternatively, the stretching enhancer500can be applied to selected locations on the model foot200where more stretching is needed (for example, on locations corresponding to hot spots on the natural foot).FIG.35shows the stretching enhancer500in a bottle with a brush (optionally attached to a lid of the bottle) and the brush can be used for applying the stretching enhancer500with precision.

FIGS.36A-36Cshow positions of the platform140relative to the model foot200in a lateral rolling movement. Turning toFIG.36A, a front view of the model foot200and the platform140are shown. The model foot200is in the neutral position. Turning toFIG.36B, the model foot200is supinating. Stated somewhat differently, the platform140presses on an outward edge of the model foot200. The outward edge of the model foot200is distal from the big toe. Turning toFIG.36C, the model foot200is pronating. Stated somewhat differently, the platform140presses on an inward edge of the model foot200. The inward edge of the model foot200is proximal to the big toe.

By control the platform140in the apparatus100shown inFIGS.22A,30and/or32, the platform140can switch and/or roll between the pronating state and the supinating state in any selected sequence, with the neutral state therebetween, to simulate lateral rolling movement of the model foot200. The lateral rolling movement can occur when a natural foot walks on rough and/or uneven terrain during, for example, hiking. Advantageously, when the model foot200wears the shoe202(shown inFIG.1), the model foot200can stretch the shoe202, such as a hiking shoe, in a manner similar to actual usage condition of the shoe202. The lateral rolling movement can be alternative and/or additional to the simulated walking movement and/or vibration of the platform140.

Turning toFIG.37, an exemplary controller320is shown. The controller320can be configured for controlling the platform control system300(shown inFIG.1). The controller320can include a processor321. The processor321can include one or more general-purpose microprocessors (for example, single or multi-core processors), application-specific integrated circuits, application-specific instruction-set processors, graphics processing units, physics processing units, digital signal processing units, coprocessors, network processing units, encryption processing units, and the like. The processor321can execute instructions for implementing the platform control system300.

As shown inFIG.37, the controller320can include one or more additional hardware components as desired. Exemplary additional hardware components include, but are not limited to, a memory322(alternatively referred to herein as a non-transitory computer readable medium). Exemplary memory322can include, for example, random access memory (RAM), static RAM, dynamic RAM, read-only memory (ROM), programmable ROM, erasable programmable ROM, electrically erasable programmable ROM, flash memory, secure digital (SD) card, and/or the like. Instructions for implementing the platform control system300can be stored on the memory322to be executed by the processor321.

Additionally and/or alternatively, the controller320can include a communication module323. The communication module323can include any conventional hardware and software that operates to exchange data and/or instruction between the controller320and another computer system (not shown) using any wired and/or wireless communication methods. Exemplary communication methods include, for example, radio, Wireless Fidelity (Wi-Fi), cellular, satellite, broadcasting, or a combination thereof.

Additionally and/or alternatively, the controller320can include a display device324. The display device324can include any device that operates to present programming instructions for operating the controller320. Additionally and/or alternatively, the controller320can include one or more input/output devices325(for example, buttons, a keyboard, keypad, trackball), as desired.

The processor321, the memory322, the communication module323, the display device324, and/or the input/output device325can be configured to communicate, for example, using hardware connectors and buses and/or in a wireless manner.

Turning toFIG.38, an exemplary diagram of an embodiment of a control process310is shown. The control process310can be implemented on the controller320(shown inFIG.37). The controller320can provide a central control panel (not shown), which can provide a user interface with a plurality of controls. Ambulatory motion can be included in the memory322(shown inFIG.37). The user interface can include a power button, start-stop control, and indicator lights. Additionally and/or alternatively, the user interface can present a cycle timer, ambulatory pattern selection, cycle modification to better account for shoe size and type, a keypad for an operator to input the duration (or number of steps) for actuation, the shoe size, the mode of actuation (walking, running, sprinting), or a combination thereof.

The controller320can be programmed using any suitable language. An exemplary controller320can be written in Arduino and/or Python. Foot motion data can be obtained, at311. For example, the foot motion data can be obtained by measuring motions of the natural foot on a treadmill with measurement functions, and/or any other foot motion measurement instruments. The foot motion data can be processed, at312, in a foot data program such that the foot motion data can be converted to control code for the actuators360(shown inFIG.30). The foot data program can include walking simulation data of displacement direction and points of contact with the ground at a set of snapshots or moments within the walking. For example, the foot data program can cyclically run through tables of values of the foot motion data to convert the foot motion data into a table of servo positions. The table of the servo positions can be provided to the control code which can convert the servos positions to pulse-width modulated signals that can be sent to the servos to determine the position.

In one embodiment, the foot data program can utilize angular displacement in the dorsi and/or plantar flexion ranges, inversion and/or eversion ranges, and/or the like, to determine the angle of the platform140at a set number of points in each walking cycle (for example, from heel strike to heel strike). At selected displacement angles, the foot data program can determine point of contact of the model foot200with the ground at the specific point in the walking cycle. Accordingly, the foot data program can operate in a “flipbook form,” where each point of contact coupled with corresponding angles of the platform140can be a single frame in the overall motion. By sequencing the individual frames together, the foot data program can create a fluid or continuous motion that can simulate the motion of walking and create accurate actuation.

The control code can be arranged, at313, in a control signal file optionally having a table structure. The control signal file can optionally be uploaded, at314, to the controller320, if the foot data program is run on a computer different from the controller320. The user can make, at315A, modifications such as changing shoe size, vertical offset, and run time. For example, the foot data program can take in the shoe size via the user interface to ensure that the actuation makes the platform140(shown inFIG.1) contact the sole of the shoe202(shown inFIG.1) at the appropriate points along the shoe202and to scale the points of contact with the platform140(shown inFIG.1) accordingly.

After any changes and the control signal file have been modified, at315, a motion control program can be run at316. The user can press, at316, ‘start.’ The apparatus100(shown inFIG.1) can start, at316A. The apparatus100can continue running, at316B, for a selected duration and/or a selected number of steps. Upon completion, the apparatus100can stop, at316C. The user interface can optionally notify the user that the run cycle is complete.

The number of steps can be greater than and/or equal to the minimum number of steps that the natural foot can make to stretch the shoe202. The number of steps can be smaller than a number of steps that can wear out the shoe202. The duration can be calculated by multiplying the number of steps and duration of each step. The number of steps can depend on the type of shoe202. For example, the number of steps can be smaller for a soft leather shoe and greater for a sports cleat. Exemplary number of steps can range from 10,000 to 200,000 or any sub-range therebetween.

Turning toFIG.39, a top view of an alternative embodiment of the apparatus100is shown. The apparatus100is similar to apparatus100as shown inFIGS.30-32and includes the actuators360A-360C (or the motors 1-3, respectively). The motion of each of the pressure components366A-366C can define a plane (illustrated as a plane x′-y′ as shown inFIG.40). The planes between the pressure components366A,366B are shown as defining an arc with an angle A1. The planes between the pressure components366B,366C are shown as defining an arc with an angle A3. The angles A1, A3 can be uniform and/or different. In one embodiment, the angle A1 can be the same as the angle A3. Advantageously, the pressure components366A,366C can more easily generate symmetric and/or synchronous movements for the platform140(shown inFIG.30). Stated somewhat differently, the pressure components366A,366C can raise and/or lower the platform140in synchronization. In one embodiment, the angles A1, A3 can each be 120 degrees.

Turning toFIG.40, a detail drawing of an exemplary actuator360and an exemplary pressure component366is shown. A home position of the actuator360can be aligned with x′ axis that is horizontal with the base member110(shown inFIG.39). For illustrative purpose only, the actuator360can be capable of having an angular motion range of 270 degrees. The pressure component366is shown as having first and second arms368,361. The first arm368can be attached to the actuator360directly and/or can be configured to move within a motion range of 90 degrees and/or any other angle ranges within the range of 270 degrees. A second arm361distal to the actuator360can move in a vertical direction based on the angle of the first arm368. By controlling an angular motion of the pressure components366, the actuators360can drive the platform140(shown inFIG.30) in one or more selected dimensions.

AlthoughFIG.40shows a home position of the actuator360and the pressure component366as being 0 degree in the x′-y′ coordinate system for illustrative purposes only, the home positions can be uniform and/or different values for the actuators360based on an installation position of each actuator360, without limitation. AlthoughFIG.40shows, for illustrative purposes only, the actuator360and the first arm368as having angular motion ranges of 270 degrees and 90 degrees, respectively, the actuator360and the first arm368can have any uniform and/or different motion ranges, without limitation.

Turning toFIG.41, an exemplary flow chart of Machine Run at316B (also shown inFIG.38, for example) is shown. The actuators360A-360C (shown inFIG.39) can be moved, at332, to home positions, respectively. At the home positions, the platform140(shown inFIG.30) can be horizontal such that the model foot200(shown inFIG.1) can be in the resting state (shown inFIG.12A, for example). The actuators360A,360B,360C can be moved, at334, to lower, upper and lower positions, respectively. Accordingly, the platform140can be tilted such that the model foot200can be in the heel-press state (shown inFIG.12B, for example). The cycle including332,334can be repeated, at336, for a selected number of times. The cycle is shown as including pause338for home position for 1 second and pause331for foot motion for 3 seconds or 0.5 second for illustrative purposes only. The duration of the pauses338,331can be any suitable time length, without limitation.

Turning toFIG.42, another exemplary flow chart of the Machine Run at316B is shown. The flow chart is similar to the flow chart shown inFIG.41but shows exemplary angles for home, lower and higher positions in an exemplary setup. For illustrative purpose only, the actuators360A-360C at332are shown as being at 205°, 170°, and 95°, respectively, and the actuators360A-360C at334are shown as being at 175°, 105°, and 55°, respectively. However, the angles for the actuators360A-360C at332can be any suitable uniform and/or different values, and the angles for the actuators360A-360C at334can have any suitable values, without limitation. As a result of the change in angle values between332and334, the actuators360A,360C can move similarly and synchronously between home and lower positions, and the actuator360B can move between home and upper positions, creating the walking motion.

FIGS.43A-43Cshow an exemplary process for making the model foot200. Turning toFIG.43A, before placing a casting material256(shown inFIG.43B) into the mold250, one or more fasteners266(for example, screws and/or bolts) can be inserted and/or screwed through and into the mold250at the selected locations corresponding to the attachment points260and be fixed at the locations at a suitable depth into the model foot200.

Turning toFIG.43B, the casting material256can be poured into the mold250. Upon curing of the casting material256, a recess complementary to a shape of the fastener266can be formed in the cured casting material256. In various embodiments, the fasteners266can be selected such that at least the portion of the fastener266that is embedded into the casting material256can have the same shape as the portion of the coupling structure120(shown inFIG.1) that is to be connected to the model foot200when the model foot200is in use.

Turning toFIG.43C, after curing of the casting material256, the model foot200can be formed and removed from the mold250(shown inFIG.43B). As shown, the attachment points260can be defined on the model foot200.FIG.43Dshows a perspective view of the model foot200for illustrating exemplary locations of the attachment points260A-260C on the model foot200. The attachment points260A-260C are shown as each defining a fastening point264.FIGS.43A-43Cshow three attachment points260including three attachment points260A-260C for illustrative purposes only. The model foot200can have any number of uniform and/or different attachment points260defined thereon, without limitation.

In some embodiments, the fasteners266(shown inFIG.43B) can each include a screw and/or bolt, thus forming a thread in cured casting material. The thread can mate with the couple structure120if the couple structure120and the fastener266have the same type of thread. Thus, at the same time of curing the casting material256, the model foot200can be shaped for accommodating the coupling structure120, and/or any other suitable structure, to be connected to the model foot200. The mold250can be reused for making multiple model feet200and the attachment points260can be defined on each model foot200at consistent location(s). In an alternative process, the model foot200can be first formed in, and then removed from, the mold250, and the attachment points260can then be formed on the model foot200. However, in comparison, the method illustrated inFIGS.43A-43Ccan eliminate the separate step of forming the attachment points260and can prevent inconsistencies in locations of the attachment points260. Advantageously, consistency, efficiency and cost of manufacturing the model foot200can be improved.

AlthoughFIGS.43A-43Cshow the fasteners266as being placed into the mold250before pouring the casting material256for illustrative purpose only, the fasteners266can be placed into the mold250at any suitable time before the casting material256is cured, without limitation. Additionally and/or alternatively, the mold250can be oriented in any suitable manner when the model foot200is being made. For example, the mold250can have uniform and/or different positions relative to ground, as shown inFIGS.3C-3F, for example.

AlthoughFIGS.43A-43Dshow three fasteners266as being placed into the mold250for illustrative purpose only, one or more, or any number of, fasteners266can be used when making the model foot200. One or more of, or all of, the formed attachment points260can be used when the model foot200is wearing the shoe202(shown inFIG.1), depending on the type of the shoe202and/or the need of the stretching of the shoe202. For example, to stretch a sneaker, all three of the attachment points260as shown can be used because a tongue of the sneaker can be lifted such that all the fasteners266can be accessed. In another example, when the model foot200wears a loafer without a movable tongue, the attachment point260proximal to the toes can be inaccessible and thus not used.

Turning toFIG.44, an exemplary mold support270is shown as at least partially enclosing the mold250. In some embodiments, the mold250can be non-rigid, and/or the mold support270can be rigid or at least more rigid than the mold250. For example, the mold250can be made of a silicone-based material. In one embodiment, the material for making the mold250can be different from the material for making the model foot200(shown inFIG.1). Thus, when the casting material256is poured into the mold250, the mold250can subside, sink and/or droop, under the weight of the casting material256, thus deviating from the correct shape. The mold support270can prevent subsiding of, and can hold the shape of, the mold250. Advantageously, the model foot200can be formed with the correct shape. For example, the mold support270can be made by any suitable methods including, for example, casting. Exemplary materials of the mold support270can be plaster.

Turning toFIG.45, another exemplary model foot200attached to the coupling structure120is shown. Only the second foot portion212of the model foot200is shown for illustrative purposes. The first foot portion211(shown inFIGS.4A,25and27A) that replicates the external shape of the entire natural foot is not shown. The second foot portion212is shown as including the foot segment216including first and second end regions218,213. The second end region213can include a sphere, oval, ellipse, and/or any other regular or irregular curved shape, to simulate internal bone structure of a heel. The foot segment216is shown as including a strip290terminating at the second end region218and directly connected with the second end region213and/or indirectly coupled with the second end region213via any suitable mechanical structure. The strip290can be configured to simulate tarsals and/or metatarsals bone structure. The strip290can be planar and/or curved. Accordingly, the second foot portion212can imitate bone structure of the natural foot via a simplified shape and may be advantageous for reducing manufacturing cost.

Turning toFIG.46, a diagram shows that the second foot portion212can be positioned in the first foot portion211, at a suitable manufacturing stage depending upon the manufacturing method, to form an endoskeleton or core of the model foot200.

Turning toFIG.47, another exemplary model foot200attached to the coupling structure120is shown. The coupling structure120can function as an ankle fixture that simulates a natural ankle. In one embodiment, the second foot portion212can include a stiff member overmold into the first foot portion211to help distribute the hold, and/or load, closer to the toes240. The second foot portion212can thus form a construction similar to a cantilever beam with the ankle being a fixed end region, and a load being applied near the toes240to function as a floating end region. Depending on the motion of the model foot200, a pressure can be applied to planes C, D, or E corresponding to the heel220, the middle portion of the bottom204, and the toes240, respectively.

In various embodiments, based upon a mechanical breakdown of the cantilever beam, a relationship between the load applied at the end of the cantilever beam versus a stiffness of the cantilever beam can be directly proportional. For example, the second foot portion212with ten times the stiffness can require ten times more force to deflect the toes240at a given distance. Therefore, a pressure near the toes240can be increased by stiffening the cantilever beam. Because a great pressure near the toes240can be advantageous for shoe stretching, a stiff cantilever beam can be useful.

In various embodiments, there can be insignificant movement of the model foot200between the heel220and the metatarsals throughout a gait cycle. The addition of the second foot portion212can act the same as the corresponding skeletal system for the natural foot. As set forth above, the model foot200can be advantageously made via a simplified process, without using a multi-material mold making process (shown inFIGS.3C-3F, for example). Because the second foot portion212can be terminated near the ends of the metatarsals, the toes240can be allowed to flex.

Turning toFIG.48, an exemplary diagram of the model foot200is shown. In various embodiments, the model foot200can include a first stretch component710and a second stretch component720connected with the first stretch component710. The first stretch component710can replicate an external shape of at least a part of the natural foot for shaping the internal surface of the shoe202(shown inFIG.1). An exemplary first stretch component710can replicate a part of the natural foot with the most significant deformation and most necessary for shoe stretching. For example, for a natural foot with a toe deformation but no other types of deformation, the first stretch component710can include at least the toes. The second stretch component720can include some or all of the remaining part of the model foot200, and can have any shapes, materials, sizes, and/or structures that imparts suitable mechanical and/or geometric properties to the model foot200such that the model foot200can mimic how the natural foot fits in, and/or moves within, the shoe202. Accordingly, the first stretch component710, by being coupled with the second stretch component720, can stretch the shoe202into the desired shape.

In one embodiment, the first stretch component710can include the first sub-portion251(shown inFIG.3B, for example). The second stretch component720can include the second sub-portion252(shown inFIG.3B) and the third sub-portion253(shown inFIG.3B). In another embodiment, the first stretch component710can include the first sub-portion251(shown inFIG.4B, for example). The second stretch component720can include the second sub-portion252(shown inFIG.4B), the third sub-portion253(shown inFIG.4B) and the second foot portion212(shown inFIG.4B). In another embodiment, the first and second stretch components710,720can include the first and second foot portions211,212(shown inFIGS.4A,25and/or27A).

Turning toFIG.49, another exemplary apparatus100is shown. The actuators360A,360B are shown as supporting the platform140. The actuators360A,360B can include vertical actuators. The actuators360A,360B can be linked such that the platform140can move vertically and/or rotate (or pitch) to strike the shoe202(shown inFIG.1) at suitable positions, and/or angles, of heel and/or toes. The coupling structure120can function as an ankle support that simulates a natural ankle. The coupling structure120can be fixed and/or compliant (or spring loaded) in plantar flexion and/or eversion such that the apparatus100can mimic the kinematics of the human body, creating all multi-directional forces to encourage movement and/or friction between the shoe202, the sock230(shown inFIG.33), and interfaces of the model foot200(shown inFIG.1).

Turning toFIG.50, the apparatus100ofFIG.49is shown in an alternative view. The platform140is shown as being capable of contacting two shoes202(shown inFIG.1) at the same time. Advantageously, the total number of components, and the manufacturing cost, of the apparatus100can be reduced.

The disclosed embodiments are susceptible to various modifications and alternative forms, and specific examples thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the disclosed embodiments are not to be limited to the particular forms or methods disclosed, but to the contrary, the disclosed embodiments are to cover all modifications, equivalents, and alternatives.