TECHNICAL FIELD

[0001] The invention relates to insoles for shoes and, in particular, to replacement and auxiliary insoles.

BACKGROUND ART

[0002] An insole is a layer of material placed within a shoe above the sole of the shoe. The foot of a wearer rests on the insole when wearing the shoe. Insoles typically span from the front of the toe to the rear of the heel.

[0003] Insoles can mitigate and prevent foot injury and pain by providing cushioning and support. The impact on feet during normal walking and exercise can lead to foot, ankle, knee, and other joint pain or injury. In turn, pain and injury prevent the afflicted person from exercising. The effect is increased by the weight of the person, the intensity of the exercise, and the duration of exercising.

[0004] Feet can be injured and fatigued when they are not properly supported. Insoles can provide support to the foot. In particular, insoles can provide support to the arch of the foot.

[0005] Insoles can be made of a cushioning material. A cushioned insole reduces impact on the foot. Cushioned insoles become compressed with use. Once the insoles become compressed, they no longer provide the original amount of cushioning.

[0006] Foam insoles often fail at the arch. The arch collapses and then no longer supports the arch of the wearer's foot.

[0007] Cushioned replacement insoles are available. The replacement insoles can replace original or compressed insoles with ones with greater cushioning. Replacement insoles are typically the length of the sole of the foot: i.e. from the tip of the toes to the rear of the heel. Accordingly, the replacement insoles are sold by size. To provide replacement insoles for every customer, the manufacturer must make an insole for each size shoe. In addition, retailers must stock each size of insole.

[0008] Replacement insoles are manufactured for a particular gender: i.e. men's or women's. Replacement insoles can be worn as primary or auxiliary insoles. A primary insole is an insole that is not used with another insole. An auxiliary insole is an insole that is placed over another insole.

[0009] Orthotic heel inserts (also known as "orthotics") exist to cushion and support the heel and/or leg of the wearer. Some orthotics only support the rear (i.e. the heel of the foot). These orthotics often move longitudinally (i.e. forward and back) with a shoe. Heel orthotics do not include support for the arch of the wearer.

DISCLOSURE OF INVENTION

[0010] It is accordingly an object of the invention to provide an insole for shoes that overcomes the above-mentioned disadvantages of the heretofore-known devices and systems of this general type.

[0011] With the foregoing and other objects in view there is provided, in accordance with the invention, an insole including a shock absorber layer, a heel insert, a woven para-aramid polymer fiber insert, an airfoam layer, and a fabric cover. The shock absorber layer has a cutout formed in a section configured to underlie an arch of a foot of a wearer. The heel insert is disposed beneath the shock absorber layer. The woven para-aramid polymer fiber insert is inserted in the cutout. The airfoam layer is disposed over the shock absorber layer. The fabric cover overlies the airfoam layer.

[0012] The insole disperses Shockwaves created during impact when wearers of shoes walk, work, and exercise. By reducing the impact, less pain occurs in wearers of the insoles.

Preventing pain obviates one of the chief reasons why people stop exercising.

[0013] The insole can be configured to be gender specific. That is a given insole is configured for a man or a woman. An insole configured for a man will have a broader width for a given length compared to a woman's insole at the same length.

[0014] The insole is configured to underlie a wearer's arch and heel. The insole is not configured to underlie the toes of the wearer. By not being as long as any particular foot, the insole can be used as insole for any sized shoe.

[0015] The invention encompasses an insole for a shoe. The insole can be used as an auxiliary insole that is added to a shoe with an existing insole. The insole can be used as a primary insole or a replacement insole.

[0016] The insole includes a shock absorber layer. The shock absorber layer is configured to fit within a shoe and rest on the footbed of the shoe. The shock absorber layer does not include a portion that underlies the toes of the wearer. The shock absorber layer is roughly configured to underlie the rear three-quarters of the wearer's foot. In this way, a given insole does not need to be configured to a particular size of shoe. Rather one insole ca n be used in many sized shoes. The shock absorber layer includes a medial section configured to underlie an arch of a foot of a wearer. A para-aramid polymer insert is placed in the medial section. The para-aramid polymer insert is significantly more rigid than the shock absorber insole. The para- aramid insert supports the arch of the wearer. Supporting the arch reduced strain on the foot. An example of a para-aramid polymer that can be used is a polymer sold under the trade name KEVLAR ^® .

[0017] The medial section can have a cutout formed therein. The para-aramid insert can be disposed on the top of the shock absorber insole. The para-aramid insert remains visible by looking through the cutout. By maintaining the visibility of the para-aramid insert, the presence of the para-aramid insert can be marketed as a distinction from insoles that do not include para-aramid inserts.

[0018] The shock absorber layer can be configured to underlie a heel of the wearer. As stated, the insole can extend from the heel of the wearer forward to the beginning of the toe box. The front edge of the insole can be arcuate to complement the curve of the front edge of the midfoot. In use, the insole is placed in the shoe of the wearer with the rear of the insole seated against the rear of the shoe.

[0019] The medial section can be arcuate. The medial section can be shaped to complement and support an arch of a wearer.

[0020] The para-aramid polymer insert can be a woven insert. Para-aramids can be generated as fibers. The fibers can be woven into an insert. By weaving fibers in more than one direction, an insert with increased strength in those directions can be produced. The insert can be held in the shock absorber layer with a form locking connection. Alternatively, the insert can be attached to the shock absorber layer with adhesive or an attachment device.

[0021] An elastomeric heel insert can be disposed on the bottom of the shock absorber layer. The elastomeric heel insert is placed on the shock absorber layer so that the heel insert will underlie a heel of the wearer. The elastomeric heel insert has a different elastic modulus than the shock absorber layer. The elastomeric heel insert has a greater elastic modulus than the shock absorber layer. The heel insert can be circular shaped.

[0022] The shock absorber layer can have a plurality of grooves running side to side (i.e. medial to lateral) on the shock absorber layer. The grooves do not necessarily need to run laterally across the entire width of the shock absorber layer. The grooves can run across a portion of the width. The grooves are formed in the bottom of the shock absorber layer. The grooves help to hold the shock absorber layer in place in the shoe. [0023] The shock absorber layer can include a lateral notch on its front edge. The lateral notch helps to hold the insole in place within the shoe. The lateral notch can be placed on the lateral (i.e. outside) portion of the front edge so that the notch does not interfere with the arcuate medial (i.e. inside) portion.

[0024] A fabric cover layer can be placed as a top layer on the insole. The fabric cover provides a comfortable surface. In addition, the fabric layer provides a moisture absorbing layer. The fabric can be imprinted with branding to identify a manufacturer or seller.

[0025] The invention encompasses a system of gender specific insoles. Women's feet and therefore shoes are generally narrower than a man's at a given length. The system includes an insole for men that is wider for a given length and an insole for women that is narrower at the length.

[0026] Other features that are considered as characteristic for the invention are set forth in the appended claims.

[0027] Although the invention is illustrated and described herein as embodied in an insole for shoes, it is nevertheless not intended to be limited to the details shown, because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.

[0028] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0029] Fig. 1 is a diagrammatic right side view of a right insole according to the invention.

[0030] Fig. 2 is a bottom side view of the insole shown in Fig. 1.

[0031] Fig. 3 is a left side view of the insole shown in Fig. 1.

[0032] Fig. 4 is a sectional view taken along line IV-IV shown in Fig. 2.

[0033] Fig. 5 is a top side view of the insole shown in Fig. 1 with the fabric layer omitted.

[0034] Fig. 6 is a sectional view taken along line VI-VI shown in Fig. 2.

[0035] Fig. 7 is a sectional view taken along line 11 - 11 shown in Fig. 2.

[0036] The left insole, which is not shown, is a mirror image of the right insole shown in Figs.

1-7. BEST MODE FOR CARRYING OUT THE INVENTION

[0037] Referring now to the figures of the drawing in detail and first, particularly, to Figs. 1-7 thereof, there is seen an insole 1. The insole 1 includes a heel insert 10, a shock absorber layer 20, a para-aramid insert 30, and a cover 50.

[0038] Fig. 2 shows a preferred embodiment of a heel insert. The preferred embodiment of the heel insert 10 is round. That is, the heel insert 10 has a circular cross section. The heel insert 10 is made of a shock absorbing material. A circular recess is formed in the bottom of the shock absorber layer 20 below where the heel of the wearer will be. The heel insert 10 is disposed, preferably with adhesive, in the circular recess in the bottom of the shock absorber layer 20.

[0039] The shock absorber layer 20 forms a foundation for the insole 1. The shock absorber layer 20 is a flexible resilient solid foam polymer footbed. The shock absorber layer 20 is preferably microcellular low density polyurethane foam. Polyurethane is a polymer formed from a chain of organic units joined by urethane (carbamate) links. Polyurethane polymers are formed through step-growth polymerization by reacting a monomer containing at least two isocyanate functional groups with another monomer containing at least two hydroxyl (alcohol) groups in the presence of a catalyst. Microcellular plastic foam is a plastic composite that has been specially fabricated so as to create micro-pores or cells in the polymer matrix. A microcellular plastic foam can be defined as a foam with pore size on the order of ten micrometers (1 X 10 ¹ μιη) in diameter (from 0.1 to 100 micrometers typically). Because the size of cells is close to the wavelength of light, microcellular plastic foams appear like a solid light colored plastic. Microcellular foams have been made in the density range of 5 to 99% of the base material. Conventional commodity foam has cell diameters of 100 to 500 micrometers and density of very light foam to hard foam (0.3 to 50% of virgin material). The shock absorber layer 20 has arcuate seams 29 and 31 that divide the shock absorber layer 20 into a medial section 24 (i.e. proximal to the arch), a mid section 23, and a lateral section 32 (i.e. distal to the arch).

[0040] The outer section 32 has a plurality of horizontal (i.e. medial to lateral) grooves 21 formed therein. The grooves 21 help to hold the insole 1 in place within a shoe.

[0041] The inner section 24 has a plurality of horizontal grooves 25 formed therein. The grooves 25 help to hold the insole 1 in place when the insole is placed in a shoe. A cutout 28 has a generally rectangular shape with rounded corners. The cutout 28 is disposed where the cutout 28 will underlie the arch of a wearer's foot when the insole 1 is worn.

[0042] A heel socket 22 is formed in the shock absorber layer 20. The heel insert 10 seats in the heel socket 22. The heel insert 10 is connected to the shock absorber layer 20 with adhesive.

[0043] An insert 30 is inserted in the cutout 28. The insert 30 is made from a woven para- aramid polymer fiber such as those sold under the trade name KEVLAR ^® and reinforces a portion of the microcellular foam shock absorber layer 20. The insert 30 protects a foot of the wearer. The insert 30 maintains the shape of the insole 1, which is configured to complement and support an arch of a wearer's foot.

[0044] The insole 1 has a front edge 26. The front edge 26 is arcuate and compliments the line on the front where the toes join the midfoot. A notch 27 is formed along the lateral portion of the edge in the outer section 32.

[0045] A cover 50 is disposed over the shock absorber layer 20. The cover 50 is made from an antibacterial and hygienic textile. A preferred textile is polyester. A logo, which is not shown, can be printed or embossed on the cover 50. The insole 1 has a rim 52 that provide a concave top surface to hold a wearer's foot. The cover 50 is adhered to the airfoam layer 50. The cover 50 absorbs moisture from the foot. The cover 50 improves the tactile feel and comfort of the insole 1.

[0046] The insole 1 is intended to underlie a portion of the wearer's foot, from the arch to the heel. The insole 1 does not underlie the toes of a wearer. By not having a forefoot, the insole 1 can be placed in a range of different sized shoes. In embodiments with a heel, the heel is placed against the rear of the shoe. Ridges that run in medial to lateral direction prevent the insole from unintentionally sliding forward in the shoe.

[0047] The insoles are gender specific. That is one embodiment of the insoles 1 are intended to be placed in women's shoes. A different embodiment of the insoles 1 is intended to be placed in men's shoes. At a given length of insole, the embodiment of insoles for men has a wider width than the embodiment for women at the same length.

[0048] A preferred method of using the insoles 1 includes removing a liner from a shoe or boot to be worn. Then, the next step is replacing the original insole with the insole 1.

[0049] Alternatively, the insole 1 can be used as an auxiliary insole along with the original insole. The insole 1 is placed into the shoe with the heel abutting the rear of the shoe. INDUSTRIAL APPLICABILITY

[0050] The invention is applicable to the footwear industry and used as a primary or secondary insole within a shoe.