TECHNICAL FIELD

The technical field generally relates to insoles, and more specifically to orthotic insoles configured in accordance with a plurality of anatomical mechanical aspects of the natural human body and to methods of manufacturing orthotic insoles.

BACKGROUND

Foot ailments are common problems experienced by many people. Common issues include over or under pronation, hammer toe, Morton’s neuroma, plantar fasciitis, heel spur also known Lenoir’s thorn or Lenoir Syndrome, hallux valgus, nerve damage, muscle imbalance, post-fractures, osteoarthritis and arthritis among others, as well as general body pain. A way of remedying these issues is using a plantar orthotic insole. These may be custom-made or prefabricated. Custom-made orthotic insoles, such as those described by patents CA2902596, CA2975649 and CA2339446, are fitted to conform exactly to the user’s foot. Prefabricated orthotic insoles, such as those from patents CA2991380 and CA2825973, are manufactured and distributed to the general public without an exact fitting to the user’s foot. Instead, they conform to standard shoe sizes and widths. The main problems with both of these types of orthotic insoles is that they vary widely between manufacturers. These are primarily made for comfort and do not necessarily correct and prevent all of the aforementioned ailments. In CA2339446, a custom insole’s design method is described. As it is a custom-made orthotic, it is manufactured to conform to the user’s foot. This customization is made by professionals such as podiatrists using plaster casting as described in CA2339446, electronically scanned as is the case with CA2902596, or vacuum- molded to the user’s foot in the case of CA2975649. In addition, these custom orthotics must then be modified to offer the corrections required. This is typically done by providing orthotics with custom geometric modifications to offer a user- specific solution. These methods are time consuming, iterative, and will vary according to every user. Prefabricated insoles, on the other hand, are standardized. However, their main limitation is that they do not offer the same degree of relief as custom orthotics. For example, CA2991580 propose an insole seeking to correct over pronation or supination through adjustable wedges as the main corrective feature, while CA2825973 proposes an insole with arch support to relieve the plantar fascia.

SUMMARY

According to one aspect, there is provided an orthotic insole comprising: an insole body receivable in a footwear, the insole body having a front body end, a rear body end opposite the front body end, a top body surface for receiving a foot of the user and a bottom surface configured to be received on an insole of the footwear, the top insole surface including a plurality of top surface portions, each top surface portion being substantially angled relative to an adjacent top surface portion, the top surface being substantially untwisted along its length between the front and rear body ends such that the top surface remains leveled in a widthwise direction as the top body surface extends from the front body end to the rear body end.

In at least one embodiment, the plurality of surface portions includes a heel portion extending forwardly from the rear end to receive a heel of a user thereon, the heel portion having a rear end located at the rear end of the insole and a front end, the heel portion extending along a heel portion plane.

In at least one embodiment, the plurality of surface portions further includes a calcaneal inclination portion extending forwardly from the heel portion, the calcaneal inclination portion having a rear end located at the front end of the heel portion and a front end, the calcaneal inclination portion extending forwardly and upwardly from the heel portion.

In at least one embodiment, the calcaneal inclination portion extends along a calcaneal inclination portion plane, the calcaneal inclination portion plane being angled upwardly relative to the heel portion plane.

In at least one embodiment, the calcaneal inclination portion plane is angled relative to the heel portion plane at an angle of between about 3 degrees and 7 degrees.

In at least one embodiment, the calcaneal inclination portion plane is angled relative to the heel portion plane at an angle of about 5 degrees.

In at least one embodiment, the plurality of surface portions further includes a midfoot portion extending forwardly from the calcaneal inclination portion, the midfoot portion having a rear end located at the front end of the heel portion and a front end. In at least one embodiment, the plurality of surface portions further includes a metatarsal portion extending forwardly from the midfoot portion, the metatarsal portion having a rear end located at the front end of the midfoot portion and a front end, the metatarsal portion extending downwardly from the rear end to the front end thereof. In at least one embodiment, the metatarsal portion extends along a metatarsal portion plane, the metatarsal portion plane being angled relative to the heel portion plane at an angle of between about 9 degrees and 19 degrees.

In at least one embodiment, the metatarsal portion plane is angled relative to the heel portion plane at an angle of about 13.5 degrees. In at least one embodiment, the orthotic insole further includes a tongue member extending forwardly from the front insole end of the insole body, the front insole end having a first width and the tongue member having a second width smaller than the first width.

In at least one embodiment, the orthotic insole further includes an arch alignment member for receiving a user’s foot arch, the arch alignment member extending upwardly from the top insole surface and extending along an inner body edge of the insole body.

In at least one embodiment, the arch alignment member includes a top arch member face for abutting the user’s foot when the user’s foot is received on the top insole surface and a bottom arch member face. In at least one embodiment, the arch alignment member further includes a plurality of slots defined in the bottom arch member face, the slots extending parallel to each other and substantially parallel to the central longitudinal body axis.

In at least one embodiment, the top arch member face is convexly curved upwardly. In at least one embodiment, the insole body includes a front insole edge located at the front insole end, the front insole edge being substantially linear and is angled relative to the central longitudinal body axis.

In at least one embodiment, the front insole edge is angled relative to the central longitudinal body axis at an angle of an angle of between about 70 degrees and 90 degrees.

In at least one embodiment, the front insole edge is angled relative to the central longitudinal body axis at an angle of an angle of 76 degrees.

In at least one embodiment, the insole body includes a styloid receiving recess defined in the top insole surface, the styloid being positioned, sized and shaped to receive a fifth metatarsal styloid of the user’s foot.

In at least one embodiment, the styloid receiving recess includes a front recess edge located towards the front insole end, a rear recess edge located towards the rear insole end, an outer recess edge extending along the outer body edge and an inner recess edge spaced inwardly from the outer recess edge.

According to another aspect, there is also provided an orthotic insole comprising: an insole body receivable in a footwear, the insole body extending between front and rear insole ends and along a central longitudinal body axis, the insole body further including a top insole surface for receiving a user’s foot and a bottom insole surface configured to be received on a footwear’s insole, the top insole surface including: a heel portion extending forwardly from the rear insole end to receive a heel of a user thereon, the heel portion having a rear end located at the rear insole end and a front end, the heel portion extending along a heel portion plane; a calcaneal inclination portion extending forwardly from the heel portion, the calcaneal inclination portion having a rear end located at the front end of the heel portion and a front end, the calcaneal inclination portion extending forwardly and upwardly from the heel portion; a midfoot portion extending forwardly from the calcaneal inclination portion, the midfoot portion having a rear end located at the front end of the heel portion and a front end; and a metatarsal portion extending forwardly from the midfoot portion, the metatarsal portion having a rear end located at the front end of the midfoot portion and a front end, the metatarsal portion extending downwardly from the rear end to the front end thereof. In at least one embodiment, the calcaneal inclination portion plane is angled relative to the heel portion plane at an angle of between about 3 degrees and 7 degrees.

In at least one embodiment, the calcaneal inclination portion plane is angled relative to the heel portion plane at an angle of about 5 degrees. In at least one embodiment, the metatarsal portion extends along a metatarsal portion plane, the metatarsal portion plane being angled relative to the heel portion plane at an angle of between about 9 degrees and 19 degrees.

In at least one embodiment, the orthotic insole further includes a tongue member extending forwardly from the front insole end of the insole body, the front insole end having a first width and the tongue member having a second width smaller than the first width.

In at least one embodiment, the orthotic insole further includes an arch alignment member for receiving a user’s foot arch, the arch alignment member extending upwardly from the top insole surface and extending along an inner body edge of the insole body.

In at least one embodiment, the arch alignment member includes a top arch member face for abutting the user’s foot when the user’s foot is received on the top insole surface and a bottom arch member face. In at least one embodiment, the arch alignment member further includes a plurality of slots defined in the bottom arch member face, the slots extending parallel to each other and substantially parallel to the central longitudinal body axis..

In at least one embodiment, the top arch member face is convexly curved upwardly. In at least one embodiment, the insole body includes a front insole edge located at the front insole end, the front insole edge being substantially linear and is angled relative to the central longitudinal body axis.

In at least one embodiment, the front insole edge is angled relative to the central longitudinal body axis at an angle of an angle of between about 70 degrees and 90 degrees.

In at least one embodiment, the front insole edge is angled relative to the central longitudinal body axis at an angle of an angle of 76 degrees.

In at least one embodiment, the insole body includes a styloid receiving recess defined in the top insole surface, the styloid being positioned, sized and shaped to receive a fifth metatarsal styloid of the user’s foot.

According to yet another aspect, there is also provided a method for manufacturing an orthotic insole, the method comprising: creating a virtual model of an orthotic insole as defined above; providing the virtual model of the orthotic insole to a 3D printer; manufacturing the orthotic insole using the 3D printer based on the virtual model of the orthotic insole.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top rear perspective view of an orthotic insole, in accordance with one embodiment, in which the orthotic insole is configured for receiving a standard misaligned foot and in which the orthotic insole is configured for being received in footwear having a standard height heel; FIG. 2 is a top front perspective view of the orthotic insole illustrated in FIG. 1 ;

FIG. 3A is a top plan view of the orthotic insole illustrated in FIG. 1 ;

FIG. 3B is another top plan view of the orthotic insole illustrated in FIG. 1 , showing a foot skeleton superimposed over the orthotic insole;

FIG. 4 is a bottom plan view of the orthotic insole illustrated in FIG. 2; FIG. 5A is an inner side elevation view of the orthotic insole illustrated in FIG. 1 ;

FIG. 5B is a longitudinal cross-sectional view of the orthotic insole, taken along cross-section line 5B-5B of FIG. 3;

FIG. 5C is a first transversal cross-sectional view of the orthotic insole, taken along cross-section line 5C-5C of FIG. 5B; FIG. 5D is a second transversal cross-section view of the orthotic insole, taken along cross-section line 5D-5D of FIG. 5B;

FIG. 5E is a third transversal cross-section view of the orthotic insole, taken along cross-section line 5E-5E of FIG. 5B;

FIG. 5F is a fourth transversal cross-section view of the orthotic insole, taken along cross-section line 5F-5F of FIG. 5B; FIG. 6 is an outer side elevation view of the orthotic insole illustrated in FIG. 1;

FIG. 7 is a top front perspective view of an orthotic insole, in accordance with another embodiment, in which the orthotic insole is configured for being received in footwear having a high heel; FIG. 8 is a top plan view of the orthotic insole illustrated in FIG. 7;

FIG. 9 is a longitudinal cross-sectional view of the orthotic insole, taken along cross-section line 9-9 of FIG. 8;

FIG. 10 is a top rear perspective view of an orthotic insole, in accordance with another embodiment, in which the orthotic insole is configured to receive a misaligned foot having a deformed scaphoid;

FIG. 11 is a bottom plan view of the orthotic insole illustrated in FIG. 10;

FIG. 12 is an inner side elevation view of the orthotic insole illustrated in FIG. 10;

FIG. 13 is a top front perspective view of an orthotic insole, in accordance with another embodiment, in which the orthotic insole is configured to receive a misaligned foot having a hammertoe; and

FIG. 14 is a top plan view of the orthotic insole illustrated in FIG. 10.

DETAILED DESCRIPTION It will be appreciated that, for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements or steps. In addition, numerous specific details are set forth in order to provide a thorough understanding of the exemplary embodiments described herein. However, it will be understood by those of ordinary skill in the art, that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the embodiments described herein. Furthermore, this description is not to be considered as limiting the scope of the embodiments described herein in any way but rather as merely describing the implementation of the various embodiments described herein. For the sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures are optional, and are given for exemplification purposes only.

Moreover, it will be appreciated that positional descriptions such as “above”, “below”, “top”, “bottom”, “forward”, “rearward” “left”, “right” and the like should, unless otherwise indicated, be taken in the context of the figures and correspond to the position and orientation in the orthotic insole and corresponding parts when being used. Positional descriptions should not be considered limiting.

Referring now to FIGS. 1 to 6, there is shown an orthotic insole 100, in accordance with one embodiment. The orthotic insole 100 is adapted to be received in footwear, not shown, to support a user’s foot when standing and/or during locomotion. The footwear could include, but is not limited to, a shoe, a boot, a skate or the like as long as the chosen footwear maintains a parallel insole surface to the ground and a sound biomechanical alignment.

In the illustrated embodiment, the orthotic insole 100 is shaped to receive thereon a left foot of the user. It will be understood that the orthotic insole 100 could instead be shaped to receive a right foot of the user. Still in the embodiment illustrated in FIGS. 1 to 6, the insole body 102 is configured for receiving a misaligned foot of an adult user having a standard configuration. It would be understood that the term “standard configuration” refers a foot which does not present any notable deformation, such as a hammertoe or the like. It will further be understood that the term “misaligned foot” refers to a foot which is not in proper biomechanical alignment, which can cause a number of health issues to the user. The orthotic insole 100 is configured such that when the orthotic insole 100 is received in the footwear and the misaligned foot is received in the footwear and on the orthotic insole 100, the orthotic insole 100 urges the misaligned foot towards a configuration corresponding to a “healthy” foot, i.e. a foot which is in proper biomechanical alignment or human natural alignment, and thereby contributes to realigning the foot into proper biomechanical alignment through repeated daily use of the orthotic insole 100.

The orthotic insole 100 includes an insole body 102 extending between a front body end 104 and a rear body end 106 opposite the front body end 104. The insole 100 is configured to receive a user’s foot such that the front body end 104 is oriented towards the foot’s toes while the rear body end 106 is oriented towards the foot’s heel. In the illustrated embodiment, the orthotic insole 100 further includes a tongue member 150 extending forwardly from the insole body 102.

In the present description, the terms “longitudinal”, “longitudinally” and “lengthwise direction” are used to refer to a direction along a longitudinal body axis B extending substantially between the front and rear body ends 104, 106 when the orthotic insole 100 is viewed in a top plan view, as illustrated in FIG. 3. The term “transversal”, “transversally” and “widthwise direction” as used hereinafter refer to a direction which is perpendicular to the above-described lengthwise direction.

The insole body 102 includes a body edge 108 which delimits the insole body 102. More specifically, the body edge 108 includes a front body edge 110 located at the front body end 104, a rear, curved edge portion 112 located at the rear body end 106, and inner and outer side edge portions 114, 116 extending between the front and rear edge portions 110, 112. When the user’s foot is received on the insole body 102, the inner and outer side edge portions 114, 116 are respectively located towards a medial side and a lateral side of the foot. As best shown in FIGS. 3 and 4, in the illustrated embodiment, the front body edge 110 is substantially linear and extends between an inner front edge end 118 located at the inner side edge portion 114 and an outer front edge end 120 located at the outer side edge portion 116. The front body edge 110 is not fully perpendicular to the longitudinal body axis B, but is instead extends along a front edge axis F which is angled relative to the longitudinal body axis B such that the inner front edge end 118 is located further frontwardly than the outer front edge end 120. In the illustrated embodiment, the front edge axis F is angled relative to the longitudinal body axis B at an angle qi of between about 70 degrees and 90 degrees, and more specifically at an angle of about 76 degrees. Alternatively, the front edge axis F could be angled at any another suitable angle or could even be perpendicular to the longitudinal body axis B. In yet another embodiment, the front body edge 110 may not be substantially linear and may instead be curved or have any other suitable shape.

As further shown in FIGS. 3 and 4, the insole body 102 has a top body surface 200 and a bottom body surface 202 opposite the top body surface 200. The top and bottom body surfaces 200, 202 extend longitudinally between the front and rear edge portions 110, 112 and extend transversely between the inner and outer side edge portions 114, 116.

The top body surface 200 is configured for receiving the user’s foot thereon. Specifically, the top body surface 200 includes a plurality of top surface portions 300, 400, 500, 600 which are configured relative to each other in accordance with a predetermined configuration.

The bottom body surface 202 is configured to be received on a footwear’s insole. Specifically, in the present embodiment, the bottom body surface 202 is configured relative to a configuration of the footwear such that when the orthotic insole 100 is received in the footwear, on the footwear’s insole, and when the footwear is positioned on a substantially planar ground surface extending along a ground plane, the top surface portions 300, 400, 500, 600 of the insole body 102 are angled at predetermined angles relative to a ground plane. In some embodiments, the bottom body surface 202 is therefore arced according to an arch corresponding to an arch of the footwear in which the orthotic insole 100 is to be received.

It will be appreciated that while most existing foot orthotics are made to conform to a foot configuration of a particular user, the orthotic insole 100 is instead made to conform to a standard corresponding foot configuration that would be desirable for the user’s foot. Specifically, the top body surface 200 is configured to substantially conform to contours of an underside of a “healthy” foot, i.e. a foot which is in proper biomechanical alignment. When used by a user having a misaligned foot, i.e. a foot which is not in proper biomechanical alignment, this orthotic insole 100 will urge the user’s foot received on the top body surface 200 to conform to the top body surface 200 and will thereby contribute to realigning the foot into proper biomechanical alignment through repeated and/or prolonged use of the orthotic insole 100.

In the embodiment illustrated in FIGS. 1 to 6, the top body surface 200 includes a heel portion 300 extending forwardly from the rear body end 106, a calcaneal inclination portion 400 extending forwardly from the heel portion 300, a midfoot portion 500 extending forwardly from the calcaneal inclination portion 400 and a forefoot portion 600 extending forwardly from the midfoot portion 400. All portions 300, 400, 500, 600 of the top body surface 200 are configured to receive a corresponding portion of the user’s foot.

FIG. 3B shows a user’s foot, and more specifically a skeleton of the user’s foot 10 showing the foot’s bones, superimposed over the top body surface 200 in a position corresponding to the insole being received in footwear and with the user’s foot received on the top body surface 200. As is known to the skilled addressee, the foot 10 includes a calcaneus bone 12 located towards a rear end of the foot, a navicular bone 14 disposed frontwardly of the calcaneus bone 12, and first to fifth metatarsal bones 18, 20, 22, 24, 26 extending frontwardly of the navicular bone 14. The top body surface 200 is sized and shaped such that the portions 300, 400, 500, 600 of the top body surface 200 are each positioned according to a predetermined position relative to the user’s foot received on the top body surface 200.

More specifically, the heel portion 300 is sized to receive the user’s heel such that a rear end of the user’s calcaneus bone 12 is substantially aligned with the rear body end 106. Specifically, the heel portion 300 extends between a rear heel portion rear end 302 substantially aligned with the rear body end 106 and a front heel portion end 304 located towards the front body end 104.

The calcaneal inclination portion 400 is sized to receive a portion of the user’s foot extending substantially between the base of the user’s calcaneus bone 12 and a rear end of the user’s navicular bone 14. Specifically, the calcaneal inclination portion 400 includes a rear calcaneal inclination portion end 402 located toward the rear body end 106 and a front calcaneal inclination portion end 404 located towards the front body end 104. The rear calcaneal inclination portion end 402 coincides with the front heel portion end 304 and meets the front heel portion end 304 at a rear portion delimitation line Li substantially delimiting the calcaneal inclination portion 400 from the heel portion 300.

The midfoot portion 500 is sized to receive a portion of the user’s foot extending substantially between the rear end of the user’s navicular bone 14 and the user’s tarsometatarsal joints, and more specifically the tarsometatarsal joint of the user’s second metatarsal bone 20. More specifically, the midfoot portion 500 includes a rear midfoot portion end 502 located toward the rear body end 106 and a front midfoot portion end 504 located towards the front body end 104. The rear midfoot portion end 502 coincides with the front calcaneal inclination portion end 404 and meets the front calcaneal inclination portion end 404 at a first intermediate portion delimitation line l_2 substantially delimiting the midfoot portion 500 from the calcaneal inclination portion 400. The metatarsal portion 600 is sized to receive a portion of the user’s foot extending between the user’s tarsometatarsal joints and the front body edge 110. More specifically, the metatarsal portion 600 includes a rear metatarsal portion end 602 oriented towards the rear body end 106, and a front metatarsal portion end 604 oriented towards the front body end 104 and coinciding with the front body edge 110. The rear metatarsal portion end 502 coincides with the front midfoot portion end 504 and meets the front midfoot portion end 504 at a second intermediate portion delimitation line l_3 substantially delimiting the metatarsal portion 600 from the midfoot portion 500. As best shown in FIG. 3A, in the illustrated embodiment, the top body surface 200 is configured such that each one of the rear, first intermediate and second intermediate delimitation lines Li, l_2, l_3 extend substantially parallel to each other.

The orthotic insole 100 is configured such that, when the user’s foot is received on the top body surface 200, the front edge axis F of the front body edge 110 extends behind the head of the first and fifth metatarsal bones 18, 26. In the illustrated embodiment, as shown in FIG. 3B, the tongue member 150 extending frontwardly from the front body edge 110 and is substantially sized and shaped to receive at least a portion of at least some of the foot’s metatarsal bones 18-26. In the illustrated embodiment, the tongue member 150 does not extend along the entire width of the front body edge 110. In one embodiment, the tongue member 150 has a width corresponding to about 30% of a width of the front body edge 110. Alternatively, the tongue member 150 could be sized and shaped differently.

Still in the illustrated embodiment, the tongue member 150 is sized and shaped for receiving a portion of the second, third and fourth metatarsal bones 20, 22, 24 and corresponding phalanges when the foot is received on the top body surface 200. More specifically, the tongue member 150 is substantially shorter than the foot’s second, third and fourth toes such that the second, third and fourth toes extend beyond the tongue member 150. Alternatively, the tongue member 150 could instead extend to the tip of the foot’s second, third and fourth toes. It will therefore be appreciated that when the orthotic insole 100 is positioned in footwear against the footwear’s insole and the user’s foot is received on the top body surface 200, the user’s foot does not entirely contact the top body surface 200. In other words, a first portion of the user’s foot contacts the top body surface 200 and a second portion of the user’s foot does not contact the top body surface

200 and instead directly contacts the footwear’s insole. In the illustrated embodiment, the heads of the first and fifth metatarsal bones 18, 26 and the corresponding phalanges are in contact with the footwear’s insole on either side of the tongue member 150. Moreover, the front body edge 110 is further sized and shaped to abut the heads of the first and fifth metatarsal bones 18, 26 of the standard healthy foot.

It will therefore be appreciated that when a misaligned foot is received on the top body surface 200, the first and fifth metatarsal bones 18, 26 will be naturally guided towards the front of the front body edge 110 and will abut the front body edge as would a standard healthy foot. The front body edge 110 thereby creates pressure points on the first and fifth metatarsal bones 18, 26 which will contribute to the realignment of the misaligned foot during use of the orthotic insole 100.

In the illustrated embodiment, the tongue member 150 includes a pair of side edges 152 which are substantially straight and which extend substantially parallel to each other. The tongue member 150 further includes a front arcuate edge 154 connecting together the side edges 152. The tongue member 150 also includes a top tongue surface 156 and a bottom tongue surface 158 extending opposite the top tongue surface 156. In the illustrated embodiment, the top and bottom tongue surfaces 156, 158 are substantially coplanar respectively with the top and bottom body surfaces 200, 202 so as to define forward extensions of the top and bottom body surfaces 200, 202.

In the illustrated embodiment, the side and front edges 152, 154 of the tongue member 150 and the front body edge 110 are substantially beveled to improve the user’s comfort. Alternatively, the side and front edges 152, 154 of the tongue member 150 and the front body edge 110 could instead be rounded or be substantially square.

It will further be understood that since the tongue member 150 does not extend along the entire width of the front body edge 110, the tongue member 150 offers less resistance to bending and therefore facilitates the flexion of the foot along the metatarsophalangeal joint between the foot’s metatarsal bones 18-26 and corresponding phalanges. Alternatively, the orthotic insole 100 could include a hinge, such as a live hinge, between the tongue member 150 and the insole body 200 to further reduce the resistance of the orthotic insole 100 to bending. In yet another embodiment, the tongue member 150 could be configured according to various alternative shapes and sizes. For example, instead of being parallel to each other, the side edges 152 of the tongue member 152 could instead diverge from each other from the front body edge 110 towards the front edge 154 of the tongue member 150. In still another embodiment, the orthotic insole 100 may not include a tongue member 150, such that the heads of all the metatarsal bones 18- 26 and the corresponding phalanges are in contact with the footwear’s insole.

In the illustrated embodiment, the insole body 102 further includes a styloid receiving recess 800 defined in the top body surface 200. The styloid receiving recess 800 is sized, shaped and located to receive the foot’s styloid process located on the fifth metatarsal bone 26 when the foot is received on the top body surface 200. The styloid receiving recess 800 thereby allows the styloid recess to sit lower than the rest of the user’s foot to thereby improve the user’s comfort. In the illustrated embodiment, the styloid receiving recess 800 is adjacent to the outer side edge portion 116 of the insole body 102 and is substantially elongated. Specifically, the styloid receiving recess 800 includes a styloid recess bottom surface 802 which is substantially planar and a styloid recess sidewall 804 surrounding the styloid recess bottom surface 802. The styloid recess sidewall 804 includes an outer sidewall segment 806 which extends along the outer side edge portion 116 of the insole body 102, an inner sidewall edge segment 808 which is spaced from the outer sidewall segment 806 and which extends generally parallel to the outer sidewall edge segment 804, and rear and front sidewall edge segments 810, 812 extending between the inner and outer sidewall edge segment 806, 808. In the illustrated embodiment, the front sidewall edge segment 812 extends substantially parallel to the front body edge 110 of the insole body 102, and the rear sidewall edge segment 810 extends substantially perpendicular to the longitudinal body axis B of the insole body 102. In the illustrated embodiment, the styloid recess sidewall 804 is bevelled to prevent otherwise sharp edges from causing discomfort to the user when the user’s foot is received on the top body surface 200. Alternatively, the orthotic insole 100 may not include a styloid receiving recess 800.

Still in the illustrated embodiment, the orthotic insole 100 further includes an arch alignment member 900 extending upwardly from the insole body 102 for receiving the foot’s arch such that the user’s foot is positioned in an appropriate position and alignment when received on the orthotic insole 100. Specifically, the arch alignment member 900 is configured such that when the user’s foot is received on the orthotic insole 100, the arch alignment member 900 will guide the user’s foot into the alignment illustrated in FIG. 3B, in which the head of the first metatarsal bone 18 is properly positioned forward of the front body edge 110 and inwardly from the tongue member 150 and in which the second metatarsal bone 20 is substantially aligned towards a central axis of a user’s foot which would be positioned in its natural alignment. This will in turn lead to the heads of all five metatarsal bones 18-26 to be properly positioned forwardly of the front body edge 110.

In the illustrated embodiment, the arch alignment member 900 is substantially elongated and extends along the inner side edge portion 114 of the insole body 102, substantially between the front body edge 110 and the rear portion delimitation line Li. As best shown in FIGS. 5D and 5E, in the illustrated embodiment, the arch alignment member 900 is angled away from the top body surface 200 such that it extends away from the outer side edge portion 116 as it extends upwardly. Specifically, the arch alignment member 900 is angled at an angle of between 35 degrees and 55 degrees, and more specifically at an angle of about 45 degrees relative to the top body surface 200. Alternatively, the arch alignment member 900 could be angled away from the top body surface 200 at any other suitable angle.

The arch alignment member 900 includes a top arch member face 902 which is convexly curved upwardly to conform to the foot’s arch and a bottom arch member face 904 extending opposite the top arch member face 902. As best shown in FIG. 5A, the arch alignment member 900 further includes a plurality of arch member slots 906 extending in the bottom arch member face 904 and towards the top arch member face 902. Specifically, the arch member slots 906 are spaced from each other vertically and extend generally parallel to the top body surface 200. It will be appreciated that while the arch alignment member 900 exerts a force on the foot’s arch, the arch member slots 906 still substantially provide at least a slight flexibility to the arch alignment member 900 to further enhance comfort for the user. This flexibility of the arch alignment member 900 provided by the arch member slots 906 can further prevent excessive pressure on the user’s foot which could position the user’s foot in an undesirable inversion position, in which the user’s ankle could be overly rotated outwardly about a longitudinal axis of the foot.

In the illustrated embodiment, the plurality of arch member slots 906 include two arch member slots 906, as shown in FIG. 5A, but alternatively, the arch alignment member 900 could instead include a single arch member slot or more than two arch member slots. In another embodiment, the arch alignment member 900 may not include any slot. Specifically, the arch alignment member 900 may instead have any other configuration and/or be made from a material selected to as to provide the arch alignment member 900 with the desired flexibility. For example, in one embodiment, the arch alignment member 900 is configured such that when a force corresponding to 60 kg is applied downwardly to the orthotic body 100, a portion of the force corresponding to about 8% or approximately 50N is applied uniformly along the top arch member face 902 and thus the arch alignment member 900 and the arch alignment member 900 is deformed with a maximum displacement of less than approximately 4.5 mm. This configuration allows the arch alignment member 900 to be flexible enough to prevent the user’s foot from being urged towards an undesirable inversion position, as described above, while being rigid enough to guide the user’s foot into proper alignment as intended. Alternatively, the arch alignment member 900 could be deformed with a maximum displacement of more than approximately 4.5 mm when a force corresponding to 60 kg is applied downwardly to the orthotic body 100 such that a portion of the force corresponding to about 8% or approximately 50N is applied uniformly along the top arch member face 902 and thus the arch alignment member 900. In yet another embodiment, the orthotic insole 100 may not even include an arch alignment member 900.

In the illustrated embodiment, the orthotic insole 100 further includes an outer lateral wall 1000 extending along the outer side edge portion 116 of the insole body 102, substantially between the front body edge 110 and rear portion delimitation line Li. More specifically, the outer lateral wall 1000 extends upwardly from the top body surface 200 and opposite the arch alignment member 900 such that when the foot is received on the top body surface 200, the foot is held laterally between the outer lateral wall 1000 and the arch alignment member 900. The outer lateral wall 1000 therefore further contributes to positioning the foot in a proper position on the top body surface 200. As best shown in FIG. 5D, the outer lateral wall 1000 does not extend fully perpendicular to the top body surface 200, but is instead angled slightly outwardly. Alternatively, the outer lateral wall 1000 could instead extend substantially perpendicular to the top body surface 200, or have any other suitable configuration. In yet another embodiment, the orthotic insole 100 may not include an outer lateral wall 1000.

In the illustrated embodiment, in addition to being sized according to different features of a corresponding foot, the portions 300, 400, 500, 600 of the top body surface 200 are further angled relative to each other so as to support properly the corresponding foot in a desired or “neutral” position when the foot is received on the top body surface 200. More specifically, each portion 300, 400, 500, 600 is substantially planar and is angled relative to the other portions 300, 400, 500, 600 at a predetermined angle to define slopes in the top body surface 200 between the front body end 104 and the rear body end 106. It will be understood that the term “substantially planar” does not mean that the portions 300, 400, 500, 600 are fully and exactly planar. One or more of the portions 300, 400, 500, 600 could instead be slightly curved to offer better support or increased comfort for the user’s foot, as is the case in the embodiment illustrated in FIG. 5B. In this case, the delimitation between adjacent portions 300, 400, 500, 600 may be defined by a significant change in angle, curvature or curvature direction between the adjacent portions 300, 400, 500, 600.

It will further be understood that although the top surface portions 300, 400, 500, 600 are described herein as separate portions of the top body surface 200 that are angled relative to each other, the top body surface 200 extends substantially continuously and smoothly between the front and rear body ends 104, 106 with no substantial discernible delimitation between the top surface portions 300, 400, 500, 600 to create a comfortable surface for the user’s foot to be received on. Alternatively, the top body surface 200 could instead include one or more discernible delimitation between at least two adjacent portions 300, 400, 500, 600. These one or more discernible delimitations could include a relatively sharp edge, a transition portion including one or more angled planar portions or any other type of discontinuity.

The inclinations of the portions 300, 400, 500, 600 of the top body surface 200 corresponding to the embodiment illustrated in FIGS. 1 to 6 are best shown in FIG. 5B. In this embodiment, the orthotic insole 100 is configured to be received in footwear having a standard heel height, which corresponds to a heel height of approximately 12.7 mm. In this embodiment, the heel portion 300 extends substantially along a heel portion plane Pi and the calcaneal inclination portion 400 extends substantially along a calcaneal inclination portion plane P2. In this embodiment, both the heel portion 300 and the calcaneal inclination portion 400 are substantially planar as defined above, although the calcaneal inclination portion 400 has a more pronounced curvature than the heel portion 300 which has little to no curvature. As shown in FIG. 5B, the calcaneal inclination portion plane P2 is angled upwardly from heel portion plane Pi such that the calcaneal inclination portion 400 extends substantially upwardly from the heel portion 300. In the illustrated embodiment, the planes Pi and P2 are angled relative to each other at an angle Q2 of about between 3 and 7 degrees, and more specifically of about 5 degrees. Still in this embodiment, the metatarsal portion 600 extends substantially along a metatarsal portion plane P3. Specifically, as shown in FIG. 5B, the metatarsal portion plane P3 extends substantially tangentially to the metatarsal portion 600 at the rear metatarsal portion end 602. In this embodiment, the metatarsal portion plane P3 is angled relative to the heel portion plane Pi at an angle Q3 of between about 12 degrees and 16 degrees, and more specifically at an angle of about 13.5 degrees.

In the illustrated embodiment, although the top surface portions 300, 400, 500, 600 are angled relative to each other such that they slope upwardly or downwardly from the rear body end 106 to the front body end 104, the top body surface 200 extends in a straight line transversely (i.e. in a widthwise direction) at every location along the length of the orthotic insole 100. Moreover, the top body surface 200 is substantially untwisted along its length between the front and rear body ends 104, 106 such that the top body surface 200 remains leveled in a widthwise direction as the top body surface 200 extends from the front insole end 104 to the rear insole end 106. In other words, the top body surface 200 does not turn or twist about a longitudinal axis of the insole body 102 or about any other axis as it extends along the between the front insole end 104 to the rear insole end 106.

For example, FIGS. 5C and 5D show transversal cross-sections of the orthotic insole 100 taken respectively at a location in the heel portion 300 and in the calcaneal inclination portion 400 of the top body surface 200. It can be appreciated that at these locations, the top body surface 200 is entirely straight as it extends transversely (i.e. in a widthwise direction) between the inner and outer side edge portions 114, 116 of the insole body 102. Axes Ai and A2 are provided in FIGS. 5C and 5D to show the orientation of the top body surface 200 at these locations. More specifically, the axes Ai and A2 extend transversely along the top body surface 200 at the locations of the orthotic insole 100 illustrated in FIGS. 5C and 5D, respectively. As explained above, since the top body surface 200 is untwisted along its entire length, the axes Ai and A2 are substantially parallel to each other.

FIG. 5E shows a transversal cross-section of the orthotic insole 100 taken at a location in the calcaneal inclination portion 400 of the top body surface 200. It can be appreciated that at this location, the top body surface 200 is still entirely straight as it extends transversely (i.e. in a widthwise direction) between the inner and outer side edge portions 114, 116 of the insole body 102. The orientation of the top body surface 200 at this location is illustrated by axis A3 which extends transversely along the top body surface 200. Since the top body surface 200 is untwisted along its entire length, axis A3 is therefore also substantially parallel to axes Ai and A2.

As further shown in FIG. 5E, the styloid recess bottom surface 802 of the styloid receiving recess 800 is also entirely straight as it extends transversely (i.e. in a widthwise direction) between the inner and outer side edge portions 808, 806 of the styloid receiving recess 800 and, in the illustrated embodiment, the styloid recess bottom surface 802 further extends parallel to the forefoot portion 500 of the top body surface 200. Alternatively, the styloid recess bottom surface 802 could instead be substantially concavely curved or have any other suitable configuration.

As shown in FIG. 5F, in this embodiment, the top tongue surface 156 of the tongue member 150 is also entirely straight as it extends transversely (i.e. in a widthwise direction) between the side edges 152 of the tongue member 150, as shown by axis A4 which extends transversely along the top tongue surface 156. In the illustrated embodiment, the top tongue surface 156 is further untwisted relative to the top body surface 200, such that the axis A4 is also substantially parallel to axes Ai, A2 and A3. Alternatively, instead of being straight in the widthwise direction, the top tongue surface 156 could be substantially concavely curved or have any other suitable configuration. It will be understood that the locations at which the cross-sections shown in FIGS. 5C to 5E are taken are merely taken as examples, and that any axis extending transversely along the top body surface 200 at any location along the insole body 102 would be substantially parallel to the axes Ai, A2 and A3 and to any other axis extending transversely along the top body surface 200 at any other location along the insole body 102.

In the embodiment illustrated in FIGS. 1 to 6, the orthotic insole 100 is configured to be received in footwear having a standard heel height, which corresponds to a heel height of approximately 12.7 mm. In other embodiments, the orthotic insole could instead be configured to be received in footwear having any heel height between 0 mm and 38.1 mm, or even a heel height greater than 38.1 mm. The orthotic insole 100 could further be configured to be received in footwear having any footwear size between US size 00 infant to US size 16 men, or even having a footwear size greater than US size 16 men. FIGS. 7 to 9 show an orthotic insole 2000, in accordance with another embodiment. In this embodiment, the orthotic insole 2000 is generally similar to the orthotic insole 100 illustrated in FIGS. 1 to 6, except that instead of being configured to be received in footwear having a standard height heel, the orthotic insole 2000 is configured to be received in footwear having a high heel, and more specifically having a heel height of between about 31.75 mm and 32.10 mm.

Specifically, the orthotic insole 2000 includes an insole body 2002 and a tongue member 2004 extending frontwardly from the insole body 2002. The insole body 2002 includes a top body surface 2010 for receiving a foot of a user and a bottom body surface 2012 configured to be received on a footwear’s insole. Similar to the top body surface 200, the top body surface 2010 includes a heel portion 2020, a calcaneal inclination portion 2030 located forwardly of the heel portion 2020, a midfoot portion 2040 located forwardly of the calcaneal inclination portion 2030 and a metatarsal portion 2050 located forwardly of the midfoot portion 2040. In this embodiment, the tongue member 2004 is angled relative to the metatarsal portion 2050 at a substantially greater angle than the tongue member 150 of the orthotic insole 100 relative to the metatarsal portion 600 to conform to a greater angle of the phalanges with respect to corresponding metatarsal bones of the foot when using a high heel footwear.

Still in this embodiment, the heel portion 2020 extends substantially along a heel portion plane Pi’ and the calcaneal inclination portion 2030 extends substantially along a calcaneal inclination portion plane P2’. Specifically, the planes Pi’ and P2’ are substantially angled relative to each other at an angle Q2’ of about between 3 and 7 degrees, and more specifically of about 5 degrees, similarly to the planes Pi and P2 of the orthotic insole 100 illustrated in FIGS. 1 to 6. Still in this embodiment, the metatarsal portion 600 extends substantially along a metatarsal portion plane P3 which is angled relative to the heel portion plane Pi at an angle Q3’ of between about 15 degrees and 19 degrees, and more specifically at an angle of about 17.5 degrees.

It will be understood that the angles between the portions and curvatures of the portions of the top body surface may vary slightly in accordance with the heel height of the footwear in which the orthotic insole is to be received but will substantially have the same overall configuration regardless of the heel height. It will also be appreciated that the length and width of the insole body may vary in accordance with the length or width of the footwear or of the user’s foot, but that the angles between the portions of the top body surface will not vary in accordance with the length or width of the footwear or of the user’s foot.

Turning now to FIGS. 10 to 12, there is shown an orthotic insole 3000, in accordance with another embodiment. The orthotic insole 3000 is substantially similar to the orthotic insole 100 and includes an insole body 3002 and a tongue member 3004 extending forwardly from the insole body 3002. The orthotic insole 3000 further includes an arch member 3010 extending substantially upwardly from the insole body 3002 and between a front arch end 3006 and a rear arch end 3008. In this embodiment, instead of extending continuously between the front and rear arch ends, the arch member 3010 includes a central gap 3050 sized and shaped to accommodate a deformed styloid process of the misaligned foot. It will be appreciated that without this central arch gap 3050, the arch may create an undesirable pressure point on the deformed styloid process of the first metatarsal bone. This configuration therefore enhances the user’s comfort.

Referring now to FIGS. 13 and 14, there is shown an orthotic insole 4000, in accordance with another embodiment. In this embodiment, the orthotic insole 4000 is substantially similar to the orthotic insole 100 and includes an insole body 4002 and a tongue member 4004 extending forwardly from the insole body 4002. Specifically, the insole body 4002 includes a top body surface 4010 which is substantially similar to the top body surface 4010 of the orthotic insole 100.

However, in this embodiment, the orthotic insole 4000 is configured to receive a foot having a hammertoe, i.e. an abnormal bend found in the middle joint of at least one of the second, third, fourth and fifth toes. Specifically, it will be understood that if the tongue member 4004 was configured similarly to the tongue member 150 of the orthotic insole 100 described above, the tongue member 150 would place undesirable pressure on the toes and thereby cause discomfort to the user. Therefore, the tongue member 4004 of the present orthotic insole 4000 is substantially shorter than the tongue member 150 of the orthotic insole 100, and more specifically, does not extend beyond the middle joint of the second, third and fourth toes such that the hammertoe may contact the footwear’s insole instead of being elevated above the footwear’s insole by the tongue member 4004.

It will be appreciated that the orthotic insoles 100, 2000, 3000, 4000 described hereinabove all can be manufactured without a detailed analysis of the specific configuration of the misaligned foot to be realigned. Instead, the orthotic insoles 100, 2000, 3000, 4000 can be manufactured using a limited number of fabrication parameters including a length and width of the foot - which can be measured or determined from the user’s shoe size - a height of the heel of the footwear with which the orthotic insole is to be used and whether the foot has any notable deformations such as a deformed scaphoid or a hammertoe. This may greatly reduce the time and resources required to manufacture the orthotic insole.

In one embodiment, a certain quantity of orthotic insoles could be prefabricated in accordance with certain fabrication parameters and stocked, and further provided to users whose misaligned foot compared to the fabrication parameters of the orthotic insoles. For example, it may be desirable to prefabricate and store a stock of orthotic insoles 100 configured for footwear having a standard height heel and for a foot having no notable deformations in a number of common shoe sizes and foot widths. This may further reduce the time and cost required to manufacture the orthotic insole.

In one embodiment, in addition to selecting an appropriate orthotic insole configuration according to a heel height of the footwear in which the orthotic insole is to be used, the orthotic insole 100, 2000, 3000, 4000 could further be at least slightly adapted in accordance with other parameters of the footwear. For example, the configuration of the bottom body surface of the orthotic insole and/or of the tongue member could be adjusted depending on a toe lift-off angle or of a heel wedge angle of the footwear. In some embodiments, one or more wedges could further be positioned at predetermined positions and configurations inside the footwear, under the orthotic insole 100, to position and orient the user’s foot and/or ankle according to a desired position and orientation. In these embodiments, the footwear’s central axis alignment may be taken into consideration to avoid reducing the orthotics’ efficiency in successfully achieving a proper biomechanical alignment.

In the embodiments illustrated hereinabove, the orthotic insole 100 is further made from a single, monolithic piece of material but alternatively, the orthotic insole 100 could be made from a plurality of distinct pieces assembled together using a suitable assembly technique such as gluing or the like.

In one embodiment, the orthotic insole 100 is further made from a semi-rigid material, rather than a fully rigid material. This allows the orthotic insole 100 to be rigid enough to urge the misaligned foot into proper alignment to thereby realign the foot, but also soft enough to continue to provide a proper biomechanical alignment to the foot under different unequal terrain conditions, and to provide shock absorption properties for the user’s comfort. In one embodiment, the orthotic insole 100 is made from cork or from an elastomeric material such as ethylene- vinyl acetate (EVA) foam, rubber, thermoplastic polyurethane (TPU) or the like. Specifically, in one embodiment, the insole body 102 has a hardness value of between about 50 and 120 on the Shore A durometer scale. More specifically, the insole body 102 may have a hardness value of between about 60 and 70 on the Shore A durometer scale, or a hardness value of between about 85 and 95 on the Shore A durometer scale. Alternatively, the orthotic insole 100 may be made from any other suitable material.

In one embodiment, the orthotic insole 100 is made by additive manufacturing, also known as 3D printing. Specifically, in accordance with a first step of a method for manufacturing an orthotic insole, a virtual model of the orthotic insole 100 may first be provided. The virtual model may be created in accordance with one or more fabrication parameters of the misaligned foot such as a length and width of the foot and an indication of whether the foot includes any notable deformation. In one embodiment, the length and width of the foot may be measured on the user using a measuring tool such as a Ritz scale or the like. Using these fabrication parameters, the virtual model of the orthotic insole 100 may then be created using a suitable program provided on a processing unit such as a personal computer. In another embodiment, instead of creating the virtual model based on the fabrication parameters, the virtual model could instead be selected from a database of preformed virtual models based on the fabrication parameters. Alternatively, the virtual model may be created using a scan of the user’s foot and/or lower limbs, one or more photographs of the user’s foot and/or lower limbs, or any other technique to obtain at least one parameter of the user’s foot and/or lower limbs such as the length and/or width of the foot. In this embodiment, the acquired data related to the user’s foot and/or lower limbs enables the creation and modification of a 3D model using a 3D modeling platform, with the modifications being based on acquired measurements of the foot and postural deficiency data observed and analysed by means of artificial intelligence and/or extensive human experience which help to generate the final required virtual model.

According to another step of the method, the virtual model is then provided to a 3D printer and the orthotic insole is manufactured using the 3D printer.

Alternatively, instead of being manufactured by additive manufacturing, the orthotic insole 100 could be made using another appropriate manufacturing process such as molding, overmolding or the like.

While the above description provides examples of the embodiments, it will be appreciated that some features and/or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. Accordingly, what has been described above has been intended to be illustrative and non-limiting and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto.