RELATED APPLICATION DATA

[0001] This application claims the benefit of United States Provisional Patent Application Serial No. 62/167,763 filed May 28, 2015, and United States Provisional Patent Application Serial No. 62/182,025 filed June 19, 2015.

TECHNICAL FIELD

[0002] The present invention relates to a shoe insole with improved cushioning, support and pronation control to the foot of a wearer.

BACKGROUND OF THE INVENTION

[0003] Because the human foot is a very complex biological mechanism, properly designed shoe insoles can assist the foot in performing these functions and protect the foot from injury. For instance, the load on the foot at heel strike is typically about one and a half times a person's body weight when a person walks. When running or carrying extra weight, such as a backpack, loads on the foot can exceed three times the body weight. The many bones, muscles, ligaments, and tendons of the foot function to absorb and dissipate the forces of impact, carry the weight of the body and other loads, and provide forces for propulsion.

[0004] Insoles may be custom made to address the specific needs of an individual. They may be made based on casts of the end user's foot or may be made of a thermoplastic material that is molded to the contours of the end user's foot. Like most custom made items, custom insoles tend to be expensive because of the low volume and extensive time needed to make and fit them properly. As such, it is not practical to make such custom made insoles for the general public.

[0005] To be practical for distribution to the general public, an insole must be able to provide benefit to the user without requiring individualized adjustment and fitting. A first type of insole commonly available over-the-counter emphasizes cushioning the foot so as to maximize shock absorption. For typical individuals cushioning insoles perform adequately while engaged in light to moderate activities, such as walking or running. That is, a cushioning insole provides sufficient cushioning and support for such activities. However, for more strenuous or technically challenging activities, such as carrying a heavy backpack or traversing difficult terrain, a typical cushioning insole will not be adequate. Under such conditions, a cushioning insole by itself would not provide enough support and control, and tends to bottom out during use by fully compressing the cushioning insole.

[0006] Another type of over-the-counter insole emphasizes control. Typically, such insoles are made to be relatively stiff and rigid so as to control the bending and twisting of the foot by limiting foot motion. The rigid structure is good at controlling motion, but is not very forgiving. As a result, when motion of the foot reaches a limit imposed by the rigid structure, the load on the foot tends to change abruptly and increases the load on the structures of the foot. Because biological tissues such as tendons and ligaments are sensitive to the rate at which they are loaded, the abrupt change in load causes injury or damage to the foot, ankle or leg.

[0007] In view of the foregoing, it would be desirable to provide an over-the-counter insole that provides both cushioning and control. It would also be desirable to provide an insole that provides both cushioning and control and is practical for use by the general public during cross-training or triathlon-related activities.

[0008] The Applicant has received patents for insoles having a stability cradle and multiple pods located thereon. These patents include U. S. Patent Nos. 7,484,319; 7,665, 169;

7,908,768; and, 8,250,784. These prior art patents, however, do not address the problems of enhanced cushioning and stability, possible movement of the insole during shoe operation, or establishing enhanced cushioning characteristics to address running and walking usages.

[0009] There is a present need for a shoe insole that accomplishes the goals to: (1) provide increased ankle and foot stability, (2) cushion the heel and forefoot during push-offs and landings, (3) custom-contour to the inside shape of all types of shoes, (4) be extremely light, (5) provide enhanced cushioning capabilities and (6) have essentially zero movement or sliding.

SUMMARY OF THE INVENTION

[0010] The current invention is an insole that provides a balanced approach to improving longitudinal arch support, prevention of pronation and prevention of supination by incorporation of the combination of the following elements: (1) a base having a lateral midfoot/heel pad indentation area, a stability cradle indentation area, and a forefoot pad indentation area, (2) an upper cooling top cloth, (3) a multi-faceted stability cradle with a plurality of traversely oriented stability ribs, (4) an elongated lateral midfoot/heel pad extending from the lateral midfoot area into the heel area, (5) a supplemental heel pad overlaying a portion of the elongated heel pad in the heel area; (6) a forefoot pad positioned in the forefoot indentation area, (7) multi-faceted groove patterns on the bottom surface of the stability cradle; and, (8) honeycomb groove patterns on the bottom surface of the lateral midfoot/heel pad, the forefoot pad and the supplemental heel pad

[0011] It is also an object of the present invention to provide an insole that provides improved cushioning, support, and control and is practical for use by the general public. The above, and other objects and advantages of the present invention are provided by an insole that provides improved motion control, support and cushioning. The insole includes a system of interacting components that cooperate to achieve a desired combination of foot cushioning, support and motion control.

[0012] In accordance with principles of the present invention, a cushioning core or base is combined with a relatively stiff stability cradle and a number of elastomeric pads to form an insole that provides greater cushioning, stability, and control than was conventionally known in the state of the art. The pads, including a lateral midfoot/heel pad that extends from the lateral midfoot area to the heel area and a supplemental heel pad that overlays a portion of the lateral midfoot/heel pad in the heel area, can have a different firmness than the base or the stability cradle. The lateral midfoot/heel pad assists with prevention of supination, and the supplemental heel pad assists with the prevention of pronation.

[0013] The firmness of the lateral midfoot/heel pad and the supplemental heel pad can be adjusted to address issues of over/under pronation, over/under supination, and other problems related to foot motion by altering the size, shape, and material properties of the pads. The stability cradle, lateral midfoot/heel pad, supplemental heel pad, and forefoot pad have random multi-faceted grooved patterns on their bottom surface for better cushioning and traction grip in the shoe.

[0014] The present invention accomplishes the goals to: (1) improve ankle and foot stability, (2) cushion the heel and forefoot during push-offs and landings, (3) help prevent over pronation and over supination conditions, and (4) provide enhanced cushioning features to the heel, midfoot, arch and forefoot areas.

[0015] The characteristics of the components, their size and shape, and their position are selected to provide a desired blend of improved cushioning and control, and more specifically to achieve a desired biomechanical function. The size and compression characteristics of the pads can be adjusted to address issues of over/under pronation, over/under supination, and other problems related to foot motion, including altering the size, shape, and material properties of the pads. In a preferred embodiment of the present invention, the components of an insole are permanently affixed to each other to create an insole designed for an intended type or category of activity. Many insole designs can be made to address a broad range of different activities.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The above, and other objects and advantages of the present invention will be understood upon consideration of the following detailed description taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:

[0017] FIG. 1A is a exploded perspective view of an illustrative embodiment of an insole in accordance with the principles of the present invention;

[0018] FIG. IB is a bottom perspective view of an illustrative embodiment of an insole in accordance with the principles of the present invention;

[0019] FIG. 2 is a bottom planar view showing the base of the insole;

[0020] FIG. 3 is a top (dorsal) view of the insole;

[0021] FIG. 4 is a medial (inner side) view of the insole;

[0022] FIG. 5 is a lateral (outer side) view of the insole;

[0023] FIG. 6 is a front (proximal) view of the insole; and,

[0024] FIG. 7 is a rear (proximal) view of the insole;

DETAILED DESCRIPTION

[0025] In accordance with principles of the present invention, a cushioning core or base is combined with a relatively stiff stability cradle and a number of elastomeric pads to form an insole that provides greater cushioning, stability, and control than was conventionally known in the state of the art. The pads, including a lateral midfoot/heel pad that extends from the lateral midfoot area into the heel area and a supplemental heel pad that overlays a portion of the lateral midfoot/heel pad, can have a different firmness than the base and/or the stability cradle. The lateral midfoot/heel pad and the supplemented heel pad assists with prevention of supination or the prevention of pronation.

[0026] The combination of the base, stability cradle, lateral midfoot/heel pad, and supplementary heel pad provide a "degree" of medial longitudinal arch support, which provides a couple of degrees of improved pronation "control." A "degree" of medial longitudinal arch support is just 1-2 degrees based on research evidence. By pronation "control," we mean the increase in supination moments acting around the joints of the rearfoot and the decrease in the magnitude of pronation moments.

[0027] The current invention is an insole 300 that provides a balanced approach to improving longitudinal arch support, prevention of pronation and prevention of supination by incorporation of the combination of the following elements, such as: (1) a base having a lateral midfoot/heel pad indentation area, a stability cradle indentation area, and a forefoot pad indentation area, (2) an upper cooling top cloth, (3) a random multi-faceted stability cradle with a plurality of stability ribs, (4) an elongated lateral midfoot/heel pad extending from the lateral midfoot area into the heel area, (5) a supplemental heel pad overlaying a portion of the elongated heel pad in the heel area; (6) a forefoot pad positioned in the forefoot indentation area, (7) random multi-faceted patterns on the bottom surface of the stability cradle; and, (8) honeycomb groove patterns on the bottom surface of the lateral midfoot/heel pad, the forefoot pad and the supplemental heel pad.

[0028] The firmness of the lateral midfoot/heel pad and the supplemental heel pad can be adjusted to address issues of over/under pronation, over/under supination, and other problems related to foot motion, which means these pads can be altered by the size, shape, and material properties of the pads. The stability cradle, lateral midfoot/heel pad, supplemental heel pad, and forefoot pad have random multi-faceted grooved patterns on their bottom surface for better cushioning and traction grip in the shoe. The present invention accomplishes the following goals to: (1) improved ankle and foot stability, (2) greater cushion of the heel and forefoot during push-offs and landings, (3) greater prevention of over pronation and over supination conditions, and (4) enhanced cushioning features to the heel, midfoot, arch and forefoot areas.

[0029] In reference to FIGS. 1A, IB, and 2 through 7, an insole 300 constructed in accordance with the principles of the present invention is disclosed. It should be understood that insoles are generally adapted to be inserted inside the interior of a user's shoe and positioned on the bottom surface of the interior of the user's shoe. The insole 300 of the invention is shaped essentially like the bottom interior of an athletic shoe and therefore adapted to receive a user's foot which has a generally similar shape when at rest. The insole 300 extends from a heel end (proximal) to a toe end (distal) and has a medial border or side on the arch side of the foot, connecting said toe end to said heel end along the arch side of the insole and a lateral border or side on the other side (opposite side from medial side) thereof, connecting said toe end to said heel end on the other side of the insole.

[0030] The insole 300 also has a forefoot area that correlates with the metatarsal area and near the phalanges of the foot located over the toe pad 340 of the insole 300, an arch area along the medial side, a heel area just forward of the heel end, and a midfoot area between the heel area and forefoot area. A user's right shoe and left shoe are mirror images of one another as are the insoles adapted to be inserted in a right shoe and a left shoe respectively. Only the left insole is illustrated in the Figures. It will be understood by those of skill in the art that the right insole has a mirror image construction of the left insole.

[0031] As shown in Figures 1 A, IB and 2, insole 300 preferably comprises a top sheet 301 and a base 302 having a top surface secured to said top sheet 301 and an opposite bottom surface. Base 302 also defines a longitudinal arch support 319 that extends upwardly along the medial side of the insole to provide extra cushion and support to the arch area of the foot.

[0032] Preferably, the top surface of the base 302 defines an upwardly-extending portion or transverse arch support 338 that lies under the metatarsal head area of the foot (best shown in FIGS. 4 and 7). The upward extension of transverse arch support 338 pushes up a portion of the top sheet 301 that corresponds to the area of the transverse arch support 338.

[0033] The bottom surface of base 302 defines a forefoot pad indentation area 307 in the forefoot area that correlates to the metatarsal area and near the phalanges of the foot located over the toe pad 340 of the insole 300, and a stability cradle indentation area 305 along the midfoot and heel areas. The bottom surface of base 302 also defines one or more ribs or protrusions 332 that extend outwardly along the arch area. The ribs 332 are preferably longer around the cuneiforms and gradually shorter distally and proximally from the cuneiforms creating a parabolic-like overall shape. An alternate embodiment has the ribs or protrusions defined by the stability cradle 306 and extending outwardly from the stability cradle 306 in the arch area. [0034] Base 302 has a raised edge that wraps around the heel and extends partially along the sides of the foot such that the insole has a heel cup, which conforms to the natural shape of the foot. As best seen in FIGS. 4-5, and 7, the height of the raised edge is generally higher and thinner on the medial side of the insole and is lower and thicker on the lateral side of the insole.

[0035] The forefoot pad indentation area 307 begins partially proximal from the toe pad 340 of the insole 300 near the distal ends of the proximal phalanges of the foot. The forefoot pad indentation area 307 extends rearward to about the 3 ^rd through 5 ^th metatarsal heads on a lateral portion and approximately halfway along the 1 ^st and 2 ^nd metatarsals on a medial portion. Preferably the forefoot pad indentation area 307 has a rear apex 357 that lies between the 1 ^st and 2 ^nd metatarsals.

[0036] Forefoot pad 308 is shaped essentially the same as forefoot pad indentation area 307 and is secured therein. Forefoot pad 308 has a medial edge, a lateral edge, a proximal (back) edge and a distal (front) edge. The medial edge of forefoot pad 308 extends along a line spaced laterally from said medial border of said insole. The proximal edge extends from said medial edge laterally and proximally to said rear apex 357, laterally and distally towards the 3 ^rd metatarsal head, then laterally and proximally to the lateral edge approximately along the 3 ^rd through 5 ^th metatarsal heads. The lateral edge of the forefoot pad connects said proximal edge to said top edge of said forefoot pad. In use, forefoot pad indentation area 307 and forefoot pad 308 underlie a portion of the big toe of a user's foot, and the "ball" of the foot, excluding the first metatarsal head or medial ball of the user's foot.

[0037] An adhesive is be used to secure the components. The forefoot pad 308 provides cushioning and energy return on landing from a vertical jump. It serves as a propulsion pad and support for the metatarsal heads of a user's foot, especially the 1 ^st and 2 ^nd metatarsal heads. It is estimated that using tougher materials increases the durability of the insole by 35 to 65% over insoles that use softer materials for this portion of the foot insole. The forefoot pad 308 has a random multi -faceted grid formation that improves durability and cushioning aspects of the forefoot pad over known materials.

[0038] The stability cradle indentation area 305 is located in the midfoot and heel areas of the bottom surface of base 302. The stability cradle indentation area 305 extends from a medial edge approximate the medial border to a lateral edge approximate the lateral border of the base and from a distal edge slightly proximal of the forefoot pad indentation area 307 to a proximal edge approximate the heel end of the base. A medial portion of the distal edge is shaped to accommodate downward motion of the 1 ^st metatarsal during toe off. Stability cradle 306 is shaped essentially the same as stability cradle indentation area 305 and has a base facing surface and a shoe facing surface. The base facing surface is secured to said stability cradle indentation area 305.

[0039] Stability cradle 306 has side and end walls that wrap up the sides and rear of base 302 to provide support for the foot by cupping the outside areas of the heel, providing stability stiffness from the mid-foot to the heel area, and providing an upward support in the medial arch area of the user's foot. Preferably, stability cradle 306 ranges from

approximately 0.5 mm to 3 mm thick and the walls taper from approximately 3 mm to about 0.5 mm. The sides of stability cradle 306 are preferably higher on the medial side of the foot because of the higher loading. Preferably, stability cradle 306 is made of a nylon material with a hardness of approximately Shore A85 - Al 10. In a preferred embodiment, the stability cradle is semi-rigid. In an alternate embodiment, the stability cradle is rigid.

[0040] Preferably, the surface of stability cradle 306 that faces the internal portion of the shoe has a random multi-faceted surface texture. This textured faceted surface increases the ability of the insole to "stay in place" when a user's foot is being placed into or out of the shoe. These faceted textures significantly improve the use and performance of these insoles for this particular use by allowing the insole to resist movement out of the shoe. The random multi-faceted design increases the internal function quotient of the insole significantly (by as much as 50% compared to non-faceted or smooth stability cradles) when located in the shoe cavity, thereby preventing the insole's movement or exit from the shoe cavity. The stability cradle 306, lateral midfoot/heel pad 312, supplemental heel pad 316, and forefoot pad 308 have different types of groove patterns. The random multi- faceted grooved patterns shown at 307A on the bottom surface of the insole 300 provides for better cushioning and traction grip inside the internal surface of the shoe. The honeycomb groove patterns 320, 321 and 323 improve cushioning and stability characteristics of the insole.

[0041] The stability cradle 306 preferably defines one or more rib-shaped openings 331 in the medial arch area. In a preferred embodiment, the rib-shaped openings 331 allow said ribs 332 of base 302 to extend therethrough. Preferably, base 302 is molded so that the ribs

332 project into rib-shaped openings 331 so that the ribs 332 are approximately flush with the outer surface of stability cradle 306 and mechanically lock stability cradle 306 and base 302 together. Advantageously, the ribs 332 are also able to bulge through rib-shaped openings 331 when base 302 is compressed (e.g., while walking or running) to provide additional cushioning and support to the arch of the foot. Preferably said ribs 332 extend outwardly approximately 0.50 mm to 1.5 mm and have a width of approximately 4 mm. The rib-shaped openings 331 allow the stability cradle 306 to be more flexible in the arch area compared to the rest of the stability cradle 306. One or more sheets of reinforcing materials may be placed in the stability cradle 306 or between the stability cradle 306 and the base 302 to increase the durability and strength/firmness of the insole. Reinforcing sheet materials can include any type of composite weaved material or any type of woven or non-woven sheet material that does not "shrink" in size or warp in shape over time.

[0042] In an alternate embodiment, stability cradle 306 defines one or more protruding ribs instead of openings. The protruding ribs extend outwardly along the arch area. The protruding ribs are longer around the cuneiforms and gradually shorter distally and proximally from the cuneiforms creating a parabolic-like overall shape. The protruding ribs extend outward approximately 0.50 mm.

[0043] Stability cradle 306 defines a lateral midfoot/heel pad opening 313 that extends from the behind the 3 ^rd through 5 ^th metatarsal heads proximally to the back of the cuboid and further back along the lateral side of the heel area of stability cradle 306 into the heel area. The length of the lateral midfoot/heel pad opening 313 is preferably sufficient to provide cushioning to the lateral aspect from the midfoot into the heel area. Lateral midfoot/heel pad 312 is shaped essentially the same as the lateral midfoot/heel pad opening 313 and is secured to the bottom surface of base 302 within the stability cradle indentation area 305 in a location that correlates to the lateral midfoot/heel pad opening 313 and allows the lateral midfoot/heel pad 312 to extend out through said lateral midfoot/heel pad opening 313.

[0044] Lateral midfoot/heel pad 312 is preferably made from a Thermoplastic Rubber ("TPR") or a Polyurethane ("PU") of a hardness of about 45-50 ASKER C. If TPR is used, a fabric is in turn secured to the base 302 in the lateral midfoot/heel pad opening 313 of said base 302. The fabric component allows the TPR to properly adhere to the base 302.

[0045| The supplemental heel pad 316 overlays a portion of the lateral midfoot/heel pad 312 in the heel area. The supplemental heel pad 316 is shaped to overlay a portion of the lateral midfoot/heel pad 312 and is secured to the bottom surface of the lateral midfoot/heel pad 312 by an adhesive or mechanical fastener (e.g. hook and loop fasteners) in a location that correlates to a portion of the heel area and a portion of the lateral midfoot/heel pad 312 that extends through the lateral midfoot/heel pad opening 313. The supplemental heel pad 316 has a side edge which extends along the medial side of the lateral midfoot/heel pad 312 located in the heel area. The side edge extends around a portion of the heel area up to a mid-section of the heel area. The supplemental heel pad 316 can, alternatively, be located on the lateral side of the lateral midfoot/heel pad 312 instead of on the medial side of the heel area. The supplemental heel pad 316 is preferably made from TPR or PU of a hardness of about 60 ASKER C ±3. If TPR is used, a fabric is in turn secured to the base 302 to permit the TPR to properly adhere to the base 302.

[0046] The firmness of the lateral midfoot/heel pad 312 and the supplemental heel pad 316 can be adjusted to address issues of over/under pronation, over/under supination, and other problems related to foot motion by altering the size, shape, and material properties of the pads. The configuration, material and position of the supplemental heel pad 316 provides cushioning and works in association with the lateral midfoot/heel pad 312 to stabilize the ankle. The hardness of the supplemental heel pad 316 and the lateral midfoot/heel pad 312 can be essentially the same, which works in concert with each other to help reduce the incidence of lateral ankle roll-overs. These heel pads are preferably made of TPR or PU of a hardness of about Shore C 45-50. If TPR is used, a fabric is in turn secured to the base 302 in the lateral midfoot/heel pad opening 313 of said base 302. The fabric component allows the TPR to properly adhere to the base 302.

[0047] A top sheet 301 is oriented to engage the user's foot on the top surface of the insole, and it serves an upper cooling and ventilation function. The top sheet 301 can be made of suitable materials, such as a j adeite top cloth material.

[0048] Foot contact with the ground is generally divided into three phases: heel strike, midfoot support, and toe off. During heel strike, the heel of the foot impacts the ground with significant force. Following the initial impact of the heel with the ground, the foot twists, or pronates, bringing the medial side of the heel into contact with the ground. The foot is sensitive to the amount of pronation as well as the rate at which the pronation occurs. Pronation is natural, and some degree of pronation is desirable because it serves to absorb the stresses and forces on the foot during walking or running. However, an excessive amount or rate of pronation can result in injury. [0049] To cushion the impact, the lateral midfoot/heel pad 312 and the supplemental heel pad 316 work in conjunction with the stability cradle 306 to accomplish the goals of the invention, such as: (1) improving ankle and foot stability, (2) cushioning the heel and forefoot during push-offs and landings, (3) helping prevent over pronation and over supination conditions, and (4) providing enhanced cushioning features to the heel, midfoot, arch and forefoot areas. Stability cradle 306 provides firm support along the medial portion of the foot, including the medial arch area and surrounding the heel area, to help control the amount of foot pronation. The lateral midfoot/heel pad 312 and the supplemental heel pad 316 also helps to control the rate of pronation.

[0050] By forming the supplemental heel pad 316 out of a material having different characteristics than the lateral midfoot/heel pad 312, the pronation and supination rates can be regulated, controlled and increased/decreased. For example, to reduce a pronation rate, supplemental heel pad 316 can be made from a firmer material the lateral midfoot/heel pad 312. A firmer or suffer material does not compress as much or as fast as a softer material under the same load. Thus, a supplemental heel pad 316 made from a firmer material would compress less than a lateral midfoot/heel pad 312 made of a softer material. As a result, the supplemental heel pad 316, when overlay ed on the medial side of the heel area on the lateral midfoot/heel pad 312 and when constructed of this type of firmer material, would tend to resist or counteract pronation and thereby help to reduce the degree and rate of pronation. Conversely, locating the supplemental heel pad 316 on the lateral side of the heel area on the lateral midfoot/heel pad 312 would tend to decrease the rate of supination and increase the amount and rate of pronation.

[0051] Preferably, the position of the supplemental heel pad 316 and firmness of the material used in supplemental heel pad 316 is selected based on the firmness of lateral midfoot/heel pad 312, on the type of intended activity, and the pronation/supination rates that are desired to be increased or decreased. For example, the firmness of lateral midfoot/heel pad 312 and the supplemental heel pad 316 differs by about 20-30 % for an insole to be used during light to moderate activities. Carrying a heavy backpack or other articles significantly increases the load on the foot and the rate of pronation during and following heel strike. Accordingly, when the supplemental heel pad 316 is made of significantly firmer material than the lateral midfoot/heel pad 312 in an insole designed for use while backpacking, a difference in firmness of about 20-40% is more appropriate for such activities. [0052] Lateral midfoot/heel pad 312 provides cushioning and control to the lateral side of the foot during the midstance portion of a step. The lateral midfoot/heel pad 312 can be formed of a material having the same properties, e.g., firmness, as supplemental heel pad 316. However, a material having different characteristics may also be used.

[0053] The lateral midfoot/heel pad 312 and the supplemental heel pad 316 are employed to cause a kinetic change in foot function to promote ankle stability. It is also contemplated that making the lateral midfoot/heel pad 312 softer than the firmness of the supplemental heel pad 316 will address and minimize certain joint movements or ankle rolls.

[0054] At the beginning of the propulsion or toe off phase of a step, the heel begins to lift from the ground and weight shifts to the ball of the foot. Forefoot pad 308 is located under this part of the foot. Preferably, forefoot pad 308 is formed of a relatively resilient material so that energy put into compressing forefoot pad 308 is returned to help propel the foot at toe off.

[0055] During toe off, the first metatarsal naturally flexes downward. Preventing this natural downward flex of the first metatarsal causes the arch of the foot to flatten and the foot to over pronate, increasing stress on the ankles and knees. To accommodate the downward flex, the rear apex 357 of forefoot pad 308 extends rearward into a corresponding concave edge portion of the distal edge of stability cradle 306. The shape of the stability cradle 306 and forefoot pad 308 permit the first metatarsal to flex more naturally and thereby encourage loading of the great toe during toe off.

[0056] Forefoot pad 308 is preferably made from a Thermoplastic Rubber ("TPR") or Polyurethane ("PU"). The hardness of the TPR or PU used in the forefoot pad 308 is preferably about 30 Asker C ±3. For a men's size 11 -12 insole, the width of the forefoot pad from the medial to lateral side is about 85 to 95 mm. The height is about 100 to 110 mm. The depth is about 0.95 to 1.50 mm.

[0057] The honeycomb groove partem 320 on the bottom surface of the forefoot pad 308, the lateral midfoot/heel pad 312, and the supplemental heel pad 316, as well as the random multi-faceted groove pattern 307A on the stability cradle 306, are constructed on the bottom surface of the insole to make contact with the bottom internal shoe surface, provide better cushioning and improve stability of the insole 300. The random multi-faceted groove pattern introduces air gaps into the pad surfaces, which positively influences the impact absorption properties of each pad as well as allowing for use of less material and providing for a lighter insole while still providing the desired cushioning function. Preferably, the honeycomb cell partem 320 on the forefoot pad 308 and the honeycomb groove pattern 323 on supplemental heel pad 316 is approximately 0.10 to 0.35 mm deep. Preferably, the random multi-faceted groove pattern 307A on the stability cradle 306 and the honeycomb groove pattern 321 on the lateral midfoot/heel pad 312 are approximately .025 to .75 mm deep. The random multi-faceted groove patterns and the honeycomb groove pattern assist with securing the insole inside the shoe cavity and keeping the insole in place on the bottom interior surface of the shoe such that the insole will not move or slide around, as well as allowing air circulation and/or providing different cushioning and spring properties.

[0058] Base 302 is preferably made of foam or other material having suitable cushioning properties. Preferably, base 302 comprises an Ethylene vinyl acetate ("EVA") foam, which is a copolymer of ethylene and vinyl acetate, a Thermoplastic Rubber ("TPR")/EVA mix, or a blown EVA material. A preferred blown EVA, EVA or TPR/EVA mix has a durometer (hardness) of about Asker C 45-50.

[0059] It is desirable to minimize the total weight of the insoles by selection of materials that promote the structural features of the insole. It is desirable that the total weight of the preferred embodiment of the insole (men's size 10/11) be about 4.0 ounces. It is desirable that the total weight of an alternate embodiment of the insole be about 5.0 to 6.0 ounces for a men's size 10/1 1 and about 6.5 to 7.5 ounces for a men's size 12/13. Other sizes will be proportional. Using the random multi-faceted groove pattern designs will also help provide for a lighter insole.

[0060] In a preferred embodiment, base 302 is covered with top sheet 301 from toe to heel areas of the insole, which is preferably a non-woven fabric layer with a low coefficient of friction so as to minimize the possibility of blisters. Preferably, top sheet 301 is made of a cooling fabric which contains a special low temperature jade obtained from a natural source. The form of jade in the fabric is a jadeite. In a preferred embodiment, the fabric is treated with an antibacterial agent, which in combination with a moisture barrier reduces odor causing bacteria and fungi.

[0061] In a first preferred embodiment of the present invention, the various pad components of an insole which are secured to base 302 in the indentation areas defined by base 302 on the bottom surface and are permanently affixed to base 302 using an appropriate means such as an adhesive or a mechanical fastener (e.g. hook and loop). The components can also be secured during the molding process using techniques known in the art of molding insoles.

[0062] The indentation areas can also be lined with a cloth having a base surface and a pad surface, or secured to said base 302 along said base surface and said pad along said pad surface. Alternatively, a cloth is secured to pad and then the composite structure secured to the indentation area.

[0063] Some shoes may slightly differ in size on the inner part of the shoe. Some shoes may also provide extra padding along the inner sides, front or back of the shoe that alter the actual space provided for the foot and/or an insole on the inner part of the shoe. Base 302 may have sizing guides 350 that allow a user to shorten the length of the insole for proper fit within the shoe. Sizing guides 350 provide various cutting guide lines that the user would cut along, preferably with scissors.

[0064] FIG. 3 is a top view of the insole 300 illustrating the top sheet 301 and transverse arch support 338. Insole 300 comprises a top sheet 301 secured across the entire top surface of the base 302 from toe area to heel area. Preferably, the top surface of the base 302 defines an upwardly-extending portion or transverse arch support 338 that lies under the metatarsal head area of the foot. The upward extension of transverse arch support 338 pushes up a portion of the top sheet 301 that corresponds to the area of the transverse arch support 338.

[0065] Transverse arch support 338 preferably lies under the second to fourth metatarsal heads. Transverse arch support 338 provides additional stability and cushioning to the forefoot and middle of the foot.

[0066] In a preferred embodiment, top sheet 301 is a non-woven fabric layer with a low coefficient of friction so as to minimize the possibility of blisters. Preferably, top sheet 301 is made of a cooling fabric which contains a special low temperature jade obtained from a natural source. The form of jade in the fabric is a jadeite. In a preferred embodiment, the fabric is treated with an antibacterial agent, which in combination with a moisture barrier reduces odor causing bacteria and fungi. A series of air holes extend through top sheet 301 and the base 302 to permit air circulation above and below insole 300.

[0067] FIG. 4 illustrates a medial side view of the insole. Insole 300 preferably comprises a top sheet 301 and a base 302 having a top surface secured to said top sheet and an opposite bottom surface. Base 302 also defines a longitudinal arch support 319 that extends upwardly along the medial side of the insole to provide extra cushion and support to the arch area of the foot.

[0068] The bottom surface of base 302 defines a forefoot pad indentation area 307 in the forefoot area and a stability cradle indentation area 305 along the midfoot and heel areas. The bottom surface of base 302 also defines one or more ribs or protrusions 332 that extend outwardly along the arch area. The ribs 332 are preferably longer around the cuneiforms and gradually shorter distally and proximally from the cuneiforms creating a parabolic-like overall shape. In a preferred embodiment, the rib-shaped openings 331 allow said ribs 332 of base 302 to extend therethrough.

[0069] Preferably, base 302 is molded so that the ribs 332 project into rib-shaped openings 331 so that the ribs 332 are approximately flush with the outer surface of stability cradle 306 and mechanically lock stability cradle 306 and base 302 together. Advantageously, the ribs 332 are also able to bulge through rib-shaped openings 331 when base 302 is compressed (e.g., while walking or running) to provide additional cushioning and support to the arch of the foot. Preferably said ribs 332 extend outwardly approximately 0.50 mm to 1.5 mm and have a width of approximately 4 mm. The rib-shaped openings 331 allow the stability cradle 306 to be more flexible in the arch area compared to the rest of the stability cradle 306.

[0070] In an alternate embodiment, stability cradle 306 defines one or more protruding ribs instead of openings. The protruding ribs extend outwardly along the arch area. The protruding ribs are longer around the cuneiforms and gradually shorter distally and proximally from the cuneiforms creating a parabolic-like overall shape. The protruding ribs extend outward approximately 0.50 mm.

[0071] Base 302 has a raised edge along the medial arch area and wraps around the outside edge of the heel area and extends partially along the sides of the foot such that the insole has a heel cup, which conforms to the natural shape of the foot. The height of the raised edge is generally higher and thicker on the medial side of the insole and is lower and thinner on the lateral side of the insole.

[0072] The forefoot pad indentation area 307 begins partially proximal from the toe pad 340 of the insole 300 near the distal ends of the proximal phalanges of the foot. The forefoot pad indentation area 307 extends rearward to about the 3rd through 5th metatarsal heads on a lateral portion and approximately halfway along the 1 st and 2nd metatarsals on a medial portion. Preferably the forefoot pad indentation area 307 has a rear apex that lies between the 1st and 2nd metatarsals. A forefoot pad 308 is shaped essentially the same as forefoot pad indentation area 307 and is secured therein.

[0073] The stability cradle indentation area 305 is located in the midfoot and heel areas of the bottom surface of base 302. The stability cradle indentation area 305 extends from a medial edge approximate the medial border to a lateral edge approximate the lateral border of the base 302 and from a distal edge slightly proximal of the forefoot pad indentation area 307 to a proximal edge approximate the heel end of the base. A medial portion of the distal edge is shaped to accommodate downward motion of the 1 st metatarsal during toe off. Stability cradle 306 is shaped essentially the same as stability cradle indentation area 305 and has a base facing surface and a shoe facing surface. The base facing surface is secured to said stability cradle indentation area 305.

[0074] Stability cradle 306 has walls that wrap up the sides and rear of base 302 to provide support for the foot. Preferably, stability cradle 306 ranges from approximately 0.5 mm to 3 mm thick and the walls taper from approximately 3 mm to about 0.5 mm. The sides of stability cradle 306 are preferably higher on the medial side of the foot because of the higher loading.

[0075] Stability cradle 306 defines a lateral midfoot/heel pad opening 313 that extends from the lateral midfoot area to the heel area along the lateral side of the midfoot area.

Specifically, stability cradle 306 defines a lateral midfoot/heel pad opening 313 that extends from the behind the 3 ^rd through 5 ^th metatarsal heads proximally to the back of the cuboid. Stability cradle 306 defines a lateral midfoot/heel pad opening 313 that extends through the lateral side of the heel area of stability cradle 306 from approximately rearward of the lateral midfoot/heel pad opening 313 toward the heel end. The lateral midfoot/heel pad 312 is shaped essentially the same as lateral midfoot/heel pad opening 313 and is secured to the bottom surface of base 302 within the stability cradle indentation area 305 in a location that correlates to the lateral midfoot/heel pad opening 313 and allows the lateral midfoot/heel pad 312 to extend out through said lateral midfoot/heel pad opening 313.

[0076] Supplemental heel pad 316 overlays onto a portion of the lateral midfoot/heel pad 312 in the heel pad area. This supplemental heel pad 316 provides directional support and cushioning over this overlaid area of the lateral midfoot/heel pad 312 and is constructed as described above with respect to Figures 1A, IB and 2. The supplemental heel pad 316 is affixed to the lateral midfoot/heel pad 312 by an adhesive or mechanical fastener (e.g. hook and loop fastener).

[0077] In a preferred embodiment, base 302 is covered with top sheet 301 , which is preferably a non-woven fabric layer with a low coefficient of friction so as to minimize the possibility of blisters. Preferably, top sheet 301 is made of a cooling fabric which contains a special low temperature jade obtained from a natural source. The form of jade in the fabric is a jadeite. In a preferred embodiment, the fabric is treated with an antibacterial agent, which in combination with a moisture barrier reduces odor causing bacteria and fungi.

[0078] Preferably, the top surface of the base 302 defines an upwardly-extending portion or transverse arch support 338 that lies under the metatarsal head area of the foot. The upward extension of transverse arch support 338 pushes up a portion of the top sheet 301 that corresponds to the area of the transverse arch support 338. Transverse arch support 338 preferably lies under the second to fourth metatarsal heads. Transverse arch support 338 provides additional stability and cushioning to the forefoot and middle of the foot.

[0079] FIG. 5 illustrates a lateral side view of the insole. Insole 300 preferably comprises a top sheet 301 and a base 302 having a top surface secured to said top sheet 301 and an opposite bottom surface. Base 302 also defines a longitudinal arch support 319 that extends upwardly along the medial side of the insole to provide extra cushion and support to the arch area of the foot. The bottom surface of base 302 defines a forefoot pad indentation area 307 in the forefoot area and a stability cradle indentation area 305 along the midfoot and heel areas.

[0080] Base 302 has a raised edge that wraps around the heel and extends partially along the sides of the foot such that the insole has a heel cup, which conforms to the natural shape of the foot. The height of the raised edge is generally higher and thicker on the medial side of the insole and is lower and thinner on the lateral side of the insole.

[0081] The forefoot pad indentation area 307 begins partially proximal from the toe pad 340 of the insole 300 near the distal ends of the proximal phalanges of the foot. The forefoot pad indentation area 307 extends rearward to about the 3rd through 5th metatarsal heads on a lateral portion and approximately halfway along the 1 st and 2nd metatarsals on a medial portion. Preferably the forefoot pad indentation area 307 has a rear apex that lies between the 1st and 2nd metatarsals. A forefoot pad 308 is shaped essentially the same as forefoot pad indentation area 307 and is secured therein.

[0082] The stability cradle indentation area 305 is located in the medial midfoot area and extends around the heel area of the bottom surface of base 302. The stability cradle indentation area 305 extends from a medial edge approximate the medial border to a lateral edge approximate the lateral border of the base and from a distal edge slightly proximal of the forefoot pad indentation area 307 to a proximal edge approximate the heel end of the base. A medial portion of the distal edge is shaped to accommodate downward motion of the 1st metatarsal during toe off. Stability cradle 306 is shaped essentially the same as stability cradle indentation area 305 and has a base facing surface and a shoe facing surface. The base facing surface is secured to said stability cradle indentation area 305.

[0083] Stability cradle 306 defines a lateral midfoot/heel pad opening 313 that extends from the behind the 3 ^rd through 5 ^th metatarsal heads proximally to the back of the cuboid.

Stability cradle 306 has walls that wrap up the sides and surround the rear of base 302 to provide support for the foot. Preferably, stability cradle 306 ranges from approximately 0.5 mm to 3 mm thick and the walls taper from approximately 3 mm to about 0.5 mm. The sides of stability cradle 306 are preferably higher on the medial side of the foot because of the higher loading.

[0084] A lateral midfoot/heel pad 312 is shaped essentially the same as the lateral midfoot/heel pad opening 313 and is secured to the bottom surface of base 302 within the stability cradle indentation area 305 in a location that correlates to the lateral midfoot/heel pad opening 313 and allows the lateral midfoot/heel pad 312 to extend out through said lateral midfoot/heel pad opening 313.

[0085] Supplemental heel pad 316 overlays onto a portion of the lateral midfoot/heel pad 312. This supplemental heel pad 316 provides directional support and cushioning over this overlaid area of the lateral midfoot/heel pad 312 and is constructed as described above with respect to Figures 1A, IB and 2. The supplemental heel pad 316 is affixed to the lateral midfoot/heel pad 312 by an adhesive or mechanical fastener.

[0086] In a preferred embodiment, base 302 is covered with top sheet 301 , which is preferably a non-woven fabric layer with a low coefficient of friction so as to minimize the possibility of blisters. Preferably, top sheet 301 is made of a cooling fabric which contains a special low temperature jade obtained from a natural source. The form of jade in the fabric is a jadeite. In a preferred embodiment, the fabric is treated with an antibacterial agent, which in combination with a moisture barrier reduces odor causing bacteria and fungi.

[00871 Preferably, the top surface of the base 302 defines an upwardly-extending portion or transverse arch support 338 that lies under the metatarsal head area of the foot. The upward extension of transverse arch support 338 pushes up a portion of the top sheet 301 that corresponds to the area of the transverse arch support 338. Transverse arch support 338 preferably lies under the second to fourth metatarsal heads. Transverse arch support 338 provides additional stability and cushioning to the forefoot and middle of the foot.

[0088] FIG. 6 illustrates the front view of the insole 300, and FIG. 7 illustrates a rear view of the insole 300. Insole 300 preferably comprises a top sheet 301 and a base 302 having a top surface secured to said top sheet 301 and an opposite bottom surface. Base 302 also defines a longitudinal arch support 319 that extends upwardly along the medial side of the midfoot area of the insole to provide extra cushion and support to the arch area of the foot.

[0089] The bottom surface of base 302 defines a stability cradle indentation area 305 along the midfoot and heel areas. The bottom surface of base 302 also define one or more ribs or protrusions 332 that extend outwardly along the arch area. The stability cradle 306 preferably defines one or more rib-shaped openings 331. In a preferred embodiment, the rib-shaped openings 331 allow said ribs 332 of base 302 to extend therethrough. Preferably, base 302 is molded so that the ribs 332 project into rib-shaped openings 331 so that the ribs 332 are approximately flush with the outer surface of stability cradle 306 and mechanically lock stability cradle 306 and base 302 together. Advantageously, the ribs 332 are also able to bulge through rib-shaped openings 331 when base 302 is compressed (e.g., while walking or running) to provide additional cushioning and support to the arch of the foot.

[0090] The rib-shaped openings 331 allow the stability cradle 306 to be more flexible in the arch area compared to the rest of the stability cradle 306. In an alternate embodiment, stability cradle 306 defines one or more protruding ribs instead of openings. The protruding ribs extend outwardly along the arch area. The protruding ribs are longer around the cuneiforms and gradually shorter distally and proximally from the cuneiforms creating a parabolic-like overall shape. The protruding ribs extend outward approximately 0.50 mm. The ribs 332 are preferably longer around the cuneiforms and gradually shorter distally and proximally from the cuneiforms creating a parabolic-like overall shape. An alternate embodiment has the ribs or protrusions defined by the stability cradle 306 and extending outwardly from the stability cradle 306 in the arch area.

[0091] Base 302 has a raised edge that wraps around the heel and extends partially along the sides of the foot such that the insole has a heel cup, which conforms to the natural shape of the foot. The height of the raised edge is generally lower and thinner on the lateral side of the insole and is higher and thicker on the medial side of the insole.

[0092] Supplemental heel pad 316 overlays onto a portion of the lateral midfoot/heel pad 312 and has a honeycomb cell pattern 323. This supplemental heel pad 316 provides directional support and cushioning over this overlaid area of the lateral midfoot/heel pad 312 and is constructed as described above with respect to Figures 1A, IB and 2. The supplemental heel pad 316 is affixed to the lateral midfoot/heel pad 312 by an adhesive or mechanical fastener.

[0093] The top surface of the base 302 defines an upwardly -extending portion or transverse arch support 338 that lies under the metatarsal head area of the foot. The upward extension of transverse arch support 338 pushes up a portion of the top sheet 301 that corresponds to the area of the transverse arch support 338. Transverse arch support 338 preferably lies under the second to fourth metatarsal heads. Transverse arch support 338 provides additional stability and cushioning to the forefoot and middle of the foot.

[0094] The stability cradle indentation area 305 is located in the midfoot and heel areas of the bottom surface of base 302. The stability cradle indentation area 305 extends from a medial edge approximate the medial border to a lateral edge approximate the lateral border of the base and from a distal edge slightly proximal of the forefoot pad indentation area 307 to a proximal edge approximate the heel end of the base. A medial portion of the distal edge is shaped to accommodate downward motion of the 1 st metatarsal during toe off. Stability cradle 306 is shaped essentially the same as stability cradle indentation area 305 and has a base facing surface and a shoe facing surface. The base facing surface is secured to said stability cradle indentation area 305.

[0095] Stability cradle 306 has walls that extend up the medial and lateral sides of the midfoot and surround the rear of base 302 to provide support for the foot. Preferably, stability cradle 306 ranges from approximately 0.5 mm to 3 mm thick and the walls taper from approximately 3 mm to about 0.5 mm. The sides of stability cradle 306 are preferably higher on the medial side of the foot because of the higher loading. [0096] Stability cradle 306 defines a lateral midfoot/heel pad opening 313 that extends from the behind the 3 ^rd through 5 ^th metatarsal heads proximally to the back of the cuboid.

Stability cradle 306 defines a lateral midfoot/heel pad opening 313 that extends through the heel area along the lateral side of the midfoot area and into the heel end. The lateral midfoot/heel pad 312 is shaped essentially the same as the lateral midfoot/heel pad opening 313 and is secured to the bottom surface of base 302 within the stability cradle indentation area 305 in a location that correlates to the lateral midfoot/heel pad opening 313 and allows the lateral midfoot/heel pad 312 to extend out through said lateral midfoot/heel pad opening 313.

[0097] In a preferred embodiment, base 302 is covered with top sheet 301 , which is preferably a non-woven fabric layer with a low coefficient of friction so as to minimize the possibility of blisters. Preferably, top sheet 301 is made of a cooling fabric which contains a special low temperature jade obtained from a natural source. The form of jade in the fabric is a jadeite. In a preferred embodiment, the fabric is treated with an antibacterial agent, which in combination with a moisture barrier reduces odor causing bacteria and fungi.

[0098] For a men's size 11 -12 insole, the width of the forefoot pad from the medial to lateral side is about 85 to 95 mm. The height is about 100 to 1 10 mm. The depth is about 0.95 to 1.50 mm. It is desirable to minimize the total weight of the insoles by selection of materials working with the structural features of the insole. It is desirable that the total weight of the preferred embodiment of the insole (men's size 10/11) be about 4.0 ounces. It is desirable that the total weight of an alternate embodiment of the insole be about 5.0 to 6.0 ounces for a men's size 10/11 and about 6.5 to 7.5 ounces for a men's size 12/13. Other sizes will be proportional. Using the open-cell designs will provide for a lighter insole.

[0099] In a first preferred embodiment of the present invention, the various components of an insole which are secured to base 302 in the indentation areas defined by base 302 on the bottom surface are permanently affixed to base 302 using an appropriate means such as an adhesive. The components are secured during the molding process using techniques known in the art of molding insoles.

[00100] The indentation areas are also lined with a cloth having a base surface and a pad surface, secured to said base 302 along said base surface and said pad along said pad surface. Alternatively, a cloth is secured to said pad and then the composite structure secured to the indentation area.

[00101] Some shoes may slightly differ in size on the inner part of the shoe. Some shoes may also provide extra padding along the inner sides, front or back of the shoe that alter the actual space provided for the foot and/or an insole on the inner part of the shoe. Base 302 may have sizing guides 350 that allow a user to shorten the length of the insole for proper fit within the shoe. Sizing guides 350 provide various cutting guide lines that the user would cut along, preferably with scissors.

[00102] An improved insole 300 has been disclosed. It will be readily apparent that the illustrative embodiments of an insole thus disclosed may be useful in cushioning the foot and controlling pronation during activities such as hiking, backpacking, and the like.

However, one will understand that the components of the insole system may be modified to accommodate other activities or to control other kinds of foot motion. Thus, the description provided herein, including the presentation of specific thicknesses, materials, and properties of the insole components, is provided for purposes of illustration only and not of limitation, and that the invention is limited only by the appended claims.