For international application pursuant to PCT Article 11 ( 1 ) ( i i i ) ( a )

TO ALL WHOM IT MAY CONCERN:

BE IT KNOWN that I, Jason Guadalajara, residing in Los Angeles, California, have invented a new and useful

VARIABLE RATE ENERGY RETURN INSOLE SYSTEM AND METHOD OF

PRODUCING THE SAME of which the following is a Description.

BACKGROUND

Field of the Invention

[0001] The present invention relates generally to shoe inserts, and more specifically, to a variable rate energy return insole system and method of producing the same.

2. Description of Related Art

[0002] Shoe insoles are well known in the art and are effective means to improve the comfort or functionality of a shoe. For example, a user may add an insert to their shoes to provide improved arch support or other functions. Conventional insoles do not take into account varying shock absorption and rebound/energy return, and accordingly, are therefore limited. For example, it can be observed that areas of the gait such as the heel strike may be prone to causing injury, especially on dense surfaces like concrete. Therefore, it may be desirable for energy to be absorbed before damaging the body in these areas. Other areas of the gait such as the forefoot may benefit from higher energy return to help spring the body forward, especially for runners, basketball players and other athletes. Currently available insoles may have colorful or fancy looking pads; however, it is believed that these pieces provide little functional significance as most materials, although they may look different, have similar energy return.

[0003] Accordingly, although great strides have been made in the area of shoe insoles, many shortcomings remain.

DESCRIPTION OF THE DRAWINGS

[0004] The novel features believed characteristic of the embodiments of the present application are set forth in the appended claims. However, the embodiments themselves, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:

FIG. 1 is a simplified side view of an insole in accordance with the present application;

FIG. 2 is a bottom view of a first embodiment of an insole in accordance with the present application; FIG. 3 is a bottom view of a second embodiment of an insole in accordance with the present application; and

FIG. 4 is a flowchart of a method of making the insole of the present invention.

[0005] While the system and method of use of the present application is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present application as defined by the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0006] Illustrative embodiments of the system and method of use of the present application are provided below. It will of course be appreciated that in the development of any actual embodiment, numerous implementation-specific decisions will be made to achieve the developer’s specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

[0007] The system and method of use in accordance with the present application overcomes one or more of the above-discussed problems commonly associated with conventional insoles. Specifically, the present invention provides for combining a heel portion with a forefoot insert portion, wherein the heel portion is shock absorbing while the forefoot insert portion is energy returning and providing for an overlap and combination of the two sections as desired to create a custom variable energy return insole. These and other unique features of the system and method of use are discussed below and illustrated in the accompanying drawings.

[0008] The system and method of use will be understood, both as to its structure and operation, from the accompanying drawings, taken in conjunction with the accompanying description. Several embodiments of the system are presented herein. It should be understood that various components, parts, and features of the different embodiments may be combined together and/or interchanged with one another, all of which are within the scope of the present application, even though not all variations and particular embodiments are shown in the drawings. It should also be understood that the mixing and matching of features, elements, and/or functions between various embodiments is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that the features, elements, and/or functions of one embodiment may be incorporated into another embodiment as appropriate, unless described otherwise.

[0009] The preferred embodiment herein described is not intended to be exhaustive or to limit the invention to the precise form disclosed. It is chosen and described to explain the principles of the invention and its application and practical use to enable others skilled in the art to follow its teachings.

[0010] Referring now to the drawings wherein like reference characters identify corresponding or similar elements throughout the several views, FIG. 1 depicts a side view of an insole 101 in accordance with a preferred embodiment of the present application. It will be appreciated that insole 101 overcomes one or more of the above-listed problems commonly associated with conventional shoe insoles.

[0011] In the contemplated embodiment, insole 101 includes a heel portion 103 composed of a shock absorbing material and a forefoot insert portion 105 composed of an energy retur material. A body 107 is created by combining the heel portion 103 and the forefoot insert portion 105 together such that a portion 109 of the forefoot insert portion overlaps with a portion of the heel portion. The body 107 having a top surface 111 extending from a first end 113 to a second end 115, wherein a user’s foot will rest.

[0012] It should be appreciated that the composition of the heel portion will be such that the material absorbs energy, thereby providing for comfort for the user’s heel when in use. Alternatively, the forefoot insert portion will be composed of a material to provide energy return, thereby providing a benefit as the user lifts off the ground.

[0013] As will be discussed with FIGS. 2 and 3, the insole includes a plurality of areas of designated energy returns throughout the body, the plurality of areas including at least a first area and a second area, wherein each of the plurality of areas of designated energy returns are created through combining one or more materials and one or more thicknesses of materials to create a desired energy return. It should be appreciated that one of the unique features believed characteristic of the present invention is that the body provides for variable energy return based on a composition of the heel portion and a composition of the forefoot insert portion.

[0014] In FIG. 2, a bottom view depicts one embodiment of an insole 201 in accordance with the present application. As shown, the heel portion 103 and the toe insert portion 105 intersect. The insole 201 optionally including arch support 203. The arch support may be configmed with an additional PU foam pad or thermoplastic elements to incorporate in a custom molding technology. In this embodiment, a plurality of areas 205, 207, 209, 211provide for variable energy return. For example, the insole may include a 10% energy retur (211), a 50% energy return (205), a 60% energy retur (207), and a 70% energy retur (209). This specific arrangement of return can be created by combining the thicknesses and combination of materials to achieve the desired percentages. It should be understood that the percentage of energy retur can be calculated in a number of ways, typically with a measmement of kN. In the preferred embodiment, the percentage of energy return is measmed by astm fl 614 international test standards for athletic shoes, wherein usually 2kN of energy is generated by dropping an anvil onto shoe outsoles/insoles with a force plate below which measmes the amount of energy which has passed through the shoe or insole.

[0015] Further as shown, the embodiment may include a plurality of holes 213 that provide for combining of the material of the toe insert portion 105 and the heel portion 103. For example, the holes may extend through an entire thickness of the toe insert portion, such that the holes can then be at least partially filled with the material of the heel portion, thereby providing for combining of the two materials.

[0016] In FIG. 3, another bottom view depicts an alternative arrangement, wherein the insole 301 includes holes 303 and a plurality of areas 305, 307, 309, 311, 313, 315, 317 of energy return (70%, 60%, 50%, 40%, 30%, 20%, 10% respectively). As shown, the overlap of the heel portion 103 and toe insert portion 105 can vary.

[0017] It should be appreciated that the exact compositions can vary as would be understood by those skilled in the art. The heel section may be created through a poured polymethane and the forefoot insert portion may be created through injection molding, heat pressing, or pouring material into a mold and forming by pressure, and gluing. Thermoplastic elastomer (TPE) gel may have the best properties for this operation. [0018] In at least some exemplary embodiments, a thermoplastic insert forefoot portion is secured in a mold on pegs to hold it in place both in terms of location and height. A mold is configured with matching pegs to fit into the insert. The pegs may be thinner at the top and thicker at the bottom while the insert has a corresponding hole. This allows the insert to rest at a certain determined elevation in the mold. Due to the nature of injection molding and gluing incompatibility with some silicone-based gels and materials, holes can be placed in insert forefoot portion which may allow the PU of heel section to form into and around the holes during the curing process thus creating a single piece.

[0019] The holes, as discussed above, can be made by puncturing the insert, by incorporating holes into the insert during the initial molding process by configuring the mold to make the holes, or by other methods. And, if needed by the material selected, to allow the exterior material such as high-density PU foam to fully form all around the forefoot section and fill the holes. This custom molding technology is an open cell foam impregnated with thermoplastic liquid that may be molded into virtually any shape and retain that shape until reheated again where it returns to its original shape due to the memory properties of the foam. When the insert melts, the thermoplastic impregnates the foam by body pressure when the end user steps on the heated insole thus creating 3D moldable foam. The insole is then placed into an oven until the insert melts enough to fully be molded to a person’s foot.

[0020] In some embodiments, the insole may include two layers having a 3D thermoplastic rigid layer embedded in the PU foam.

[0021] The controlled energy return regions on the insoles is considered a unique feature of the present invention and may be created by blending materials together. Incompatible material blending may be achieved through curing liquid foam PU into holes or slots in the incompatible section. For example, without limitation, the curing of PU around the holes, as described above, may be done by way of blending other compatible materials in different ways. Where the blending may comprise different thickness combinations of at least two materials; such as, without limitation, 30% pu and 70% gel in one area vs 50/50 in another. In some embodiments the different energy returning materials may be combined in varying thicknesses to control the amount of energy retur in different section of the gait.

[0022] In one embodiment of the present invention, the system and method of producing a custom orthotic insole may comprise a lateral heel structure made of rate sensitive foam such as, but not limited to, fluidx non-Newtonian foam which can absorb up to 90% of shock energy in astm fl 614 testing which is rate sensitive. Therefore, the harder the impact the more energy is absorbed due to a mechanical freezing function of the molecules in the foam. The heel structure may be produced in a 3D poured PU mold to specification for heel configuration. Since this section of the foot typically needs the most impact energy absorption, the heel structure would have the highest level of energy absorption. As shown in the Figures, the heel may thin out in a gradual slope towards the forefoot portion where it meets with a shock attenuating higher energy return material such as, but not limited to, TPE gel and high rebound foams. This allows the gait to gradually move from shock absorbing to energy returning which protects the body from the harmful impact energy while still assisting the body in springing forward at the end of the step. The blend of materials allows for precise control of energy return anywhere desired in the insole. An exemplary configmation of energy retur in the gait could for example be 90% of shock energy in the heel to 50% in the forefoot based on astm fl 614 or similar testing standards. A converse way to describe the energy absorption in said example configmation would be 10% energy rebound in the heel with a gradual slope to 50% energy return in the forefoot.

[0023] In FIG. 4, a flowchart 401 depicts a method of making the insoles of the present invention. The heel portion and forefoot insert portions are both created through a selection of desired materials, as discussed above, as shown with boxes 403, 405. These two are then combined, again through the selection process discussed above such as with the user of holes, to create the insole, as shown with box 407. Based on thicknesses, means of combining, and selected materials, the designated energy returns throughout the insole are created, as shown with box 409.

[0024] The particular embodiments disclosed above are illustrative only, as the embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. It is therefore evident that the particular embodiments disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the application. Accordingly, the protection sought herein is as set forth in the description. Although the present embodiments are shown above, they are not limited to just these embodiments, but are amenable to various changes and modifications without departing from the spirit thereof.