Footwear Stability and Comfort System

A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document of the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

FIELD OF THE DISCLOSURE

Embodiments relate to footwear systems including shoe insoles and shoes incorporating insoles. In particular but not exclusively, embodiments relate to woman's shoes, high heeled shoes, low heeled and flat shoes, and insoles for such shoes.

BACKGROUND OF THE DISCLOSURE

Styled shoes may often be associated with discomfort and foot pain. High-heeled shoes in particular, are known to cause discomfort, which may increase with an increased height of the heel. Typically, the greater the heel elevation the more of a user's weight is shifted to the ball of the foot and/or metatarsal area. In some shoes weight shifted to the metatarsal may range to over 70% of the user's weight. This added pressure on the metatarsal may often cause pain and/or stinging sensations at the ball of the foot, which may be felt after several minutes of wear. The added pressure may also cause muscle fatigue and toe numbness.

Additionally, conventional shoes, including high-heeled shoes, may typically be designed with minimal support for the foot, resulting in a lack of torsional and lateral stability within the shoe. Without the needed support, the foot is apt to pronation or supination, meaning the user's foot may easily twist from left to right. In high-heeled shoes in particular, the lack of foot support, in combination with the increased elevation/angle of the foot due the addition of a heel, may further exacerbate muscular strain and fatigue. Furthermore, there may be an increased risk of twisting, straining, tearing, or even breaking the foot, ankle, or leg, due to a misstep or giving out of the foot or ankle due to fatigue.

As such, there is a need for an improved footwear system, designed for increased comfort, support, and stability.

BRIEF SUMMARY OF THE DISCLOSURE

According to various embodiments, disclosed is a high-heeled shoe, comprising: a shoe outer sole; an insole; and a shoe heel, wherein said outer sole includes a top side and a bottom side, wherein the shoe heel is coupled directly or indirectly to the bottom side of the outer sole, wherein said insole is affixed either directly or indirectly to the top side of the outer sole, wherein the insole includes an anatomic footbed at a rearfoot portion of the insole, the anatomic footbed including a central arch portion; a heel portion adjacent a back side of the central arch portion; a medial arch portion adjacent a medial side of the central arch portion; and a lateral arch portion adjacent to a lateral side of the central arch portion.

In embodiments, the shoe further comprises a shoe upper coupled directly or indirectly to the outer sole on the top side of the outer sole, forming an internal shoe cavity therewith, wherein the insole is situated within said cavity. In further embodiments the medial arch portion and the lateral arch portion of the anatomic footbed are raised with respect to the central arch portion, to provide medial arch and lateral arch support to the foot. In yet further embodiments, the heel portion of the anatomic footbed includes a raised portion and forms a heel cup, wherein the anatomic footbed is configured to support both bottom and side regions of the foot. In yet further embodiments, the medial arch portion is raised at least 18 mm at a medial side outer edge of the footbed, wherein the later arch portion is raised at least 12 mm at a lateral side outer edge of the footbed, and wherein the heel portion is raised at least 6 mm at a heel side outer edge of the footbed.

In embodiments, the insole further includes: a cushioning layer on a forefoot portion of the insole, adjacent a front side of the anatomic footbed, wherein the cushioning layer comprises an open cell foam, and wherein the footbed comprises polyurethane. In further embodiments, the shoe further comprises a platform layer beneath the cushioning layer. In yet further embodiments, the insole comprises a top layer and a base layer, wherein the top layer is affixed to a top side of the base layer, wherein a rearfoot portion of the top layer comprises the anatomic footbed, wherein a forefoot portion of the top layer comprises a cushioning layer, the cushioning layer including an open cell foam material, and the anatomic foot-bed comprising polyurethane. In yet further embodiments, the shoe further comprises a platform layer beneath a forefoot portion of the base layer.

In embodiments, the heel portion includes an inner heel section which dips downwards with respect to the central arch portion. In further embodiments, the heel portion further includes an outer heel section which extends upwards with respect to the central arch portion, such that the heel portion forms a heel cup configured to support a heel bottom region and a heel side region of the foot. In yet further embodiments, the inner heel section is at least 2 mm below the central arch portion, and wherein the medial arch and lateral arch portions extend at least 3 mm above the central arch portion.

According to various embodiments, an insole for a high heeled shoe, comprises: a) a top layer comprising: i) an anatomic foot-bed including: a central arch portion; a heel portion adjacent a back side of the central arch portion, said heel portion comprising a raised region and forming a heel cup; a medial arch portion adjacent a medial side of the central arch portion, and which extends upwards with respect to the central arch portion; and a lateral arch portion adjacent to a lateral side of the central arch portion, and which extends upwards with respect to the central arch portion, wherein the anatomic foot-bed is configured to support a bottom region and a side region of the foot; and ii) a forefoot portion extending from a front side of the central arch portion; and b) a base layer affixed to the bottom side of the top layer.

In some embodiments, the insole further comprises a third platform layer beneath a forefoot portion of the base layer, wherein the base layer is configured to reduce an effective heel height of the shoe. In further embodiments, the raised region of the heel portion includes an outer heel section which extends upwards with respect to the central arch portion, and wherein the heel portion includes an inner heel section which dips downwards with respect to the central arch portion, wherein the outer heel section and outer heel section together form the heel cup configured to support a heel bottom region and a heel side region of the foot. In further embodiments, the inner heel section is at least 2 mm below the central arch portion, and wherein the medial arch and lateral arch portions extend at least 3 mm above the central arch portion. In yet further embodiments, the forefoot portion of the top layer comprises an open celled foam, the base layer comprises fiberboard and/or fiberglass, and wherein the anatomic foot-bed comprises polyurethane.

According to various embodiments, a shoe comprising an insole including an anatomic foot-bed, is produced according to a process comprising: a) forming the insole by: i) attaching a forefoot layer atop a forefoot region of a base layer of the insole; ii) injecting a polymer atop a rearfoot region of the base layer and molding the polymer to form an anatomic footbed adjacent to the forefoot layer, wherein the anatomic footbed comprises a central arch portion; a heel portion adjacent a back side of the central arch portion, said heel portion comprising a raised region and forming a heel cup; a medial arch portion adjacent a medial side of the central arch portion, and which extends upwards with respect to the central arch portion; and a lateral arch portion adjacent to a lateral side of the central arch portion, and which extends upwards with respect to the central arch portion, wherein the anatomic foot-bed is configured to support a bottom region and a side region of the foot; iii) attaching a platform layer beneath the forefoot region of the base layer; b) affixing a shoe heel beneath the rearfoot region of the base layer, wherein the heel is affixed either directly or indirectly to the base layer; and c) attaching an outsole beneath the base layer, wherein the outsole is attached either directly or indirectly to the base layer.

In some embodiments, the process for producing the shoe further comprises affixing an upper to the insole prior to affixing the shoe heel. In further embodiments, the medial arch portion is raised at least 15 mm at a medial side outer edge of the footbed, wherein the later arch portion is raised at least 9 mm at a lateral side outer edge of the footbed, and wherein the heel portion is raised at least 6 mm at a heel side outer edge of the footbed, and the base layer comprises fiberglass and/or fiberboard, the anatomic foot-bed comprises polyurethane, and the forefoot layer comprises an open cell foam.

According to various embodiments, disclosed is a shoe comprising: a shoe sole; and an insole, wherein said shoe sole includes a top side and a bottom side; wherein said shoe sole further includes a rearfoot portion and forefoot portion; wherein said insole is affixed to the top side of the shoe sole; wherein the insole includes an anatomic footbed, and wherein the anatomic footbed at least partially overlays the rearfoot portion of said sole.

In some embodiments, the shoe further comprises a shoe upper, wherein the shoe upper is coupled directly or indirectly to the shoe sole on the top side of the shoe sole, forming an internal shoe cavity therewith; wherein the shoe insole is situated within said shoe cavity. In further embodiments, the anatomic footbed includes: a central arch portion having a topside configured to support a central bottom region of a foot of a user wearing the shoe; a heel portion extending from an aft side of the central arch portion; a medial arch portion extending from a medial side of the central arch portion; and a lateral arch portion extending from a lateral side of the central arch portion. In further embodiments, said heel portion includes an inner heel portion which dips downwards from the central arch portion, and an outer heel portion which extends upwards from the central arch portion, such that the heel portion forms a heel cup configured to contact and support a heel bottom region and a heel side region of said foot, and wherein the lateral arch portion and the medial arch portion both extend upwards from the central arch portion, wherein both of said lateral arch and medial arch portions are configured to support a medial bottom region and a medial side region of the foot, respectively. In yet further embodiments, the shoe further comprises a forefoot portion extending from a front side of the central arch portion, said forefoot portion configured to support a front bottom and/or toe region of the foot. In yet further embodiments, the medial arch comprises an inner portion configured to support a medial flange region of the foot, and outer portion extends outwardly from said inner portion.

In some embodiments, the insole comprises a top layer configured to contact the foot, and a base layer below the top layer, wherein said top layer includes said anatomic foot-bed. In further embodiments, the insole further comprises a forefoot portion extending from a front side of said central arch, wherein the top layer includes a forefoot top layer, and wherein the base layer includes a forefoot base layer below the forefoot top layer. In yet further embodiments, the base layer comprises fiberboard with a metal frame. In yet further embodiments, the forefoot top layer comprises a cushioning material.

In some embodiments, the cushioning material includes Poron® Urethane. In further embodiments, the shoe is high-heeled, and wherein the forefoot portion further comprises a platform layer below the base layer, said platform layer providing a platform for the shoe to reduce the effective height of the shoe. In yet further embodiments, the inner heel section extends at least 2 mm below the central arch portion, and wherein the medial arch and lateral arch portions extend at least 2 mm above the central arch portion.

According to various embodiments, an insole for a shoe, comprises a) a top layer having a top side configured to contact a user's foot and a bottom side, the top layer comprising: i) an anatomic foot-bed including: a central arch portion; a heel portion adjacent an aft side of the central arch portion, said heel portion including an inner heel section which dips downwards with respect to the central arch portion; a medial arch portion adjacent a medial side of the central arch portion, and which extends upwards with respect to the central arch portion; and a lateral arch portion adjacent to a lateral side of the central arch portion, and which extends upwards with respect to the central arch portion, wherein the anatomic foot-bed is configured to contact and support a side region of the foot; and ii) a forefoot portion extending from a front side of the central arch portion; and b) a base layer affixed to the bottom side of the top layer.

In some embodiments, the insole further comprises a third platform layer beneath a forefoot portion of the base layer, wherein the insole is configured for use with a high-heeled shoe. In further embodiments, the heel portion further includes an outer heel section which extends upwards with respect to the central arch portion, such that the heel portion forms a heel cup configured to contact and support a heel bottom region and a heel side region of the foot. In yet further embodiments, the forefoot portion of the top layer comprises Poron®, the base layer comprises fiberboard and/or fiberglass, and wherein the anatomic foot-bed comprises polyurethane. In yet further embodiments, the inner heel section is at least 2 mm below the central arch portion, and wherein the medial arch and lateral arch portions extend at least 3 mm above the central arch portion.

According to various embodiments disclose is a shoe comprising an insole including an anatomic foot-bed atop an insole layer, the shoe produced according to a process comprising: forming the insole by: attaching a forefoot layer atop a forefoot region of the insole layer; injecting polymer to a rear region of the insole layer and molding the polymer to form an anatomic foot-bed region adjacent to the forefoot region; and attaching a platform layer to the bottom of the forefoot region of the insole layer. In embodiments, the insole layer comprises fiberglass; the anatomic foot-bed comprises polyurethane; the forefoot layer comprises Poron™; and the platform layer is comprised of a cushioning material.

In further embodiments, the process for producing the shoe further comprises: providing a last having a bottom profile conforming to a form of the insole and a heel height corresponding to the desired height of a heel of the shoe less a thickness of the platform layer; attaching the insole to the last via removable attachment elements; attaching an upper for the shoe to the last via removable attachment elements; affixing a bottom sole layer to a bottom side of the shoe insole; and affixing the upper to the insole including the sole layer. In yet further embodiments, the process for producing the shoe further comprises affixing the heel to a bottom side of the shoe sole layer via at least one nail and or screw driven through a top side of the insole; and affixing an outsole to the sole layer.

According to various embodiments, disclosed is a shoe comprising: a shoe sole; and an insole, wherein said shoe sole includes a top side and a bottom side; wherein said shoe sole further includes a rearfoot portion and forefoot portion; wherein said insole is affixed to the top side of the shoe sole; wherein the insole includes an anatomic footbed, wherein the anatomic footbed at least partially overlays the rearfoot portion of said sole, and wherein an outer section of the rear-foot portion is firmer than an inner section of the rear-foot portion.

In some embodiments, the insole includes: a central arch portion having a top side configured to contact and support a central bottom region of a foot of a user wearing the shoe; a heel portion extending from an aft side of the central arch portion; a medial arch portion extending from a medial side of the central arch portion; and a lateral arch portion extending from a lateral side of the central arch portion. In further embodiments, said heel portion includes an inner heel portion which dips downwards from the central arch portion, and an outer heel portion which extends upwards from the central arch portion, such that the heel portion forms a heel cup configured to contact and support a heel bottom region and a heel side region of said foot. In yet further embodiments, the lateral arch portion and the medial arch portion both extend upwards from the central arch portion, wherein both of said lateral arch and medial arch portions are configured to contact and support a medial bottom region and a medial side region of the foot, respectively. In yet further embodiments, the shoe further comprises a forefoot portion extending from a front side of the rear-foot portion, said forefoot portion configured to contact and support a front bottom and/or toe region of the foot.

In some embodiments, the medial arch comprises an inner portion configured to support a medial flange region of the foot, and outer portion extends outwardly from said inner portion. In further embodiments, the insole comprises a top layer configured to contact the foot, and a base layer below the top layer, wherein said top layer includes said anatomic foot-bed. In yet further embodiments, the insole further comprises a forefoot part extending from a front side of said central arch of said rear-foot part, wherein the top layer includes a forefoot top layer, and wherein the base layer includes a forefoot base layer below the forefoot top layer. In yet further embodiments, the base layer comprises fiberboard or fiberglass.

In some embodiments, the forefoot top layer comprises a cushioning material. In further embodiments, the cushioning material includes Poron® Urethane. In yet further embodiments, the inner heel section extends at least 2 mm below the central arch portion, and wherein the medial arch and lateral arch portions extend at least 3 mm above the central arch portion.

According to various embodiments, disclosed is an insole for a shoe, comprising: a) a top layer having a top-side configured to contact a user's foot and a bottom side, the top layer comprising: i) a rear-foot part including an anatomic foot-bed, the anatomic foot-bed comprising: a central arch portion; a heel portion adjacent an aft side of the central arch portion; a medial arch portion adjacent a medial side of the central arch portion, and which extends upwards with respect to the central arch portion; and a lateral arch portion adjacent to a lateral side of the central arch portion, and which extends upwards with respect to the central arch portion, wherein the anatomic foot-bed is configured to contact and support a bottom and a side region of the foot, and wherein an outer region of the rear-foot part is firmer than an inner region of the rear-foot part; and ii) a forefoot part extending from a front side of the central arch portion of the rear-foot part; and b) a base layer affixed to the bottom side of the top layer.

In some embodiments, the heel portion includes an inner heel section which dips downwards with respect to the central arch portion. In further embodiments, the heel portion further includes an outer heel section which extends upwards with respect to the central arch portion, such that the heel portion forms a heel cup configured to contact and support a heel bottom region and a heel side region of the foot. In yet further embodiments, the forefoot portion of the top layer comprises Poron®, the base layer comprises fiberboard and/or fiberglass, and wherein the anatomic foot-bed comprises polyurethane. In yet further embodiments, an inner heel section is at least 2 mm below the central arch portion, and wherein the medial arch and lateral arch portions extend at least 2 mm above the central arch portion. In yet further embodiments, an outer heel portion extends above the central arch portion, and wherein the outer heel, medial arch, and lateral arch portions extending above the central arch portion have a higher density than the central arch portion.

According to various embodiments, disclose is a shoe comprising an insole including an anatomic foot-bed atop an insole layer, the shoe produced according to a process comprising: forming the insole by: attaching a forefoot layer atop a forefoot region of the insole layer; injecting a first polymer to an inner rear region of the insole layer and molding the first polymer to form an inner section of an anatomic foot-bed, injecting a second polymer having higher density than the first polymer, to an outer rear region of the insole layer and molding the second polymer to form an outer section of the anatomic foot-bed, said anatomic foot-bed being adjacent to the forefoot region. In embodiments, the insole layer comprises fiberglass; the anatomic foot-bed comprises polyurethane; and the forefoot layer comprises Poron™. In further embodiments, the process for producing the shoe further comprises: providing a last having a bottom profile conforming to a form of the insole; attaching the insole to the last via removable attachment elements; attaching an upper for the shoe to the last via removable attachment elements; affixing a bottom sole layer to a bottom side of the shoe insole; and affixing the upper to the insole including the sole layer.

According to various embodiments, disclosed is a high-heeled shoe, comprising: a shoe sole; an insole; and a shoe heel, wherein said shoe sole includes a top side and a bottom side; wherein the shoe heel is coupled directly or indirectly to the bottom side of the shoe sole; wherein said shoe sole further includes a rearfoot portion and forefoot portion; wherein said insole is affixed to the top side of the shoe sole; wherein the insole includes an anatomic footbed, and wherein the anatomic footbed at least partially overlays the rearfoot portion of said sole.

In embodiments, the high-heeled shoe further comprises: a shoe upper coupled directly or indirectly to the shoe sole on the top side of the shoe sole, forming an internal shoe cavity therewith, wherein the insole is situated within said cavity. In further embodiments, the anatomic footbed includes: a central arch portion; a heel portion adjacent an aft side of the central arch portion; a medial arch portion adjacent a medial side of the central arch portion; and a lateral arch portion adjacent to a lateral side of the central arch portion. In further embodiments, the medial arch portion and the later arch portion both extend upwards with respect to the central arch portion, and wherein the anatomic foot-bed is configured to contact and support a side region of the foot.

In yet further embodiments, the insole comprises a forefoot portion extending from a front side of the central arch portion, and wherein the anatomic footbed is on a rear-foot portion of the insole. In yet further embodiments, the insole comprises a top layer and a base layer, wherein the top layer has a top side and a bottom side, wherein the top side of the top layer is configured to contact a user's foot and includes the anatomic footbed, wherein the base layer has a top side affixed to the bottom side of the top layer. In some embodiments, the high-heeled shoe of claim 48, further comprising a third platform layer beneath a forefoot portion of the base layer. In yet further embodiments, the forefoot portion of the top layer comprises Poron®, the base layer comprises fiberboard and/or fiberglass, and wherein the anatomic foot-bed comprises polyurethane.

In some embodiments, said heel portion includes an inner heel section which dips downwards with respect to the central arch portion. In further embodiments, the heel portion further includes an outer heel section which extends upwards with respect to the central arch portion, such that the heel portion forms a heel cup configured to contact and support a heel bottom region and a heel side region of the foot. In yet further embodiments, the inner heel section is at least 2 mm below the central arch portion, and wherein the medial arch and lateral arch portions extend at least 3 mm above the central arch portion.

According to various embodiments, disclosed is a low or flat heeled shoe, comprising: a shoe sole; and an insole; wherein said shoe sole includes a top side and a bottom side; wherein said shoe sole further includes a rearfoot portion and forefoot portion; wherein said insole is affixed to the top side of the shoe sole; wherein the insole includes an anatomic footbed, wherein the anatomic footbed at least partially overlays the rearfoot portion of said sole. In some embodiments, an outer region of the anatomic footbed is firmer than an inner region of the anatomic footbed. In some embodiments, the anatomic footbed comprises a material of uniform density. In some embodiments, the inner region is thicker and has a softer feel than the outer region.

In some embodiments, the low or flat heeled shoe of further comprises: a shoe upper coupled directly or indirectly to the shoe sole on the top side of the shoe sole, forming an internal shoe cavity therewith, wherein the insole is situated within said cavity. In further embodiments, the anatomic footbed includes: a central arch portion; a heel portion adjacent an aft side of the central arch portion; a medial arch portion adjacent a medial side of the central arch portion; and a lateral arch portion adjacent to a lateral side of the central arch portion.

In further embodiments, the medial arch portion and the later arch portion both extend upwards with respect to the central arch portion, and wherein the anatomic foot-bed is configured to contact and support a side region of the foot. In yet further embodiments, the insole comprises a forefoot portion extending from a front side of the central arch portion, and wherein the anatomic footbed is on a rear-foot portion of the insole. In yet further embodiments, the insole comprises a top layer and a base layer, wherein the top layer has a top side and a bottom side, wherein the top side of the top layer is configured to contact a user's foot and includes the anatomic footbed, wherein the base layer has a top side affixed to the bottom side of the top layer. In yet further embodiments, the low or flat-heeled shoe further comprises a third platform layer beneath a forefoot portion of the base layer. In yet further embodiments, the forefoot portion of the top layer comprises Poron®, the base layer comprises fiberboard and/or fiberglass, and wherein the anatomic foot-bed comprises polyurethane.

In some embodiments, said heel portion includes an inner heel section which dips downwards with respect to the central arch portion. In yet further embodiments, the heel portion further includes an outer heel section, which extends upwards with respect to the central arch portion, such that the heel portion forms a heel cup configured to contact and support a heel bottom region and a heel side region of the foot. In yet further embodiments, the inner heel section is at least 2 mm below the central arch portion, and wherein the medial arch and lateral arch portions extend at least 3 mm above the central arch portion.

BRIEF DESCRIPTION OF THE DRAWINGS

The present subject matter will now be described in detail with reference to the drawings, which are provided as illustrative examples of the subject matter so as to enable those skilled in the art to practice the subject matter. Notably, the FIGs and examples are not meant to limit the scope of the present subject matter to a single embodiment, but other embodiments are possible by way of interchange of some or all of the described or illustrated elements and, further, wherein:

FIG. 1A is a plan view of an insole, in accordance with various embodiments of the present disclosure (elevation and depression lines are included in the figure for illustrative purposes);

FIG. 1B is a plan view of a bottom of a foot, illustrating various foot regions corresponding to the support portions of the insole of FIG. 1A, according to various embodiments;

FIG. 1C is a perspective view of the foot of FIG. 1B;

FIG. 2 illustrates the insole of FIG. 1A, configured for a high heeled shoe, in accordance with various embodiments;

FIG. 3 shows a high heeled shoe including the insole of FIG. 2, in accordance with various embodiments;

FIG. 4 is an exploded view of the insole of FIG. 2, in accordance with various embodiments;

FIG. 5 illustrates the insole of FIG. 1B, configured for a low heeled or flat shoe, in accordance with various embodiments;

FIG. 6 shows a low or flat heeled shoe including the insole of FIG. 5, in accordance with various embodiments;

FIG. 7 is an exploded view of the insole of FIG. 5, in accordance with various embodiments;

FIG. 8 outlines a method for producing the insole of FIG. 1, in accordance with various embodiments;

FIG. 9 illustrates a production step for the method shown in FIG. 8, relating to the production of an insole for a high heeled shoe according to various embodiments;

FIG. 10 illustrates a production step for the method shown in FIG. 8, relating to the production of an insole for a low heeled or flat heeled shoe according to various embodiments;

FIG. 11 outlines a method of manufacture for a high heeled shoe, incorporating the insole produced via the method outlined in FIG. 8, according to various embodiments;

FIGS. 12-15 illustrate various method step(s) and equipment used for the method of FIG. 11, in accordance with various embodiments;

FIG. 12 illustrates the steps of providing a last and attaching the insole to the last, in accordance with various embodiments;

FIG. 13 illustrates the steps for attaching an upper to the insole, in accordance with various embodiments;

FIG. 14 illustrates the steps for attaching a shoe heel, in accordance with various embodiments;

FIG. 15 illustrates the steps for attaching an outsole, in accordance with various embodiments;

FIG. 16 outlines a method of manufacture for a low or flat heeled shoe, incorporating the insole produced incorporating the insole produced via the method outlined in FIG. 8, according to various embodiments;

FIGS. 17-19 illustrate various method step(s) and equipment used for the method of FIG. 16, in accordance with various embodiments;

FIG. 17 illustrates the steps of providing a last and attaching the insole to the last, in accordance with various embodiments;

FIG. 18 illustrates the steps for attaching an upper to the insole, in accordance with various embodiments; and

FIG. 19 illustrates the steps for attaching an outsole, in accordance with various embodiments.

While the disclosure is subject to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and the accompanying detailed description. It should be understood, however, that the drawings and detailed description are not intended to limit the disclosure to the particular embodiments. This disclosure is instead intended to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The detailed description set forth below in connection with the appended drawings may be intended as a description of exemplary embodiments in which the presently disclosed process can be practiced. The term “exemplary” used throughout this description means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description includes specific details for providing a thorough understanding of the presently disclosed method and system. However, it will be apparent to those skilled in the art that the presently disclosed process may be practiced without these specific details. In some instances, well-known structures and devices are shown in block diagram form in order to avoid obscuring the concepts of the presently disclosed method and system.

In the present specification, an embodiment showing a singular component should not be considered limiting. Rather, the subject matter preferably encompasses other embodiments including a plurality of the same component, and vice-versa, unless explicitly stated otherwise herein. Moreover, applicants do not intend for any term in the specification or claims to be ascribed an uncommon or special meaning unless explicitly set forth as such. Further, the present subject matter encompasses present and future known equivalents to the known components referred to herein by way of illustration. Although the device(s), system(s), and method(s) here disclosed have been described in detail herein with reference to the illustrative embodiments, it should be understood that the description may be by way of example only and may be not to be construed in a limiting sense. It may be to be further understood, therefore, that numerous changes in the details of the embodiments of the disclosure will be apparent to, and may be made by, persons of ordinary skill in the art having reference to this description. It may be contemplated that all such changes and additional embodiments are within the spirit and true scope of this disclosure as claimed below. Additionally, the terms “about” or “approximately” imply a +/−10% variance with respect to a stated value.

According to various embodiments, disclosed is a footwear stability and comfort system (footwear system) including an insole and various footwear, such as low or flat-heeled shoes, and high heeled shoes, incorporating the insole.

In embodiments, the insole of the system incorporates an anatomic footbed designed to provide a cradle around the bottom and sides of the foot for support during flexion while walking, and for proper placement of the foot within the shoe.

To this end, the anatomic footbed may include a heel cup, configured to provide medial and lateral foot stably and to control supination and pronation of the foot. This may give the user a more even gait and help to prevent potential injury (sprain, twist, tear, or break) associated with over-pronation or over-supination the foot. The anatomic footbed may further include support at the medial and lateral arches, which follows the natural contours of the foot, and provides a wider surface area for support and contact with the foot.

In embodiments, the insole may comprise flexible and resilient materials, which provide an even dispersion of weight across the foot, for reducing pressure at the metatarsal and absorbing shock, amongst other benefits. In embodiments, such materials may include flexible polyurethane for construction of the anatomic footbed. Such materials may further include a layer of cushioning in the toe box, such as foam or Poron®, which is an open-cell foam. The materials are further breathable and flexible, and conform to the shape of the foot during wear, while retaining their original shape after each use.

Thus, the disclosed system provides a combination of features which together distribute the user's weight more evenly across the foot, provide essential support and stability, and position the users foot correctly within the shoe. The disclosed footwear system further provides enhanced comfort and the ability to wear shoes without pain or fatigue, for significantly longer than conventional footwear, amongst other benefits disclose.

As shown in FIGS. 1-7, a footwear system 100 in accordance with disclosed embodiments, may comprise an insole 102 incorporating an anatomic footbed 104. The footbed 104 may form at least a portion of a rearfoot support 127 of the insole 102, wherein the rearfoot support 127 is configured to generally support a rearfoot region 128 of a user's foot 101. (See FIGS. 1B and C)

In embodiments, the insole 102 may further comprise a forefoot support 129, configured to generally support a forefoot region 133 of the foot 101, wherein the forefoot support 129 may extend from a front side 131 of the rearfoot support 127 and/or anatomic footbed 104 of the insole 102.

According to various embodiments, the insole 102 may comprise a top layer 103. In some embodiments, the insole 102 may further comprise a base layer 105 beneath the top layer 103, wherein a bottom side 109 of the top layer 103 may be affixed to a top side 107 of the base layer 105.

The top layer 103 may include a rearfoot top section 139, configured to support the rearfoot region 128 of the user's foot 101, wherein the rearfoot top section 139 may comprise the anatomic footbed 104. In embodiments, the top layer 103 may further include a forefoot top section 141 extending from the rearfoot top section 139 and/or anatomic footbed 104. In embodiments, the forefoot top section 141 may comprise a cushioned and/or shock-absorbing layer, for providing cushioned support to the forefoot region 133 or metatarsal area of the foot 101.

In embodiments, base layer 105 may include a rearfoot base section 143, beneath the rearfoot top section 139, and may further include a forefoot base section 145 beneath the forefoot top section 141. In embodiments, the rearfoot base section 143 and forefoot base section 145 of the base layer 105 may be a unitary piece extending beneath the top layer 103. Although the rearfoot top section 143/anatomic footbed 104 is formed over a top side of the rearfoot base section 143, in some embodiments, a material used in forming the anatomic footbed 104 may also coat a bottom side of the rearfoot base section 143.

According to various embodiments, the rearfoot support 127 may be angled from 0° about 90° with respect to the forefoot support 129. For example, in a high heeled shoe, the rearfoot support 127 may be angled slightly less than 90° to about 20° with respect to the forefoot support 129 (see FIG. 2) in order to accommodate an elevated heel structure of the shoe; and in a substantially flat shoe the rearfoot support 127 may be generally in line with the forefoot support 129 (see FIG. 5).

In some embodiments, the insole may further include a platform layer 111 beneath the forefoot base section 145. The platform layer 111 may be particularly suitable for use with an insole for a high-heeled shoe, as it may flatten the pitch and/or reduce the effective height of the shoe for greater comfort to the wearer.

In some embodiments, the rearfoot region 128 and/or anatomic footbed 104 may include an outer section which is firmer than an inner section of the rear-foot portion. This may be particularly beneficial for a flat and/or low-heel shoe, a more weight/pressure is placed on the rearfoot and heel regions.

Anatomic Footbed 104

With particular reference to FIG. 1A, the anatomic footbed 104 may comprise a central arch portion 106, a heel portion 108 adjacent back side 110 of the central arch portion 106, a medial arch portion 112 adjacent a medial side 114 of the central arch portion 106; and a lateral arch portion 116 adjacent to a lateral side 118 of the central arch portion 106, according to various embodiments. (The medial arch portion 112 may include an inner portion 113 configured to support a medial flange region 151 of the foot 101, and an outer portion 115 corresponding to a first metatarsal region 153 of the foot 101). The central arch, heel, medial arch, and lateral arch portions (i.e. 106, 108, 112, and 116, respectively) may approximately correspond to and/or be configured to support and/or contact a central arch region 120, a heel region 122, a medial arch region 124, and lateral arch region 126 of the foot 101, respectively.

In embodiments, the anatomic footbed 104 is contoured to contact and orthopedically support the bottom 160 of the foot 101. In further embodiments, the footbed 104 may also be configured to contact and support side region(s) 162 of the foot 101 for medial, lateral, and/or torsional stability, and to control supination and pronation of the foot.

To this end, the footbed may include at least one raised region 130, which extends upwards with respect to the central arch portion 106. In embodiments, the at least one raised region 130 may include the medial arch portion 112, the lateral arch portion 116, or both. In embodiments, the at least one raised region 130 may include at least a part of the heel portion 108, which may be an outer heel section 132 of the heel portion 108. Additionally, the at least one raised region 130 may extend to the side region(s) 162 of the foot 101, to provide support to the sides of the foot extending from the medial arch region 124, the lateral arch region 126, and/or heel region 122. Thus, the raised region 130 may be advantageous in providing foot stability, and controlling supination and pronation of the foot.

In embodiments, the footbed 104 may further include at least one depressed region 134, which dips downwards with respect to the central arch portion 106 (see FIG. 1A). In embodiments, the at least one depressed region 134 may include at least a part of the heel portion 108, which may be an inner heel section 136. According to various embodiments, the inner heel section 136 may be depressed, and the outer heel section 132 may be elevated to form a heel cup. In embodiments, the outer heel section 132 may be configured to at least partially contact and support a heel side region 164 of the foot 101. Thus, the heel cup may provide lateral stability, as well as control supination and pronation of the foot 101.

According to various embodiments, the elevation and/or depression of the at least one raised region 130 and/or at least one depressed region 134 may follow a general curvature/counter of the human foot. In some embodiments, the elevation and/or depression from the central arch portion 106 may be gradual and steady. In some embodiments, the elevation may include a sharp rise around the side region(s) 162 of the foot 101.

The elevated/depressed region(s) may be described with reference to elevation lines 138, 140, 142, 144, 146, and 148, and depression lines 150, 152, 154, and 156, which are provided in FIG. 1A for purpose of illustration.

In embodiments, the elevation increase for each elevation line may be between about 1 mm and 5 mm, or between about 1.5 mm and 4.5 mm, or between about 2 mm and 4 mm, or about 2 mm, or about 3 mm. According to one embodiment, which may be an insole for a high heeled shoe for example, the elevation lines may follow a gradual and steady rise, wherein the elevation of line 138 may be approximately 3 mm above central arch portion 106, the elevation of line 140 may be approximately 6 mm above central arch portion 106, the elevation of line 142 may be approximately 9 mm above central arch portion 106, the elevation of line 144 may be approximately 12 mm above central arch portion 106, the elevation of line 146 may be approximately 15 mm above central arch portion 106, and the elevation of line 148 may be approximately 18 mm above central arch portion 106.

According to another embodiment, which may be an insole for a low heeled or flat shoe, for example, the elevation lines may follow a gradual and steady rise, wherein the elevation of line 138 may be approximately 2 mm above central arch portion 106, the elevation of line 140 may be approximately 4 mm above central arch portion 106, the elevation of line 142 may be approximately 6 mm above central arch portion 106, the elevation of line 144 may be approximately 8 mm above central arch portion 106, the elevation of line 146 may be approximately 10 mm above central arch portion 106, and the elevation of line 148 may be approximately 12 mm above central arch portion 106.

In embodiments, the dip for each depression line may be between about 1 mm and 3 mm, or about 2 mm, or about 1 mm, or less than 1 mm. According to an exemplary embodiment, depression line 150 may dip approximately 2 mm below the central arch portion 106, line 152 may dip approximately 4 mm below central ach portion 106, line 154 may dip approximately 5 mm below central ach portion 106, and line 156 may also dip approximately 5 mm below central ach portion 106.

According to various embodiments, the inner heel section 136 may be at least 2 mm below the central arch portion 106; and the medial arch portion 112, lateral arch portion 116, and/or outer heel section 132 may extend at least 2 mm, or at least 3 mm above the central arch portion.

In embodiments, which may include an insole for a high heeled shoe, for example, the raised region 130 may have a total maximum rise (i.e. from the central arch portion 106 to an outer edge 158 of the insole 102) of at least about 6 mm, or about 9 mm, or about 12 mm, or 15 mm, or about 18 mm, or about 20 mm. In various embodiments, which may include an insole for a low or flat heeled shoe, for example, the total maximum rise of the raised region 130 may at least about 4 mm, or about 6 mm, or about 8 mm, or 10 mm, or about 12 mm, or about 15 mm.

According to various embodiments, the raised region may extend higher for an insole for a high heeled shoe, than for a low or flat heeled shoe. For example, the total maximum raise may be at least 15 mm, or at least about 18 mm, or at least about 20 mm for an insole for a high heeled shoe; and at least about 10 mm, or at least about 12 mm, or at least about 14 mm for an insole for a low heeled or flat shoe.

In embodiments, the medial arch portion 112 may extend higher than the lateral arch portion 116 and the heel portion 108. For example, in a high heeled shoe, the medial arch portion 112 may extend to a maximum height of about 20 mm, while the lateral arch portion 116 and the heel portion 108 may extend to a maximum height of about 15 mm. Or, in a low or flat heeled shoe, the medial arch portion 112 may extend to a maximum height of about 14 mm, while the lateral arch portion 116 and the heel portion 108 may extend to a maximum height of about 10 mm.

In embodiments, the depressed region 134 may have a total maximum depression (i.e. from the central arch portion 106 to a lowest point of the insole 102, which may be in the inner heel section 136) of at least about 3 mm, or at least about 4 mm, or at least about 5 mm. In embodiments, the total maximum depression may be about 5 mm.

In embodiments, a ratio of the rise over a cross length 166 (based on the shortest path between adjacent elevation lines in FIG. 1A) for the raised region 130 may be between about 3:2 and 2:3. For example, this ratio may be about 1:1 for an insole for a high heeled shoe; or about 2:3 for an insole for a low heeled or flat shoe. In embodiments, a ratio of the dip over a cross length 168 (based on the shortest path between adjacent depression lines in FIG. 1A) for the depressed region 134 may be about 2:3, or about 1:3, or less than 1:3.

Materials/Compositions

According to various embodiments, the rearfoot top section 139 and/or anatomic footbed 104 may be formed from various moldable a materials such as curable and/or thermosetting elastomers, polymers, plastics, and the like. In some embodiments, the footbed 104 may be formed from a polyurethane. In embodiments, the footbed may be formed from a material such as a polyurethane having a density of less than 1 g/cc. In some embodiments, the polyurethane may have a density of less than about 5 g/cc. In some embodiments, the material may have a density of between about 0.20 g/cc and about 0.30 g/cc. For example, for a flat and/or low heel shoe, the anatomic footbed 104 may comprise a Polyurethane having a density of between about 0.28 g/cc and 0.30 g/cc. As another example, for a high heeled shoe, the anatomic footbed 104 may comprise a Polyurethane having a density of between about 0.20 g/cc and 0.22 g/cc.

According to various embodiments, the footbed 104 may have a degree of hardness ranging from soft to medium hard, or from medium soft to medium hard. In some embodiments, the hardness of footbed 104 may be on average Shore A of about 36. In some embodiments, the hardness of footbed 104 may be on average shore D of about 21. In some embodiments, a Shore hardness of the footbed may range from a (Durometer) Shore A of about 30 to a Shore A of about 80; or from a Shore A of about 30 to a Shore D of about 30. In some embodiments, the footbed hardness for the insole of a high-heeled shoe may be medium hard and/or range from a Shore D of about 10 to a Shore D of about 30, or from a Shore D of about 15 to a Shore D of about 25. In embodiments, the footbed hardness for the insole of a high heeled shoe may be a Shore D of about 20 to about 22, or at about Shore D 21. Such degree of hardness for the footbed, including raised regions of the footbed, may be particularly advantageous in providing additional stability to the foot including side regions of the foot, and in preventing pronation/supination of the foot. In some embodiments, a degree of the footbed hardness for an insole for a low and/or flat-heeled shoe may be soft to medium soft and/or range from a Shore A of about 25 to about 45, or from a Shore A of about 30 to about 40, or have a Shore A of about 35 to about 37, or about Shore A 36. As more weight is placed at the rearfoot region of a low/flat heeled shoe, a softer material of the footbed 104 may be advantageous in providing increased cushioning. In some embodiments, the footbed 104 of the insole for a low and/or flat-heeled shoe may have a higher degree of hardness at the outer and/or side/raised regions than at the inner region supporting the bottom of the foot. For example, the outer region may have a hardness ranging from a Shore D of about 10 to a Shore D of about 30, while the inner region may have a hardness ranging from a Shore A of about 25 to about 45, according to various embodiments. This may be advantageous as the a harder material at the outer regions provides support for the sides of the foot, while the softer material at the inner region provides increased cushioning for the bottom of the foot.

In embodiments, the forefoot top section 141 may comprise a layer of a cushioned material, such as for example, rubber, foam, sponge, gel and the like. In embodiments, the material may be resistant to deformation. In embodiments, the layer may be a foam, such as a urethane foam and/or an open cell foam, such as Poron® Foam. In embodiments, such material may have a specific gravity of less than 1, or less than about 0.5, or less than about 0.4, or about 0.32, or about 0.27, or about 0.24. As a non-limiting example, the forefoot top section 141 may comprise a layer of Poron® foam having a thickness 170 of between about 0.5 mm and 5.5 mm, or between about 1.5 mm and 4.5 mm, or between about 2 mm and 4 mm, or about 3 mm.

The base layer 105 may comprise an insole structure layer to support and/or hold the shape of the insole 102. In embodiments, base layer 105 may comprise a fiberboard (i.e. cardboard) and/or a fiberglass layer. In embodiments, the layer 105 may have a rigid frame, such as a metal frame. In other embodiments, a metal frame need not be included. An example of a suitable material may include Texan®. In embodiments, the layer 105 may be a unitary structure comprising both the rearfoot base section 143 and the forefoot base section 145. In embodiments, the rearfoot base section 143 may be angled obtusely or at about 90° with respect to the forefoot base section 145 to accommodate an elevated structure of a heeled shoe (see FIG. 2). In this embodiment, a fiberboard with metal frame may be used to retain the angled structure. In other embodiments, the rearfoot base section 143 and forefoot base section 145 may be in line. According to various embodiments, a thickness 172 of the base layer 105 may be between about 0.5 mm and 4 mm, or between about 1 mm and 3 mm, or between about 1.5 mm and 2 mm, or about 1.7 mm.

In embodiments, the platform layer 111, may be included in an insert for a high heeled shoe, to reduce the effective height of the shoe (see FIGS. 2 and 4). In embodiments, the layer 111 may comprise a rigid, shock absorbing, and/or cushioning material. For example, layer 111 may comprise plastic, rubber, cork, foam, gel, and the like, according to various embodiments. The thickness 174 of the platform layer 111 may depend on the desired height or height reduction for the shoe. For example, the thickness may be at least about 3 mm, or at least about 5 mm, or at least about 8 mm, or at least about 10 mm, according to various embodiments. For example, for a shoe having a heel of about 105 mm, the thickness 174 of the platform layer 111 may be approximately 6 mm. In some embodiments, the platform may be slightly thinner near the front side of the shoe.

High Heeled Shoe

FIG. 3 illustrates a high-heeled shoe 200, incorporating the insole 102, according to an exemplary embodiment.

As shown, the high heeled shoe 200 may comprise a shoe outer sole 202 (outsole) including a top side 204 and a bottom side 206; a rearfoot portion 208 and a forefoot portion 210; and a shoe heel 214, which may be coupled directly or indirectly to the bottom side 206 of the shoe sole 202. In embodiments, the insole 102 including anatomic footbed 104 may be affixed, either directly or indirectly, to the top side 204 of the shoe outer sole 202, such that the anatomic footbed 104 at least partially overlays the rearfoot portion of the sole 202. In some embodiments, the high heeled shoe 200 may further comprise a shoe upper 212 coupled directly or indirectly to the shoe sole 202 on the top side 204 of the shoe sole, forming an internal shoe cavity 214 therewith, such that the insole 102 is situated within the cavity 214. In embodiments, the shoe upper 212 may comprise a leather and/or synthetic material.

In some embodiments, the insole 102 may include a platform layer 111 to reduce the pitch or effective height of the shoe, according the thickness 174 of the platform layer, as shown in FIGS. 2 and 3. Additionally, the rearfoot support 127 of the insole 102 may be obtusely angled or substantially perpendicular to the forefoot support 129 of the insole 102, in order to accommodate the relative elevation of the rearfoot support 127 due to the heel 214 of the shoe 200, as shown in FIGS. 3-4.

According to an exemplary embodiment, the high heeled shoe 200 may have a shoe heel of about 105 mm in height; a medial arch portion 112 which is raised up to 20 mm on the outer edge of the medial side of the footbed 104; a lateral arch portion 116 which is raised up to 15 mm on the outer edge of the later side of the footbed; and a heel portion 108 which is raised up to 8 mm on the outer edge of the heel side of the footbed. The forefoot top section 141 of the exemplary shoe comprises a Poron® foam layer having a thickness of 3 mm; the base layer comprises a cardboard having a thickness of 1.7 mm; and the platform layer 111 has a thickness of 6 mm.

Low Heeled or Flat Shoe

FIG. 6 illustrates a low or flat heeled shoe 300, incorporating the insole 102, which may have a heel of an inch or less, or no heel, according to an exemplary embodiment.

As shown, the shoe 300 may comprise a shoe outer sole 302 (outsole) including a top side 304 and a bottom side 306; and a rearfoot portion 308 and a forefoot portion 310. In embodiments, the insole 102 including anatomic footbed 104 may be affixed, either directly or indirectly to the top side 304 of the shoe outer sole 302, such that the anatomic footbed 104 at least partially overlays the rearfoot portion 308 of the outer sole 302. In some embodiments, the shoe 300 may further comprise a shoe upper 312 coupled directly or indirectly to the shoe sole 302 on the top side 304 of the shoe sole, forming an internal shoe cavity 314 therewith, such that the insole 102 is situated within the cavity 314.

In some embodiments, the anatomic footbed 104 of the insole 102 may an outer region which is firmer than an inner region of the anatomic footbed. Additionally, the rearfoot support 127 of the insole 102 may be substantially in line with the forefoot support 129 of the insole 102, as shown in FIGS. 5 and 6.

Manufacturing Method for Insole

As illustrated in FIG. 8, a method 400 for manufacturing the insole 102 of the footwear system 100 may comprise providing a base layer forming the base shape of the insole (step 402), wherein the base layer comprises a rearfoot section. In embodiments, the base layer may further comprise a forefoot section. In embodiments, method 400 may further comprise attaching a forefoot support section to a top side of the base layer at the forefoot section of the base layer (step 404). In embodiments, method 400 may further comprise molding an anatomic footbed to the top side of the base layer at the rearfoot section of the base layer a (step 406). In some embodiments, the material used to mold the anatomic footbed 104 may also form a coating on the bottom side of the base layer 105 during the molding process. In some embodiments, the method 400 may further comprise attaching a platform layer to a bottom side of the base layer, at the forefoot section of the base layer (step 408). According to various embodiments, step 408 may be applicable to the production of an insert for a high heeled shoe, wherein the platform may reduce the effective height of the shoe.

In embodiments, the base layer may comprise fiberglass or fiberboard. In some embodiments the base layer may also include a metal frame. In some embodiments, the base layer may include a rearfoot section which is angled obtusely with respect to the forefoot section. In other embodiments, the base layer may include a rearfoot section which is in line with the forefoot section, and thus the base layer may have a flat shape.

In embodiments, attaching a forefoot support section according to step 404 may comprise various methods of adhesion or bonding (e.g. gluing, nailing, etc.). In embodiments, the forefoot support section may comprise a layer of a cushioned material, such as for example, rubber, foam, sponge, and the like. In embodiments, the layer may be a foam, such as a urethane foam and/or an open celled foam, such as Poron® Foam.

In embodiments, step 406 may comprise injecting at least one molten material onto the top rearfoot region of the base layer, then molding and curing the material to form the footbed shape. The material may comprise, for example, a thermoplastic and/or thermosetting polymer. According to various embodiments, the material may comprise polyurethane. In embodiments, step 406 may comprise injecting a first polymer to an inner rear region of the insole layer and molding the first polymer to form an inner section of an anatomic foot-bed, and injecting a second polymer having higher density than the first polymer, to an outer rear region of the insole layer and molding the second polymer to form an outer section of the anatomic foot-bed.

FIGS. 9 and 10 illustrate a partially formed insert (i.e. comprising the base layer 105 with the forefoot top section 141 attached to the top side of the base layer) within a mold injecting apparatus 500. The insert shown in FIG. 9 has a rearfoot section (i.e. rearfoot support 127) which is angled obtusely with respect to the forefoot section (i.e. forefoot support 129), and may be suitable for a high heeled shoe. The insert shown in FIG. 10 is substantially flat and may be suitable for a low heeled or flat shoe.

As shown in the figure, the mold injecting apparatus 500 may include a holding component 502 for holding the base layer and/or partially formed insert, and a molding component 504 for forming the footbed shape by pressing the molding component into the molten material to form the shape of the footbed 104.

Manufacturing Method for a High Heeled Shoe

FIG. 11 outlines a method 600 for manufacturing a high heeled shoe (e.g. shoe 200) comprising the insole 102. In embodiments, the insole 102 may be manufactured according to steps 402, 404, 406, and 408 of method 400.

According to various embodiments, method 600 may comprise affixing an upper of the shoe to the insole 102 (step 602). This may include providing a last having a bottom profile conforming to the top layer of the insole 102 (step 604), wherein the bottom profile of the last may correspond to the elevation of the shoe heel less the thickness of the platform layer of the insole 102; attaching the insole to the last via removable attachment elements (step 605); placing an upper for the shoe on the last, which may comprise using removable attachment elements to hold the upper to the last (step 606); applying adhesive/glue to a bottom side of the insole 102; and pulling the upper to extend over the bottom side of the insole to affix it to the insole (step 608).

In embodiments method 600 may further comprise affixing a shoe heel to a bottom side of the unfinished shoe (step 610). This may include nailing the heel to the bottom side of the shoe (which has been removed from the last) by driving nails through the top side of the insole 102 and through the bottom side to firmly attach the shoe heel. In embodiments, nailing the heel may comprise attaching the shoe heel via high temperature fused thermoplastic and/or a screw to keep the heel in place prior to nailing the heel (The thermoplastic solidifies and functions as a powerful glue to hold the heel); and pushing a few (e.g. 3-6) nails obliquely through the insole and shoe heel in order to fix the heel firmly to the shoe. Both the nails and screw may be inserted via an air pressure machine. The nails should be long enough to pass through the insole and heel, and need to be inserted at an angle so as not to break through the sides of the heel.

In embodiments, method 600 may further comprise attaching an outsole to the bottom of the unfinished shoe (step 612). This may comprise gluing the outsole to the bottom of the shoe (step 614) wherein the bottom of the shoe may be rasped to gain traction with the glue prior to gluing the outsole. In embodiments, attaching the outsole may further comprise pressing the outsole to the bottom of the shoe (step 616) once the glue has dried. This may be done using a press machine or manual hammering. In embodiments, reinserting the shoe in the last may facilitate attachment of the outsole. In embodiments, the outsole may comprise rubber or other high friction material to prevent slipping.

FIGS. 12-14 illustrates various steps and equipment which may be used in carryout out method 600.

FIG. 12 illustrates providing a last 620 and attachment of the insole 102 to the last 620, according to steps 604 and 605. In embodiments, a bottom 621 of the last 620 has a profile corresponding to the top layer 103 of the insole 102. In embodiments, the elevation of the bottom 621 of the last 620 may be reduced according to the thickness 174 of the platform 111 layer of the insole 102. For example, for a shoe having a shoe heel height of about 105 mm, the height of the last may be about 96 mm. Additionally, according to various embodiments, the last 620 is sized and shaped with the goal of providing a comfortable and supportive shoe including a toe box which allows the toes to spread and provide a wide and stable base on which to walk. To this end, a forepart 622 of the last may be sized to produce a shoe with enough room for the ball of the foot to comfortably fit, while a topline 624 of the last 620 may be sized to produce a shoe which is sufficiently tight to hold the foot in place.

FIG. 13 illustrates the placement of the upper (e.g. upper 212) and the gluing of the upper to the insole according to steps 606 and 608. In embodiments, glue may be applied to the bottom 607 of the insole 102, then the upper may be pulled over the insole for attachment to the bottom of the insole to produce a partially formed shoe 626 comprising the attached upper and insole.

FIG. 14 illustrates the attachment of the shoe heel (e.g. heel 214) according to step 610. As shown, nails 628 may be inserted through the top layer 103 of the insole 102 to firmly attach the heel to the partially formed bottom 613 of the shoe. This may be done using a high air pressure machine 630. In embodiments, high temperature fused thermoplastic and/or a screw may keep the heel in place so that the nails 628 may be inserted. The nails are pushed obliquely (at an angle, as shown) through the insole and the heel in order to fix the heel firmly to the bottom 613. In embodiments, a decorative layer or liner may be placed over the insertion site to cover up the nails, once the shoe is finished and reading for detailing. In embodiments, this may comprise attaching a non-slip liner to at least a portion of the top layer 103.

FIG. 15 illustrates attachment of an outsole 632 (or sole outer 202), according to step 612, and including steps 614 and 616. As shown, the last 620 may be reinserted for completing these steps. In embodiments, the outsole 632 may be glued to the bottom 613, which may be rasped all around to gain traction with the glue. In embodiments, the bottom 613 The outsole 632 is shaped to substantially cover the bottom of the shoe and may include an outsole heel portion 634 shaped to cover a front facing side 638 of the shoe heel 214, as shown in the figure. In embodiments, glue may be applied throughout the full surface(s) of the shoe bottom 613 and/or outsole 632. Thereafter, (once the glue has dried) the outsole may be pressed into the shoe bottom through a press machine and/or manually via hammering. The last may then be removed, and the shoe may be ready for finishing and detailing.

Manufacturing Method for a Low or Flat Heeled Shoe

FIG. 16 outlines a method 700 for manufacturing a low or flat heeled shoe (e.g. shoe 300) comprising the insole 102. In embodiments, the insole 102 may be manufactured according to steps 402, 404, and 406 of method 400.

According to various embodiments, the method 700 may comprise affixing an upper of the shoe to the insole 102 (step 702). This may comprise providing a last having a bottom profile conforming to the top layer of the insole 102 (step 704); attaching the insole to the last via removable attachment elements (step 705); placing an upper for the shoe on the last, which may comprise using removable attachment elements to hold the upper to the last (step 706); applying adhesive/glue to a bottom side of the insole 102 (step 707); and pulling the upper to extend over the bottom side of the insole to affix it to the insole (step 708).

In embodiments, method 700 may further comprise attaching an outsole to the unfinished shoe (step 710). This may comprise gluing the outsole to the bottom of the shoe (step 711) wherein the bottom of the shoe may be rasped to gain traction with the glue prior to fully gluing the outsole to the bottom of the shoe. In embodiments, attaching the outsole may further comprise pressing the outsole to the bottom of the shoe (step 712) once the glue has dried. This may be done using a press machine or manual hammering.

FIGS. 17-19 illustrate various steps and equipment which may be used to carry out method 700.

FIG. 17 illustrates attachment of the insole 102 to a last 800, suitable for the manufacturing the shoe 300, according to steps 704 and 705. The insole may be temporarily attached via tape and/or temporary nails, for example. In embodiments, the last 800 may comprise a forepart region 802 and a footbed region 804. Preferably, the forepart region 802 is designed to provide comfort and enough room for the toes and ball of the foot to stand and walk comfortably. The footbed region 804 may generally conform to a profile of the footbed 104 of the insole 102.

FIG. 18 illustrates attachment of a shoe upper (e.g. upper 312) to the insole 102, including the placement of the upper (e.g. upper 312) and the gluing of the upper to the insole 102 according to steps 706 and 707. In embodiments, glue may be applied to the bottom 607 of the insole 102, then the upper 312 may be pulled over the insole for attachment to the bottom of the insole to produce a partially formed shoe 726 comprising the attached upper and insole.

FIG. 19 illustrates attachment of an outsole 732 (or outer sole 302), according to step 710, and including steps 711 and 712. As shown, the last 800 may remain inserted for completing these steps. In some embodiments, the outsole 732 may include a short heel section 736 at a rear bottom side of the outsole 732. In embodiments, the outsole 732 may be glued to the bottom 713 of the partially formed shoe 726, which may be rasped all around to gain traction with the glue. In embodiments, the outsole 732 is shaped to substantially cover the bottom 713 of the shoe, as shown in the figure. In embodiments, glue may be applied throughout the full surface(s) of the shoe bottom 713 and/or outsole 732. Thereafter, (once the glue has dried) the outsole may be pressed into the shoe bottom through a press machine and/or manually via hammering. The last may then be removed, and the shoe may be ready for finishing and detailing.

In embodiments, the shoe may be finished and/or detailed by applying various decorative layers and/or attachments. For example, a sheet layer may overlay at least a portion of the footbed on the top layer to cover up seams, discontinuities, holes (e.g. from insertion of nails), and the like.

The detailed description set forth herein in connection with the appended drawings may be intended as a description of exemplary embodiments in which the presently disclosed subject matter may be practiced. The term “exemplary” used throughout this description means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments.

This detailed description of illustrative embodiments includes specific details for providing a thorough understanding of the presently disclosed subject matter. However, it will be apparent to those skilled in the art that the presently disclosed subject matter may be practiced without these specific details. In some instances, well-known structures and devices are shown in block diagram form in order to avoid obscuring the concepts of the presently disclosed apparatus.

The foregoing description of embodiments may be provided to enable any person skilled in the art to make and use the subject matter. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the novel principles and subject matter disclosed herein may be applied to other embodiments without the use of the innovative faculty. The claimed subject matter set forth in the claims may be not intended to be limited to the embodiments shown herein, but may be to be accorded the widest scope consistent with the principles and novel features disclosed herein. It may be contemplated that additional embodiments are within the spirit and true scope of the disclosed subject matter.

Footwear Stability and Comfort System

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