INSOLE

Abstract

There is described an insole comprising a flexible base and a reinforcing member arranged within the base. The insole may be an orthotic insole. The insole can be used for treating fallen arches, flat feet, plantar fasciitis and pronation problems.

Description

CROSS REFERENCE TO RELATED PATENT APPLICATIONS

This application claims the benefit of and priority to Great Britain Application No. 1812816.5 filed on Aug. 7, 2018.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to an insole. More specifically, the present invention relates to a cut-to-size orthotic insole.

Insoles form the interior bottom of a shoe. They provide the surface of the shoe on which the foot is placed. The insole may be a removable insole added to the shoe to provide a desired characteristic, such as extra cushioning or support.

Orthotic removable insoles can provide support for conditions such as fallen arches, flat feet, plantar fasciitis and pronation problems, for example. The use of silicone in an insole can provide a high level of cushioning compared to other materials. However, silicone can suffer from lower durability. It is desirable to improve the durability of silicone insoles whilst maintaining a high level of cushioning.

Furthermore, for orthotic insoles to function effectively, the insole must form a good fit within the shoe, such that the insole is held in the desired position in use.

The size of an insole varies depending on the shoe size. The cost effective way to produce removable insoles is to make a single large size insole and allow for a portion of the insole to be cut so that the size of the insole can be reduced to the desired size by the end user. However, it has been found that cutting an insole can undermine the structural integrity of the insole. This can mean that the immediate functioning of the insole is diminished or the effective lifetime of the insole reduced.

Therefore, there is a requirement for an insole having a high level of support in combination with a high level of durability. It is therefore an object of aspects of the present invention to address one or more of the abovementioned or other problems.

BRIEF SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided an insole comprising a flexible base and a reinforcing member arranged within the base.

Suitably, the insole is an orthotic insole. Preferably, the insole is for treating one or more of fallen arches, flat feet, plantar fasciitis and pronation problems.

The insole may be a full length insole, operable to abut substantially the whole length of the sole of the foot; a ¾ length insole, operable to abut about ¾ of the sole of the foot; or a heel length insole, operable to abut the heel region of the sole of the foot. The insole may be a cut-to-size insole, suitably a full length cut-to-size insole. Suitably, the insole comprises at least one cutting guide line. The cutting guide line may comprise a channel extending through a part of the base. The insole may comprise cutting guide line(s) toward the toe end. The insole may comprise at least 2, such as at least 3 or at least 4 cutting guide lines.

The thickness of the base of the insole may taper from a greatest thickness at the heel end to a smallest thickness at the toe end. Suitably, the thickness of the base of the insole at the heel portion of the insole is at least 30% more than the thickness of the base at the ball portion of the insole, such as at least 40% more or at least 50% more. Suitably, the thickness of the base of the insole at the heel portion of the insole is at least 100% more than the thickness of the base at the toe end of the insole, such as at least 150% more or at least 200% more.

The base may formed of silicone.

The reinforcement member may be a porous member, preferably comprising a plurality of apertures, suitably a porous sheet. The reinforcement member is preferably flexible. The reinforcement member may be a mesh, such as a mesh having repeating moieties, such as hexagonal moieties, that define apertures. The reinforcement member may comprise a plurality of apertures having a largest lateral dimension of ≤5 mm, such as ≤3 mm, preferably ≤2 mm, more preferably ≤1.5 mm. At least 50% of the apertures of the reinforcement member may have a largest lateral dimension of ≤5 mm, such as ≤3 mm, preferably ≤2 mm, more preferably ≤1.5 mm, such as at least 60%, at least 70%, at least 80%, preferably at least 90%, more preferably at least 95% of the apertures. The reinforcement member may comprise at least 10 apertures, such as at least 50 apertures, such as at least 100 apertures, or at least 500 apertures, for example at least 1000 apertures.

The reinforcement member may be formed from polymeric material, such as polyester. The reinforcement member may be less laterally extensible than the material of the base of the insole. Suitably, the thickness of the reinforcement member is significantly thinner than the thickness of the base, suitably the silicone base, for example the ratio of the thickness of the base to the thickness of the reinforcement member may be at least 3:1, such as at least 6:1 or at least 8:1, or at least 10:1.

The reinforcement member may be embedded within the base of the insole such that the material of the base of the insole extends over, and preferably substantially covers, the upper and lower faces of the reinforcement member. The base material preferably penetrates through the reinforcing member such that the base material arranged over the upper face of the reinforcing member is attached to the base material arranged over the lower face of the reinforcing member through the reinforcing member.

Advantageously, it has been found that the inclusion of a reinforcing member in the base of the insole of the present invention provides improved durability in the insole, and in particular improved integrity when the insole is cut to size, reducing disintegration of the insole in use. Attaching non-silicone materials to silicone is known to be difficult, however, it has been found that arranging a porous reinforcing member within the silicone base material provides a reliable reinforced insole having improved structural reliability.

The insole may comprise one or more support portions, suitably support portions attached to the base material of the insole. The support portion may be in the form of a raised area of the insole. The support portion may be formed of silicone. The support portion may be formed of material that is less deformable than the base material and/or the material of the shock absorption portions, suitably of less deformable silicone. The insole may comprise a ball support portion and/or an arch support portion, preferably a medial arch support portion.

The insole may comprise one or more shock absorption portions, suitably shock absorption portions attached to the base material of the insole. The shock absorption portions may be formed of silicone. The shock absorption portions may be formed of more deformable material than the base material and/or the material of the support portions, suitably of more deformable silicone. The shock absorption portions may comprise one or more channels extending through the shock absorption portion to allow for additional deformation thereby providing further improved comfort and shock absorption. The insole may comprise a forefoot shock absorption portion and/or a heel shock absorption portion.

The density of the silicone of the support portions may be higher than the density of the silicone of the shock absorption portions and/or the silicone of the base. The density of the silicone of the shock absorption portions may be lower than the density of the silicone of the support portions and/or the silicone of the base. The silicone of the base may have a density that is in-between the density of the silicone of the support portions and the density of the silicone of the shock absorption portions. The silicone of the support portions may have a density that is at least 10% higher than the density of the silicone of the base, such as at least 20% higher, preferably at least 30% higher.

By ball support portion, arch support portion, forefoot shock absorption portion and heel shock absorption portion it is meant portions operable to abut the respective foot region in use.

The support portion(s) and/or the shock absorption portion(s) may each be arranged in a recess in the base.

The insole may further comprise gripping members operable to improve the roughness of the upper face of the insole and improve the grip of the insole. The gripping members may be arranged between the heel and ball region of the insole. Suitably the gripping members comprise a plurality of projections extending upwardly from the upper face of the base of the insole. The projections may have a height of ≤2 mm, such as ≤1.5 mm, preferably ≤1 mm, more preferably ≤0.5 mm. Preferably, the gripping members are integrally formed in the base.

Preferably, the insole comprises at least one support portion and at least one shock absorption portion. More preferably, the insole comprises the combination of a ball support portion and an arch support portion, preferably a medial arch support portion, with a forefoot shock absorption portion and a heel shock absorption portion.

Advantageously, it has been found that the combination of the reinforced cut-to-size insole of the present invention with the orthotic support portions and/or shock absorption portions provided improved orthotic support for a cut-to-size insole in use due to improved stability and support.

The insole of the present invention is flexible, lightweight, reusable and requires minimal maintenance. The insole of the present invention can be used to help with flat feet/fallen arches, help with plantar fasciitis, to help reduce stress on joints and to help improve and maintain posture.

According to a further aspect of the present invention, there is provided a method of producing an insole according to the first aspect of the present invention, comprising the steps of:

• • a. moulding one or more support portions and/or one or more shock absorption portions;
  • b. moulding a base having a reinforcement member arranged within the base
  • c. attaching the support portion(s) and/or shock absorption portion(s) to the base.

“Flexible” when used herein is intended to mean capable of bending easily without breaking. Suitably, the base, and preferably also the support and/or the shock absorption portions, of the insole are also resiliently deformable.

“Sheet” when used herein implies no restriction as to thickness of the reinforcing member but is intended to mean a member having a significantly larger width and length than height.

All of the features contained herein may be combined with any of the above aspects in any combination.

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the following figures.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a top plan view of an insole according to a first embodiment of the present invention.

FIG. 2 shows a bottom plan view of the insole of FIG. 1.

FIG. 3 shows a side view of the insole of FIG. 1.

FIG. 4 shows an enlarged top plan view of the toe end of the insole of FIG. 1.

FIG. 5 shows an enlarged top plan view of the toe end of the insole of FIG. 1 partially cut along a cutting guide line.

FIG. 6 shows a top plan view of an insole according to a second embodiment of the present invention.

FIG. 7 shows a side view of the insole of FIG. 6.

FIG. 8 shows a top plan view of an insole according to a third embodiment of the present invention.

FIG. 9 shows a top plan view of an insole according to a fourth embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

FIGS. 1 to 5 show a first embodiment of a full length insole 100 according to the present invention. Insole 100 is formed of foot-outline-shaped flexible transparent silicone base 102 which tapers from a thickness of 7 mm at the heel end to a thickness of 4 mm at the ball portion indicated by support portion 110 and 2 mm at the toe end. Insole 100 is configured for use with a right foot.

Silicone base 102 has embedded therein polymeric porous mesh 104. Integrally formed mesh 104 extends across substantially the whole of base 102, from the heel end to the toe end and from the inner side to the outer side. Mesh 104 is arranged approximately halfway between the upper and lower faces of base 102. Mesh 104 is formed of a plurality of directly connected open hexagonal moieties. The silicone of base 102 penetrates the hexagonal moieties to thereby hold mesh 104 in position.

Silicone shock absorption portions 106 and 108 are located at the forefoot and heel portions of insole 100, respectively. Each of portions 106 and 108 are arranged in a recess of base 102 and are fixedly attached to the base. Both of shock absorption portions 106, 108 are formed from a more deformable silicone than the silicone of base 102. Portions 106 and 108 each contain a rectangular grid of intersecting straight channels extending throughout the portion. Portions 106 and 108 are arranged at the heavy impact areas of the insole and help to cushion the impact in use. Portions 106 and 108 furthermore have more grip than the base material due to the lower density of the silicone and the presence of channels, and therefore also help to grip the foot in use.

Shock absorption portion 106 has an asymmetrical crescent shape, wherein the apex of the crescent is proximate to the inside side edge of the insole. The point of crescent-shaped portion 106 that is proximate to the outer side edge of the insole extends approximately 3 cm further down the base of the insole toward the heel end compared to the other point of the portion which is proximate to the inside side edge of the insole, thus matching the curved shape of the toes of a foot.

Shock absorption portion 108 is an oval shape with the longitudinal axis of the oval extending from the heel end toward the toe end.

Insole 100 further has two silicone support portions 110 and 112, each located within a recess in the base 102 and operable to abut the ball and medial arch areas of the foot in use, respectively. Support portions 110, 112 are formed from a less formable silicone material than portions 106 and 108, and also base 102, which helps to ensure the correct alignment of the foot and provides improved comfort.

Medial arch support portion 112 has a concave side face that extending steeply upwardly along the arch portion of the inside side face of insole 100. The upper edge of the side face of portion 112 is curved such that it has a highest point approximately in the middle of the side face of portion 112 and lowest points at either end of the side face where the upper edge meets base 102. Extending downwardly at a shallow gradient from the upper edge of the side face of portion 112 to base 102 is the convex upper face of portion 112. The upper face of portion 112 follows the curved shape of the upper edge of the side face such that the upper face has a highest point adjacent to the highest point of the upper edge. The upper face then extends downwardly at approximately the same gradient such that the opposite terminal edge of the upper face that contacts base 102 is also curved and approximately the middle of this terminal edge is the point of portion 112 closest to the outer side edge of insole 100.

Oval ball support portion 110 is arranged at the ball region of insole 100, in the middle thereof. The longitudinal axis of portion 110 extends off the heel to toe longitudinal axis of insole 100. Specifically, the longitudinal axis of portion 110 extends approximately 25° off the longitudinal axis of insole 100 such that the longitudinal axis of portion 100 extends through the inner side edge of insole 100 toward the toe end and extends through the outer side edge of insole 100 toward the heel end. The lower points of shock absorption portion 106 extend partially around support 110.

Silicone base 102 has two gripping areas 114 and 116 which each comprise a plurality of closely spaced silicone hemispherical projections extending upwardly from the upper face of insole 102. Gripping areas 114, 116 help the foot stays in the correct alignment on the insole such that the support and shock absorption portions are able to provide the intended effect on the desired areas of the foot.

FIG. 4 shows an enlarged view of toe end region A of FIG. 1. In region A the cutting guide line channels 118 are shown. Cutting guideline channels 118 are in the form of four discrete substantially evenly spaced and parallel arched-shaped channels in base 102.

FIG. 5 also shows an enlarged view of region A, but in FIG. 5 the second cutting guideline has been partially cut from the outer side face of insole 100 inwardly along the curve of the cutting guideline. In use, the cut may be continued to the inner side face of insole 100 to separate the undesired portion of the insole and resize the insole.

FIGS. 6 and 7 show an insole 200 according to a second embodiment of the present invention. Insole 200 is the same as insole 100 except that it is configured for use with a left foot.

FIG. 8 shows a ¾ length insole 300 according to a third embodiment of the present invention, and is configured to fit under the rear ¾ of the foot, as opposed to the whole foot as for insole 100. Insole 300 is configured for a right foot. Insole 300 comprises silicone base 302, which aside from the difference in shape is the same as silicone base 102. Insole 300 further comprises silicone shock absorption portions 306, 308 located at the forefoot and heel portions of insole. Portions 306 and 308 are the same as respective portions 106 and 108 of insole 100.

FIG. 9 shows a heel insole 400 according to a fourth embodiment of the invention, and is configured to fit under the heel region, as opposed to the whole foot as for insole 100. Insole 400 comprises silicone base 402 which aside from the difference in shape is the same as silicone base 102. Insole 400 further comprises a silicone shock absorption portion 408, located on the heel portion of the insole. Portion 408 is the same as respective portion 108 of insole 100.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1. An insole comprising a flexible base and a reinforcement member arranged within the base.

2. An insole according to claim 1, wherein the insole is a cut-to-size insole, and comprises at least one cutting guide line.

3. An insole according to claim 1, wherein the thickness of the base of the insole tapers from a greatest thickness at the heel end to a smallest thickness at the toe end.

4. An insole according to claim 1, wherein the thickness of the base of the insole at the heel portion of the insole is at least 30% more than the thickness of the base at the ball portion of the insole.

5. An insole according to claim 1, wherein the base is formed of silicone.

6. An insole according to claim 1, wherein the reinforcement member is a porous sheet.

7. An insole according to claim 1, wherein the reinforcement member is flexible.

8. An insole according to claim 1, wherein the reinforcement member comprises a plurality of apertures having a largest lateral dimension of ≤5 mm.

9. An insole according to claim 1, wherein the ratio of the thickness of the base to the thickness of the reinforcement member is at least 3:1.

10. An insole according to claim 1, wherein the base material penetrates through the reinforcement member.

11. An insole according to claim 1, wherein the insole comprises one or more support portions.

12. An insole according to claim 1, wherein the insole comprises one or more shock absorption portions.

13. An insole according to claim 11, wherein the support portion is formed of material that is less deformable than the material of the base of the insole and the material of the shock absorption portions formed of less deformable silicone.

14. An insole according to claim 13, wherein insole comprises a ball support portion and a medial arch support portion.

15. An insole according to claim 12, wherein the shock absorption portion is formed of more deformable material than the material of the base of the insole and the material of the support portions, formed of more deformable silicone.

16. An insole according to claim 12, wherein the shock absorption portion comprises one or more channels extending through the shock absorption portion.

17. An insole according to claim 12, wherein the insole comprises a forefoot shock absorption portion and a heel shock absorption portion.

18. An insole according to claim 11, wherein the density of the silicone of the support portions is higher than the density of the silicone of the shock absorption portions and the silicone of the base.

19. An insole according to claim 11, wherein the density of the silicone of the shock absorption portions is lower than the density of the silicone of the support portions and the silicone of the base.

20. An insole according to claim 19, wherein the silicone of the base has a density that is in-between the density of the silicone of the support portions and the density of the silicone of the shock absorption portions.

21. An insole according to claim 20, wherein the silicone of the support portions has a density that is at least 10% higher than the density of the silicone of the base.

22. An insole according to claim 1, wherein the insole further comprises gripping members operable to improve the roughness of the upper face of the insole.

23. An insole according to claim 22, wherein the gripping members are integrally formed in the base.

24. An insole according to claim 1, wherein the insole comprises a ball support portion and a medial arch support portion, with a forefoot shock absorption portion and a heel shock absorption portion.

25. A method of producing an insole according to claim 1, comprising the steps of:

a. moulding one or more support portions and one or more shock absorption portions;

b. moulding a base having a reinforcement member arranged within the base; and

c. attaching the support portion(s) and shock absorption portion(s) to the base.