COMPOSITE FOOTWEAR INSOLE

Abstract

A composite footwear insole, and a method for making and assembling the composite footwear insole, includes a plurality of sections either removably or securably attachable to a bottom layer. The sections are made of different materials to provide different types of support, such as rigid or shock absorbing. Each section may also have different surface characteristics. The composite footwear insole may be used to at least partially abate and/or prevent foot and related ailments commonly suffered by diabetics and others with pathologic or painful foot conditions. A kit for making an insole is provided wherein a variety of insole sections are provided that have different cushioning or support features and/or different surface characteristics, allowing a user to choose the preferred insole sections and assemble the sections onto the bottom layer, thereby constructing a composite footwear insole.

Description

This application is a divisional application from co-pending application Ser. No. 11/146,841 entitled MULTIPIECE FOOTWEAR INSOLE filed on Jun. 7, 2005 for which the U.S. Patent Office has issued a notice of allowability to the same sole inventor named in this application. The specification of the pending application is incorporated by reference into this document.

FIELD OF TECHNOLOGY

The composite footwear insole disclosed, shown, and claimed in this document pertains generally to footwear. More particularly, the new and useful composite footwear insole provides an insole that relieves pain suffered by footwear users whose footwear does not include the composite footwear insole disclosed, shown, and claimed in this document.

BACKGROUND

Diabetes mellitus is a chronic disease that affects the lives of millions of people in the United States and around the World. Many diabetics develop a serious foot conditions at some time during their lives, which in some cases require toe amputations or even amputations of the entire foot. High blood sugar levels also affect the body's immune system and delays wound healing.

Neuropathy is an impairment that affects about half of those with diabetes. It causes loss of feeling in feet, which increases the risk of undetected injury. Diabetics suffering from neuropathy can unknowingly develop minor cuts or scrapes, blisters, or pressure sores due to the feeling insensitivity. If such minor injuries are left untreated or fail to heal, complications may lead to ulceration, infection, and gangrene. In fact, diabetic foot complications are the most common cause of non-traumatic lower extremity amputations in the United States. The risk of lower extremity amputation has been estimated to be about 15 to 46 times higher in diabetics than in non-diabetics. Importantly, the majority of diabetic foot complications begin with the formation of skin ulcers on the bottom of the foot.

Specially designed footwear for diabetics as well as other orthopedic devices can reduce the risk of many foot complications, such as the formation of calluses, foot ulcers, poor circulation, decreased resistance to infection, foot deformities, and neuropathy, all of which are especially problematic for diabetics.

Custom orthopedic foot wear for diabetics often has a relatively rigid, but resilient base comprising a heel portion and an arch portion contoured to fit the plantar, or bottom surface, of a foot. Unfortunately, most customized prescription orthopedic footwear and/or footwear devices for diabetics require the preparation of molds for the feet that in turn require subsequent manufacturing of footwear and/or devices causing significant delay between the measuring of feet for an orthopedic shoe or device, and the arrival of the new customized device such as insoles as well as footwear. The custom insoles are generally created from hard plastics by making a mold based on detailed foot measurements. The mold is modified to provide prescribed corrections by a podiatrist. Custom orthopedic footwear may also be unattractive. The resulting footwear will not be as versatile as insoles insertable within ordinary shoes and other footwear.

Conventional footwear inserts or soles consist of materials such as rigid plastic and/or elastomeric foam with an impact cushioning foam layer or space filler. They provide insufficient foot protection and/or do not address the different needs of the various areas of the foot, which can be unique to wearers. Such insoles often do not provide enough protection or support for proper biomechanical functions of a foot, particularly in the rear foot area, and in the arch areas of a foot. Conventional insoles typically do not hold a wearer's heel in place or provide arch support, or allow movement of the foot such as in the toe area that allows toes to slide and move. Thus, conventional inserts and soles are often ineffective in preventing or alleviating foot conditions experienced by diabetics and other persons with foot problems.

Special footwear and/or footwear components and devices are considered significant in preventing the problems of diabetics and others. It is also believed that many foot and toe complications of non-diabetics could be prevented through the use of the composite footwear insole disclosed, illustrated, and claimed in this document. The composite footwear insole has sections that are for a variety of foot shapes and that can be customized for a variety of wearers and wear requirements. One or more of the sections may have different cushioning and/or surface characteristics.

SUMMARY

It will become apparent to one skilled in the art that the claimed subject matter as a whole, including the structure of the apparatus, and the cooperation of the elements of the apparatus, combine to result in a number of unexpected advantages and utilities. The structure and co-operation of structure of the composite footwear insole will become apparent to those skilled in the art when read in conjunction with the following description, drawing figures, and appended claims.

The foregoing has outlined broadly the more important features of the invention to better understand the detailed description that follows, and to better understand the contributions to the art. The composite footwear insole is not limited in application to the details of construction, and to the arrangements of the components, provided in the following description or drawing figures, but is capable of other embodiments, and of being practiced and carried out in various ways. The phraseology and terminology employed in this disclosure are for purpose of description, and therefore should not be regarded as limiting.

As those skilled in the art will appreciate, the conception on which this disclosure is based readily may be used as a basis for designing other structures, methods, and system. The claims, therefore, include equivalent constructions. Further, the abstract associated with this disclosure is intended neither to define the composite footwear insole, which is measured by the claims, nor intended to limit the scope of the claims.

The novel features of the composite footwear insole are best understood from the accompanying drawing, considered in connection with the accompanying description of the drawing, in which similar reference characters refer to similar parts, and in which:

DRAWINGS

FIG. 1 is a top side view of an insole of this invention for the left foot in an assembled state;

FIG. 1A is a view of an insole of FIG. 1 showing the undersides of the sections;

FIG. 2 is a bottom view of the bottom layer of the insole of FIG. 1;

FIG. 2A shows the top side of the bottom layer of the FIG. 2;

FIG. 3 is a right side view of an insole for the left foot, with the sections of the insole unassembled, but in their respective positions;

FIG. 3A is a left side view of the insole of FIG. 3, with the sections of the insole in their respective positions, unassembled;

FIG. 4 is a right side view of the insole of FIGS. 3-3A in an assembled state;

FIG. 4A is a left side view of the of the insole of FIG. 4 in use in footwear;

FIG. 4B is a right side view of the insole of FIG. 4 in use in footwear;

FIG. 5 is a top view of insole sections for a right foot in a disassembled state like that of FIGS. 3, 3A, and 4;

FIG. 5A is an underside view of the sections of FIG. 5 in a disassembled state;

FIG. 6 is a bottom view of the bottom layer of FIG. 6A with the insole sections of FIGS. 5 and 5A in an assembled state like FIGS. 1, 4;

FIG. 6A is the top view of the bottom layer of FIG. 6 before the sections of FIGS. 5-5A are attached thereto;

FIGS. 7A-7G show a kit for making a right sided and left sided insole that is comprised of toe sections, metatarsal sections, base sections, arch sections, heel sections, and bottom insole layers;

FIGS. 7A and 7B show an assortment of insole sections for a left foot insole;

FIG. 7C shows the top view of an embodiment of a bottom insole layer for a left foot insole;

FIG. 7D shows the top view of an embodiment of a bottom insole layer for a right foot insole;

FIGS. 7E and 7F show an assortment of insole sections for a right foot insole; and

FIG. 7G shows an embodiment of the underside of the insole sections for a left foot.

Claim elements and steps in this document have been numbered solely as an aid in understanding the description. The numbering is not intended to, and should not be considered as intending to, indicate the ordering of elements and steps in the claims. In addition, the composite footwear insole shown in drawing FIGS. 1 through ● shows at least one embodiment that is not intended to be exclusive, but merely illustrative of the disclosed embodiments.

Means-plus-function clauses in the claims are intended to cover the structures described as performing the recited function that include not only structural equivalents, but also equivalent structures. Thus, although a nail and screw may not be structural equivalents, a nail and a screw may be equivalent structures.

DETAILED DESCRIPTION

Composite footwear insole 2 disclosed, illustrated, and claimed in this document includes multiple pieces or sections that can be made from a variety of materials and/or sections that can have different surface characteristics. The composite footwear insole is versatile, and can be constructed in a fraction of the time in comparison to conventional custom or special-fit insoles. Further, depending on needs and changes in a wearer's foot, certain sections can be switched with other counterpart sections that can be made from a spectrum of different materials having different hardnesses and/or different surfaces. For example, the insole sections can be comprised of cushioning materials or rigid materials to lend support, and those in between. The surface type can also vary based upon type and location of the sections. For example, certain enable the toes to move and slide, to surface types that are gripping to prevent sliding of portions of the foot, such as the heel. The ability to slide and move the toes of the foot may also enhance circulation in the foot.

FIG. 1 shows a top side view 5 of a composite footwear insole 2 of this invention for the left foot with the insole sections in their respective positions and in an assembled state, with at least one medial edge shaped to fit together with a medial edge of an adjacent section. FIG. 1A shows the undersides 19, 26, 32, 38, respectively, of the toe sections 18, metatarsal section 24, base section 30, arch section 36, and heel section 42 of FIG. 1. FIG. 2 shows the bottom view 8 of the bottom layer 4 of the insole of FIG. 1. FIG. 2A shows the top side 6 of the bottom layer 4 of FIG. 2, and the attachment members 12 on the top side 6 of the bottom layer 4. As shown in FIGS. 1-2A, as well as FIGS. 3, 3A, 4, 4A, and 4B which show a side view, the composite footwear insole has a bottom layer 4 having a top side 6 and a bottom side 8, and includes a plurality of sections 10.

Beginning at the anterior-most end 1 of the composite footwear insole 2 of FIG. 1 is a toe section 18, having a top surface 20. Moving toward the posterior end of the composite footwear insole 2, the toe section 18 has a medial edge 21 that in an embodiment is irregular and is waved. The pattern or design of the respective edge of the adjacent piece, here the medial edge 21 of the toe section 18, is of a shape complimentary to the medial edge 27a of the metatarsal section 24, which has a top side 25. In the embodiment of FIG. 1, the longitudinal arch section 36 is shaped so as to extend into the metatarsal section 24 of the composite footwear insole 2. Moving further posteriorly is another medial edge 27b of the metatarsal section 24 that interfaces with the medial edge 33a of the base section 30, which has a top side 31. The longitudinal arch section 36 is adjacent to the base section 30 and has a curved 54 medial edge 39 adjacent to medial edge 33a of the base section 30. The top side of the arch section 37 is shown. The medial edge 33b of the base section 30 is adjacent to the medial edge 40 of the heel section 42. Here, the top side 43 of the heel section 42 has a plurality of protrusions 44 that are raised areas that serve to grip the heel of a wearer's foot. FIG. 1 shows a left insole for a left foot. The right insole for the right foot would be a mirror image of the left foot insole of FIG. 1.

The sections of the composite footwear insole 2 disclosed, illustrated, and claimed in this document are usually of different sizes and of different shapes and can vary in thicknesses, depths, and/or elevations. Each composite footwear insole section can be comprised of one or more of material types and can be a variety of thicknesses from a few millimeters to a few centimeters. The sections of composite footwear insole 2 disclosed, illustrated, and claimed in this document can be securably attached to a bottom layer, removably attachable to a bottom layer, or alternatively, integral with the bottom layer. The composite footwear insole can be designed so that any section can be integral with the bottom layer. FIGS. 7A-7G also show a kit for making the composite footwear insole.

The composite footwear insole sections can be comprised of one or more layers of material. In one embodiment, one or more of the composite footwear insole sections have semi-rigid or rigid support members underneath or molded within the insole section. Also, if desired, a section can be constructed from one type of material, and may have a covering layer on the top surface comprised of another material. A variety of materials can be used as a top covering layer for the composite footwear insole sections. If a top layer is used, it can have a variety of thicknesses of material from a few millimeters to less than about 1 to 1.5 centimeters. The top layer can have a variety of surface characteristics and be made of synthetic and/or natural materials such as silk, fur, felt, satin, leather, polyester, cloth or sheeting, as well as foam, rubber, plastic materials, and any other materials known to one skilled in the art that are suitable for insoles and insole coverings.

The assembled composite footwear insole 2 is generally foot-shaped and/or has the approximate shape of the inside perimeter of the bed 7 of conventional footwear or shoes. See e.g. FIGS. 1, 2, 4, 4A, 4B, and 6. The composite footwear insole 2 is formed of a plurality of sections 10 that are integral with the composite footwear insole 2 or that are removably attachable or securably attachable to at least a portion of the top side 6 of the bottom layer 4 of the insole 2. In one embodiment, the sections are comprised essentially of a longitudinal arch section 36, a heel section 42, a toe section 18, a metatarsal section 24, a base section 30, or any combination thereof. Of course one or more of these sections can be combined or can extend into other areas of the insole. The various insole sections fit together similar to puzzle pieces to form an composite footwear insole 2. In one embodiment, the sections have medial edges that fit together with the medial edge of at least one other section in a puzzle-like manner.

The edges between the pieces can be straight 50 as those between the toe section 18 of FIG. 5 and the heel in FIG. 1, or curved as in the medial edge 39 of the longitudinal arch section 36 and medial edge 33c of the base piece 30 in FIGS. 1,5. However, for comfort, the edges of the insole in the weight bearing areas are preferably irregular so that the wearer does not feel a seam or separation between the sections. For example, the edges can be wave shaped or shaped like a repeating “w”, “u”, or “v”, or any combination of the foregoing. As shown in FIG. 1, for example, the toe section 18 adjacent to the metatarsal section 24 has edges that are wave-shaped edge 58 and wave-shape medial edge 27 of the metatarsal piece 24 adjacent to toe section 18 and is irregular in a corresponding wave-shaped edge 58. As shown in FIG. 5, the medial edge 33 of the base piece 30 adjacent to the heel piece 42 is wave-shaped edge 58 and the medial edge 40 of the heel piece 42 adjacent to the base piece 30 is irregular and wave-shaped edge 58 in a corresponding shape. As defined herein, a medial edge is the edge of the insole sections that is adjacent to at least one other section and interfaces with another insole section. Also as shown in FIG. 1, some edges between some pieces are straight, while the edges between other pieces are irregular.

For sections that are removably attachable to form the composite footwear insole 2, there are various ways to attach the sections to the insole or a bottom layer of the insole, such as using attachment members including adhesives, glue, magnets, a wedge and aperture connection, studs, snaps, hook and loop fasteners such as Velcro® and other hook and loop fasteners, hook and eye fasteners, and other means or materials known to one skilled in the art for removably attaching materials to each other. The attachment members 12 are located on the top side 6 of the bottom layer 4 and on the underside 11 of such plurality of sections 10. In the composite footwear insole 2 embodiments of FIGS. 1, 4, 5A, 6A, 7C, 7D, and 7G the attachment members 12 comprise hook components 14 and counterpart loop components 16 like those found in Velcro® and similar materials. The Velcro®-type attachment members are secured to the sections and bottom layer by adhesives and/or stitching. The hook components 14 can be attached to the top side 6 of the bottom layer 4 and the counterpart loop components 16 can be attached to the underside 11 of the removable plurality of sections 10 or similarly, the hook components 14 can be attached to the underside 11 of the removable plurality of sections 10 and the counterpart loop components 16 can be attached to the top side 6 of the bottom layer 4. Regardless of the position of the attachment members 12 on the underside 11 of plurality of sections 10 and the bottom layer 4, when the hook components 14 and counterpart loop components 16 are joined together, they form a holding assembly 17. Also, Velcro-compatible continuous-loop fabrics can be used for the loop counterparts such as nylon which is available under the trade designation “Tricot.”

The hook components 14 and counterpart loop components 16 can cover the entire surface of the plurality of sections 10 and bottom layer 4, see e.g. FIG. 7G or instead, a portion thereof, see e.g. FIGS. 2, 7G. Alternatively, if the plurality of sections 10 are securably attached to the bottom layer 4, they can be integral or part of the bottom layer 4 such as though molding, or attached by adhesives, heat bonding glue, and/or stitching, or other ways known to one skilled in the art.

The bottom layer 4 of the composite footwear insole 2 is a support layer and/or is a cushioning layer and can be made from a variety of materials, especially foam materials which have elastic or rebounding properties, such as those consisting essentially of silicon, polyester, neoprene, natural rubber foams, synthetic rubber foams, polyurethane, polyether and polyester foams, neoprene, vinyl nitrile, styrene-butadiene rubber (SBR), polyethylene (PE), ethyl vinyl acetate (EVA), ethylene propylene terpolymer (EPT), EPT/PE/butyl rubber, neoprene/EPT/SBR, epichlorohydrin (ECH), and nitrile (NBR) or any combination thereof, as well as other cushioning materials known or used by one skilled in the art. Of course, the bottom layer 4 of the insole 2 may also be comprised of natural materials, such as leather, cotton, felt, linen, and other such materials known to one skilled in the art. The bottom layer 4 should also be durable so that it does not tear apart when the plurality of sections 10 are removed and replaced during use. Also, only a portion of the bottom layer 4 can be made of a support type material with the remainder being cushioning material. The support materials comprise materials that provide at least some support that can be shaped and not completely rigid, such as leather and metal, but can also be rigid or semi-rigid, such as plastic, rubber and other materials known to one skilled in the art for such purposes. The bottom layer 4 can be of a variety of thicknesses from a few millimeters to a centimeter or less.

If different material characteristics are desired, one or more of the plurality of sections 10 will be made of different materials. The composite footwear insole 2 plurality of sections 10 can be comprised of one or more synthetic or natural materials selected from plastic, metal, metal alloys, gels, and those consisting essentially of silicon, polyester, neoprene, natural rubber foams, synthetic rubber foams, polyurethane, polyether and polyester foams, neoprene, vinyl nitrile, styrene-butadiene rubber (SBR), polyethylene (PE), ethyl vinyl acetate (EVA), ethylene propylene terpolymer (EPT), EPT/PE/butyl rubber, neoprene/EPT/SBR, epichlorohydrin (ECH), and nitrile (NBR), and various types of polymer foams, leather, cotton, felt, linen, or any combination of one or more of the foregoing, or other materials known or used by one skilled in the art. In one embodiment, the foam of the plurality of sections 10 also molds to the contours of the foot when worn to reduce the pressure points and for enhanced comfort. If desired, the insole 2 plurality of sections 10 can contain rigid or semi-rigid materials that are enclosed or encapsulated in other materials that give support to the composite footwear insole 2, plurality of sections 10.

The materials for each section are chosen based upon the desired characteristics for each section. For example, if the composite footwear insole 2, plurality of sections 10 should have elastic or rebounding properties, it is typically comprised of materials that have cushioning abilities that rebound. In contrast, if the composite footwear insole 2, plurality of sections 10 should support a certain area of the foot, such as the arch area, then the material would be chosen from a type of material known by one skilled in the art that can be shaped and used to support an area of a foot, for example, such as metal, leather, and/or plastic with or without a top layer of another type of material. As a further example, if the composite footwear insole 2 plurality of sections 10 should allow a portion of the foot to easily move, such as the toe area, the ideal material will have a low co-efficient of friction such as sheared fur 22 or silk 80 as shown in FIG. 1, or nylon, polyester, metals, metal alloys and other such materials known to one skilled in the art. If the insole 2, plurality of sections 10 should have gripping properties such as in the heel section 42, the material would be chosen from a type of material known by one skilled in the art that is used to grip an area of a foot such as rubber or foam, with or without a contoured surface. Of course, any other materials that are known or used by one skilled in the art for making insoles can be used for any of the sections.

Also, certain sections have a top covering layer 3 that is made of different materials to give the top portion of the sections different characteristics. See e.g. FIGS. 3, 3A. A variety of materials can be used for a top layer 3 such as silk 80, nylon, polyester 92, leather 83, cotton, felt, linen, furs, partially sheared fur 22 or short fur, such as moleskin 79, plastic 86, metal, metal alloys, gels, and those consisting essentially of silicon, polyester 92, neoprene 84, natural rubber foams, synthetic rubber foams, polyurethane, polyether and polyester foams, neoprene, vinyl nitrile, styrene-butadiene rubber (SBR), polyethylene (PE), ethyl vinyl acetate (EVA), ethylene propylene terpolymer (EPT), EPT/PE/butyl rubber, neoprene/EPT/SBR, epichlorohydrin (ECH), and nitrile (NBR), and various types of polymer foams, and other such materials known to one skilled in the art. For example, the toe section 18 may have a top layer that is slick like silk, or that is soft and/or has a low coefficient of friction like fur. If another layer is desired, the additional layer may be connected to the topside of a section by any means known by one skilled in the art, including attachment members, comprising hook and loop fasteners, snaps, magnets, stitching, glue, adhesives, or any combination thereof.

Beginning at the posterior-most end 51 of the composite footwear insole 2 disclosed, illustrated, and claimed in this document of FIGS. 1, 3, 3A, 4, 4A, 5, 5A, 6, 6A, 7A-7G, there is a heel section 42. The heel section 42 corresponds to the heel area 42b of the foot and is placed in the heel area 42a of the bottom layer 4 of the insole 2. See FIGS. 3, 3A, and 4. The heel section 42 can be made of a variety of materials previously listed or any combination of one or more of the foregoing, as well as others known to one skilled in the art. In an embodiment, materials that have gripping and/or cushioning properties are preferred. Also, portions of the topside 5 of the section may be raised such as the heel section 42 that have rounded protrusions 44, but may be of like material like that of the section. For example, the heel section 42 can made of rubber 90 or polymer foam 85 based materials that have a plurality of protrusions 44 that are essential and have a gripping and/or massaging action on the wearer's heel 42b. See FIGS. 1, 3, 3A, 4, 4A and 4B. The plurality of protrusions 44 can be of various heights from about 1/16 inch to about ¼ inch. The heel section 42 may also have a slight concave shape 66 so as to cup the heel of the wearer's foot. See FIG. 4B. The protruding members should also be rounded or flat at the top end so they do not puncture or damage the heel of a wearer's foot, and can be evenly or irregularly spaced. The heel section 42 can be removably or securably attached to the bottom layer 4, or can be an integral part of the bottom layer 4 and in an embodiment is molded neoprene 84.

As illustrated in FIG. 4, a longitudinal arch section 36 as provided that corresponds to the longitudinal arch section 36b portion of a foot and is placed in the arch area 36a of the bottom layer 4 of the composite footwear insole 2. The longitudinal arch section 36 can be of various lengths and widths and is usually adjacent to the base section 30 area, see e.g. FIG. 5, or may be longer and extend into the heel 42 and metatarsal sections 24 as in FIG. 1

The longitudinal arch section 36 can be removably or securably attached to the bottom layer 4, or can be an integral part of the bottom layer 4. In an embodiment, the longitudinal arch section 36 is shaped similarly to a wearer's foot arch, and serves to support the arch. The longitudinal arch section 36 can be comprised of a variety of materials that provide at least some support and can be shaped, such as plastic 86, rubber 90 and other materials known to one skilled in the art of such purposes.

Also, composite footwear insole 2 includes a metatarsal section 24, which corresponds to the metatarsal section 24b of a foot and is placed in the metatarsal area 24a of the bottom layer 4 of the insole 2. See FIGS. 3, 3A, 4. As shown in the side view of FIGS. 3, 3A, 4, 4A, and 4B the metatarsal piece 24 is shaped with a concave recess 67 that accommodates the first metatarsal joint of a foot. It is made of materials that provide at least some support and can be shaped and that are not completely rigid such as leather 83. Of course, synthetic materials that can be rigid or semi-rigid, such as plastic and rubber and other materials known to one skilled in the art for such purposes are also suitable. In an embodiment, the surface of the metatarsal section 24 is preferably substantially smooth, but does not have to be smooth. The metatarsal section 24 corresponds to the metatarsal area of the food.

Adjacent the anterior end 1 of the composite footwear insole 2 is the toe section 18 that corresponds to the toe region 18b of a foot, and is placed in the toe are 8a of the bottom layer of the insole 2. See FIGS. 4A-4B. The toe section 18 can be removably or securably attached to the bottom layer 4, or can be an integral part of the bottom layer 4. The toe section 18 can be comprised from a variety of materials previously listed or any combination of one or more of the foregoing, as well as others known to one skilled in the art. Typically, the toe section 18 is covered with a top covering layer 3, but does not require that the section be covered by another type of material. In one embodiment, the top covering layer 3 of the toe section 18 allows toe to easily move, and materials that are slick 80, nylon, polyester 92, and furs that are partially sheared or short fur 22, such as moleskin 79, which have a low coefficient of friction and allow the toes to move or slide, are preferable.

The base section 30 corresponds to the area of the composite footwear insole 2 not covered by the other sections. In FIGS. 1 and 5, the base section 30 is the area adjacent to the longitudinal arch section. The base section 30 is one of the largest, if not the largest section, and should be made of durable material such as leather 83, but can also be a variety of materials previously listed or any combination of one or more of the foregoing, as well as others known to one skilled in the art. The base section 30 corresponds to the base section of the foot and is placed in the base area 30a of the bottom layer 4 of the composite footwear insole 2. See FIGS. 3, 3A, and 4. In one embodiment, the base section 30 is comprised of materials that have gripping and/or cushioning properties.

FIG. 2 shows the bottom side 8 of the bottom layer 4 of FIG. 1. The bottom side 8 of the bottom layer 4 can be smooth or textured. It can also have at least one attachment member 12, such as those previously described with corresponding attachment members 12 on the bed 7 of the shoe to keep the composite footwear insole 2 in place. Of course, if desired, an assembled insole 2 can be permanently anchored to the inside of the footwear 75 by adhesives, glue, stitching, or other means known by one skilled in the art.

FIG. 3 shows a right side view of a composite footwear insole 2 of FIG. 3 with the plurality of sections 10 of the composite footwear insole 2 in their relative positions but unassembled. The left side of the composite footwear insole 2 of FIG. 3A has a similar appearance of that of the right side view of FIG. 4A with the exception that the bottom layer 4 appears adjacent the arch section of the composite footwear insole 2 as dotted lines in FIGS. 3 assembled composite footwear insole 2 in use in footwear 75, with the composite footwear insole 2 resting on the bed 7 of the footwear 75.

FIGS. 3, 3A show the plurality of sections 10 of the composite footwear insole 2 over a bottom layer 4 having a top side 6 and a bottom side 8. In an embodiment, the top side 6 of the bottom layer 4 is covered with attachment members 12 that are complimentary to those on the undersides of the plurality of sections 10. Here, the hook components/fasteners 14 and counterpart loop component/fasteners 16 are present on the bottom layer 4 and on the underside 26 of the plurality of sections 10. The composite footwear insole 2 also has a toe section 18 with a top surface 20 that in this embodiment is moleskin 79 or another type of short or sheared fur 22. Next to the toe section 18 is a metatarsal section 24 with a concave recess/depression 67 to accommodate the metartarsal joint of the foot. The metatarsal section 24 has a top side 25 and an underside 26, wherein the underside 26 is attached to the counterpart loop component/fasteners 16 in the same manner as that described for the toe section 18. Adjacent to the metatarsal section 24 is an arch section 36 with a raised arch area 35 that has a top surface 37 and a bottom surface 38, with attachment members 12 attached thereto. The heel section 42 has a top side 43. The top side 43 may have a plurality of protrusions 44 that serve to grip the heel, with a concave shape 66 that cradles the heel of a wearer. In one embodiment, there is also a base section 30 that has attachment members 12 on the underside 32. FIG. 4 shows the toe section 18, metatarsal section 24, arch section 36, and heel section 42 in its assembled state with the attachment members 12 joined to one another, thereby forming a holding assembly 17.

FIGS. 5, 5A, 6, and 6A show composite footwear insole 2 for a right foot with FIG. 5 being the top surface and FIG. 6 being the bottom surface of the insole. FIG. 6 shows the bottom side 8 of the bottom layer 4 of the composite footwear insole 2 with the plurality of sections 10 comprising a toe section 18, a metatarsal section 24, a base section 30, and an arch section 36. As also shown by cross-reference between FIGS. 6-6A, a heel section 8 is included

While the embodiment in FIGS. 5A and 6A show a continuous section of attachment members 12 along the undersides of the sections 18, 24, 30, 36, and 42, and along the top side of the bottom layer, the attachment members 12 such as hook component/fasteners 14 and counterpart loop component/fasteners 16 need not extend to the edges of the composite footwear insole 2 plurality of sections 10 or completely cover the bottom layer 4. Moreover, if there is a void between the different sections, it may be advantageous to avoid having hook component/fasteners 14 or counterpart loop 16 component/fasteners along the entire length of the bottom layer 4 in order to prevent snagging of hosiery and socks, and to prevent discomfort for bare feet. The side views of the composite footwear insole 2 plurality of sections 10 demonstrate that in an embodiment the sections have different elevations 70 from the other sections, and the sections can have different thickness 72 with respect to one another. See FIG. 3. For comfort, the sections preferably have the same or similar elevations where the sections interface one another. FIG. 4B shows the use of the insole 2 in footwear 75 that has a raised arch area 36c. While the sections may have differing elevations, it is desirable to have gradual changes in elevation so as to provide a surface that is continuous, or nearly continuous for a user's foot.

If desired, one or more of the composite footwear insole 2 plurality of sections 10 of invention may be combined with one another, but yet have different materials in the region of the toes, and/or metatarsal, and/or arch, and/or heel, and/or the remainder of the insole, herein referred to as a base section 30.

A kit for providing the composite footwear insole 2 disclosed, illustrated, and claimed in this document for footwear 75 is shown in FIGS. 7A-7G. The kit comprises a bottom layer 4 having a top side 6, a plurality of sections 10 having a underside 31, wherein the underside 31 of one or more of plurality of sections 10 is removably or securably attachable to the top side 6 of the bottom layer 4, wherein the plurality of sections 10 consist essentially of at least one longitudinal arch section 36, at least one heel section 42, at least one toe section 18, at least one metatarsal section 24, a base section 30, attachment members 12 for removably attaching the removably attachable sections to the top of the bottom layer 4, wherein the attachment members are located of the top side of the bottom layer 4 and on the underside 31 of the removable plurality of sections 10, wherein an composite footwear insole 2 is formed by removably attaching the underside 31 of one of each of the plurality of sections 10 to the top side 6 of the bottom layer 4. If desired one or more sections can also be integral with the bottom layer 4.

In one embodiment, at least one section is comprised of at least one material that is different from the material of the other plurality of sections 10.

Also in an embodiment, the attachment members 12 comprise Velcro® or similar hook components/fasteners 14 and counterpart loop components/fasteners 16, wherein the hook components/fasteners 14 are attached to the top side 6 of the bottom layer 4 and the counterpart loop components/fasteners 16 are attached to the underside 31 of the removable plurality of sections 10, or wherein the hook components/fasteners 14 are attached to the underside 31 of the removably plurality of sections 10 and the counterpart loop components/fasteners 16 are attached to the top side 6 of the bottom layer 4. The hook and loop components form a holding assembly 17 and hold the plurality of sections 10 and bottom layer 4 together with the hook components/fasteners 14 and counterpart loop components/fasteners 16 are joined.

Further in an embodiment, at least some of the sections have a top layer 6.

The composite footwear insole 2 kit gives the user versatility in choosing sections and is especially useful in footwear for diabetics and others with pathologic or painful foot conditions.

The kit has composite footwear insole 2 plurality of sections 10 that are constructed of materials previously set forth herein and any other materials used by one skilled in that art for such purposes.

FIGS. 7A-7G show a kit that allows the user to choose the material types for each section based upon comfort and needs. In this system, one or more of each of the removable plurality of sections 10 are provided for each foot, which allows the user to choose and interchange sections depending upon what is most comfortable and/or desirable. For example, while engaging in exercise, a more or less rigid arch ay be preferred over the worn in work shoes. Also, the arch, metatarsal, base, toe, and/or heel sections can be of varying shapes, materials and elevations to accommodate the feet of different users and for usage in different activities for the same user, as long as there is a smooth transition between the elevations of the sections so that the edges of the sections do not protrude and do not cause discomfort during use. FIGS. 7A, 7B, 7E and 7F show an assortment of sections in a disassembled state that can be used in this composite footwear insole 2. The plurality of sections 10 have attachment members 12 on at least a portion of their undersides as those shown on the inside areas of the heel 42, base 30 and metatarsal 24 sections FIG. 7G. The attachment members 12 can be placed on the entire underside of the sections, for example longitudinal arch 36 and toe 18 sections. A strip of attachment members 12 such as hook components/fasteners 14 and counterpart loop components/fasteners 16 of Velcro is placed on the underside of the metatarsal section 24 as in FIG. 7G, or in a cut-out type fashion, e.g. see heel section 42, and any other or configuration so long as the sections are adequately attached and do not become detached during use. FIGS. 7C-7D shows two embodiments the top side 6 of the bottom layer 4 of the composite footwear insole 2 with attachment members 12 thereon, so that the composite footwear insole 2 plurality of sections 10 can be removably attached to the bottom layer 4. The insole 2 plurality of sections 10 of FIGS. 7A-7B, 7E-7G can be of varying elevations, shown in FIGS. 3A, 4A, that show the side view of certain sections demonstrating that the sections have varying thickness. FIG. 7F shows the top surface 20 covering toe section 18 covered with moleskin 79, while toe section 18 of FIG. 7G is covered in silk 80, while another is covered in satin 88, see FIG. 7A, and another is covered in sheared fur 22, see FIG. 7E, and yet another in polyester 92, see FIG. 7B. Other materials with a low co-efficient of friction as well as other suitable materials known to one skilled in the art can also be used. Of course, other natural or synthetic materials, that are soft, cushioning, or rigid or semi-rigid, can also be used or the section may not have any covering over the material used to make the section.

FIGS. 7A-7B show metatarsal sections 24 made of leather 83 and of neoprene 84, respectively, and FIG. 7E and shows a base section 30 made of EVA foam 85. These materials choices shown in FIGS. 7A-7E are illustrative and other materials previously listed and/or known to one skilled in the art can also be used for the metatarsal sections of the insoles. Of course, other natural or synthetic materials, that are soft, cushioning, or rigid or semi-rigid, can also be used. While in some cases the section for one foot is different than that for the material choices for the other foot, in the accompanying figures for the other foot, the figures are merely illustrative of the types of materials that can be used for the sections of either or both feet.

FIG. 7A shows a base section 30 of made of leather 83, FIG. 7B shows a base section 30 made of EVA foam 85, FIG. 7E shows a base section 30 made of neoprene 84, and FIG. 7F shows a base section 30 comprised of plastic 86. Of course, other natural or synthetic materials, that are soft, cushioning, or rigid or semi-rigid, can also be used.

Heel section 42 of FIG. 7B is made of EVA foam 85 and has protrusions 44 and a slightly concave surface, FIG. 7E shows a heel section 42 made of rubber 90 that has protrusions 44 and a slightly concave surface, while heel section 42 of FIG. 7A lacks protrusions, and is made of neoprene 84.

Of course, the material types and surfaces of the sections for the kits as well as the bottom layer can be comprised of any material known to one skilled in the art as well as any of those previously set forth herein.

There can be more or fewer of each of the sections in the kit. These materials choices shown in FIGS. 7A-7F, as well as those previously discussed are illustrative and other materials known to one skilled in the art can also be used for the toe sections of the insoles. Further, in an embodiment, the kits contain sections made from like materials for each foot, but the insoles need not have sections for each foot that are comprised of the same materials.

It is also possible that some of the sections such as the toe piece, heel piece, and metatarsal piece may be used for the right foot and the left foot.

A method of making a multiface and/or multipiece insole for footwear is also contemplated which comprises: providing a bottom layer having a top side, providing a plurality of sections having an underside, wherein the underside of one or more of the sections is attachable to the top side of the bottom layer, and removably or securably attaching the plurality of sections to the top side of the bottom layer to form an insole.

In this method, the sections are comprised essentially of a longitudinal arch section, a heel section, a toe section, a metatarsal section, a base section, or any combination thereof.

In an embodiment, at least one section is integral with the bottom layer, wherein the sections are comprised essentially of a longitudinal arch section, a heel section, a toe section, a metatarsal section, a base section, or any combination thereof.

The method can also further comprise the steps of: placing attachment members for removably attaching the removably attachable sections upon the top of the bottom layer and on the underside of the removable sections, and attaching the sections to the bottom layer. In an embodiment attachment members that comprise hook components and loop components, wherein the hook components are attached to the top side of the bottom layer and the loop components are attached to the underside of the removable sections, or wherein the hook components are attached to the underside of the removable sections and the loop components are attached to the top side of the bottom layer. When the hook and loop components are joined, they form a holding assembly and hold the sections and bottom layer together.

In this method, at least a portion of some of the sections is comprised of materials different from those in the other sections. Also, this method can be used in footwear for diabetics and others with pathologic or painful foot conditions.

In an embodiment, a longitudinal arch section is removably attached to the bottom layer and/or a heel section is removably attached to the bottom layer and/or a toe section is removably attached to the bottom layer and/or a metatarsal section is removably attached to the bottom layer and/or a base section is removably attached to the bottom layer.

In this method, the sections fit together similar to puzzle pieces, and have shapes different from one another.

The insole is suitable for those with and without medical conditions and is especially beneficial in footwear for diabetics and others with pathologic or uncomfortable foot conditions.

The above description is that of preferred embodiments of the invention. It is intended that all matter contained in the above description and shown in the accompanying drawing is illustrative rather than limiting. It should further be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described.

Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents.

Claims

1. A method of making an insole for footwear, comprising:

providing a bottom layer having a top side;

providing a plurality of insole sections having an underside, wherein one of the plurality of insole sections includes a medial edge;

placing attachment members on the top side of the bottom layer and to the underside of the plurality of insole sections for attaching the bottom layer and one or more of the plurality of insole sections;

selecting one or more of the plurality of insole sections for assembly into an insole;

arranging the one or more of the plurality of insole sections in relationship to the bottom layer for attachment to the bottom layer; and

attaching the one or more of the plurality of insole sections to the top side of the bottom layer to form the insole.

2. A method of making an insole for footwear as recited in claim 1, wherein the step of attaching the one or more of the plurality of insole sections to the top side of the bottom layer includes the substep of removably attaching the one or more of the plurality of insole sections to the top side of the bottom layer.

3. A method of making an insole for footwear as recited in claim 1, wherein the step of attaching the one or more of the plurality of insole sections to the top side of the bottom layer includes the substep of affixing the one or more of the plurality of insole sections to the top side of the bottom layer.

4. A method of making an insole for footwear as recited in claim 1, wherein the step of selecting one or more of the plurality of insole sections includes the substep of selecting the sections from the group consisting of a longitudinal arch section, a heel section, a toe section, a metatarsal section, and/or a base section.

5. A method of making an insole for footwear as recited in claim 1, wherein the step of providing a plurality of insole sections having an underside formed with at least one medial edge includes the substep of forming the at least one medial edge for fitting one or more of the plurality of insole sections to one another.

6. A method of making an insole for footwear as recited in claim 1, further comprising the step of placing attachment members on the top side of the bottom layer and to the underside of the plurality of insole sections includes the substeps of:

selecting attachment members that comprise hook components and loop components;

mounting the hook components on the top side of the bottom layer;

mounting the loop components on the underside of the plurality of insole sections intended for removable attachment; or

mounting the hook components on the underside of the bottom layer; and

mounting the loop components on the top surface of insole sections intended for removable attachment.

7. A method of making an insole for footwear as recited in claim 1, wherein the step of providing a plurality of insole sections includes the substep of making the plurality of insole sections from different materials.

8. A method for making a composite footwear insole, comprising the steps of:

selecting one or more materials adapted to make a bottom insole layer having a top side;

choosing one or more materials adapted to make a plurality of insole sections having an underside, further including the substep of choosing materials having different cushioning, hardness, thickness and/or surface characteristics;

shaping the plurality of insole sections for engagement with the top side of the bottom insole layer; and

including attachment members mountable on at least one side of the bottom layer and on the underside of the plurality of insole sections adapted to attach the plurality of insole sections with the bottom layer.

9. A method for making a composite footwear insole as recited in claim 8, wherein the step of shaping the plurality of insole sections for engagement with the top side of the bottom insole layer includes the substep of affixing the one or more of the plurality of insole sections to the top side of the bottom layer.

10. A method for making a composite footwear insole as recited in claim 8, wherein the step of shaping the plurality of insole sections for engagement with toe top side of the bottom insole layer includes the substep of providing one or more layers of material to provide a substantially continuous top surface of assembly of the plurality of insole sections on the bottom layer.

11. A method for making a composite footwear insole as recited in claim 8, wherein the step of shaping the plurality of insole sections for removable engagement with the top side of the bottom insole layer includes the substep of shaping the materials to form a longitudinal arch section, a heel section, a toe section, a metatarsal section, a base section, or any combination thereof.

12. A method for making a composite footwear insole as recited in claim 8, wherein the step of shaping the plurality of insole sections for securable engagement with the top side of the bottom insole layer includes the substep of shaping the materials to form a longitudinal arch section, a heel, a top section, a metatarsal section, a base section, or any combination thereof.

13. A method for making a composite footwear insole as recited in claim 8, whereing the step of shaping the plurality of insole sections for securable engagemet with the top side of the bottom insole layer includes the substep of shaping the materials to form a longitudinal arch section, a heel section, a top section, a metatarsal section, a base section, or any combination thereof.

14. A method for making a composite footwear insole as recited in claim 8, wherein the step of including attachment members includes the substep of selecting hook components and loop components for attachment.

15. A method for making a composite footwear insole as recited in claim 8, wherein the step of choosing one or more materials adapted to make a plurality of insole sections includes the substep of choosing the one or more materials from the group consisting of leather, neoprene. EVA foam, or any combination thereof.

16. A method for making a composite footwear insole as recited in claim 15, wherein the step of choosing one or more materials adapted to make plurality of insole sections includes the substep of choosing for a toe section a material for a top layer selected from the group consisting of moleski, fur, polyester, satin, silk, or any combination thereof.

17. A method for making a composite footwear insole as recited in claim 15, wherein the step of choosing one or more materials adapted to make a plurality of insole sections includes the substep of choosing for a heel section a material for a top layer selected from the group consisting of rubber, neoprene, EVA foam, or any combination thereof.

18. A method for forming components of a kit for assembling a composite footwear insole, comprising the step of:

selecting material to form a bottom layer having a top side;

selecting material to form a plurality of insole sections having an underside.

further comprising the substeps of selecting the material to provide different cushioning,

hardness, thickness and/or surface characteristics for either secure or removable attachment to the bottom insole layer;

providing means for attaching the top side of the bottom layer to the underside of the plurality of insole sections; and shaping the plurality of insole section for attachment to the bottom insole layer.

19. A method for forming components of a kit for assembling a composite footwear insole as recited in claim 18, wherein the step of shaping the plurality of insole section for attachment to the bottom insole layer includes the substeps of:

providing at least one longitudinal arch section;

providing at least one heel section;

providing at least one toe section;

providing at least one metatarsal section; and/or

providing at least one base section.

20. A method for forming components of a kit for assembling a composite footwear insole as recited in claim 19, wherein the step of providing means for attaching the top side of the bottom layer to the underside of the plurality of insole sections includes the substep of:

removably attaching the top side of the bottom layer to the underside of the plurality of insole sections; or

affixedly attaching the top side of the bottom layer to the underside of the plurality of insole sections; or

removably and affixedly attaching selected insole sections of the plurality of insole sections to the top side of the bottom layer.