REMOVABLE FOOTWEAR INSERT

Abstract

A removable puncture protective footwear insert with an insole with an orthotic shape that includes an arch support and a heel cup made of a cellular foam product, a multiple layer protective material where the layers are coupled together and held within the insole and a cushioning and shock absorption material that helps maintain the insole orthotic shape. The cellular foam product is PORON™ or ethylene vinyl acetate, PORON™ and ethylene acetate and the insole may be with or without a tile heel cup. The multiple layer protective material is a SWEN-FLEX® material LENZI EGISTO PS5 ES L-PROTECTION® material, or other puncture proof material. There are also two or more separate methods for manufacturing a removable footwear insert.

Description

The present application is a Continuation-In-Part application of U.S. Non-Provisional application Ser. No. 12/955,820 filed on Nov. 29, 2010, the entire disclosure of which is incorporated by reference. The present application claims priority to U.S. Provisional Application 61/264,825 filed on Nov. 29, 2009, the entire disclosure of which is incorporated by reference.

TECHNICAL FIELD & BACKGROUND

Men, women, children and workers such as residential, commercial, industrial and construction workers that include contractors, brick layers, framers, roofers, siding installers, laborers, supervisors and project manager workers, technicians, law enforcement officers, firemen, demolition workers and clean-up crews that work in hazardous environments, job sites and facilities that are closed-off from the public that are not constantly clean and safe from unseen dangers such as nails, screws, metal, and glass, welding rods and other unforeseen threats that may be exposed to injury to the bottom of their feet. Children may be also at risk for the same type of injuries. In the process of playing, walking or running they often may be not aware of all the unforeseen dangers that may be around them that may be serious dangerous threats.

The present invention generally relates to a removable footwear insert. More specifically, the invention is a removable puncture protective footwear insert.

It is an object of the present invention to provide a removable footwear insert to help prevent serious puncture or cut wounds to the sole of a user's foot from stepping on nails, screws, metal, wood and other sharp objects.

It is an object of the present invention to provide a removable footwear insert that would eliminate the costly effects of the end user having any sharp objects penetrating the soles of their feet and result in pain and suffering, emergency room and doctor fees, x-rays, bloodstream and skin infections, loss of work or school, increase in insurance rates, possible lawsuits, infection and a possible amputation act.

It is an object of the present invention to provide a removable footwear insert that may be orthotic or non-orthotic.

What is needed is a removable footwear insert to help prevent serious puncture or cut wounds to the sole of a user's foot from stepping on nails, screws, metal, wood and other sharp objects, that would eliminate the costly effects of the end user having any sharp objects penetrating the soles of their feet and resulting in pain and suffering, emergency room and doctor fees, x-rays, bloodstream and skin infections, loss of work or school, increase in insurance rates, possible lawsuits, infection and a possible amputation act and provide a removable footwear insert that may be orthotic or non-orthotic.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be described by way of exemplary embodiments, but not limitations, illustrated in the accompanying drawing in which like references denote similar elements, and in which:

FIG. 1 illustrates a side environmental perspective view of a removable footwear insert, in accordance with one embodiment of the present invention.

FIG. 2 illustrates an overhead side perspective view of a removable footwear insert, in accordance with one embodiment of the present invention.

FIG. 3 illustrates a cross-sectional view along line 2′-2′ of FIG. 2 of a removable footwear insert, in accordance with one embodiment of the present invention.

FIG. 4 illustrates a cross-sectional side perspective view along line 2-2 of FIG. 2 of a heel cup, in accordance with one embodiment of the present invention.

FIG. 5 illustrates an exploded side perspective view of a removable footwear insert, in accordance with one embodiment of the present invention.

FIGS. 6A-6C illustrates a flow chart of a first method for manufacturing a removable footwear insert, in accordance with one embodiment of the present invention.

FIGS. 7A-7C illustrates a flow chart of a second method for manufacturing a removable footwear insert, in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Various aspects of the illustrative embodiments will be described using terms commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. However, it will be apparent to those skilled in the art that the present invention may be practiced with only some of the described aspects. For purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the illustrative embodiments. However, it will be apparent to one skilled in the art that the present invention may be practiced without the specific details. In other instances, well-known features are omitted or simplified in order not to obscure the illustrative embodiments.

Various operations will be described as multiple discrete operations, in turn, in a manner that is most helpful in understanding the present invention however the order of description should not be construed as to imply that these operations are necessarily order dependent. In particular, these operations need not be performed in the order of presentation.

The phrase “in one embodiment” is used repeatedly. The phrase generally does not refer to the same embodiment, however, it may. The terms “comprising”, “having” and “including” are synonymous, unless the context dictates otherwise.

FIG. 1 illustrates a side environmental perspective view of a removable footwear insert 100, in accordance with one embodiment of the present invention. The removable footwear insert 100 may be worn by men, women, children and workers such as residential, commercial, industrial and construction workers that may include contractors, brick layers, framers, roofers, siding installers, laborers, supervisors and project manager workers, technicians, law enforcement officers, firemen, demolition workers, clean-up crews and other suitable workers that may work in hazardous environments, job sites and facilities that may be closed off from the public that may be not constantly clean and safe from unseen dangers such as nails, screws, metal, and glass, welding rods and other unforeseen threats that may be exposed to injury to the bottom of their feet. The removable footwear insert 100 may be puncture protective or other suitable removable footwear insert. The removable footwear insert 100 may be an orthotic or a non-orthotic insert made to help prevent serious puncture and cut wounds to the soles of a user's feet from stepping on nails, screws, metal, wood and other suitable sharp objects. The removable footwear insert 100 may be trimmed or shaped to serve as an insert for any type of footwear that covers the entire sole of a user's foot from the user's toes to the user's heel. The removable footwear insert 100 may also be a pre-made insert of various sizes of various types of footwear. The various types of footwear include boots, work boots, sneakers, shoes and other footwear that may be suitable to be utilized in combination with the removable footwear insert 100.

FIG. 2 illustrates an overhead side perspective view of a removable footwear insert 200, in accordance with one embodiment of the present invention. The removable footwear insert 200 may include an insole 210, an arch support 220 and a heel cup 230. The insole 210 may be disposed on top of the removable footwear insert 200. The insole 210 may include a cushioning material 212. The arch support 220 may be formed from the insole 210. The heel cup 230 may be formed from the insole 210.

FIG. 3 illustrates a cross-sectional view along line 2′-2′ from FIG. 2 of a removable footwear insert 300, in accordance with one embodiment of the present invention.

The removable footwear insert 300 may include an upper layer 310 and a lower layer 320. The upper layer 310 may include a cushioning material 312 that serves to provide comfort to a user wearing the removable footwear insert 300. The cushioning material 312 may be disposed on a first portion 310A of the upper layer 310 or other suitable location. The lower layer 320 may be protective material 322 to provide protection from punctures, cuts and other injuries from sharp objects and other suitable objects to a user wearing the removable footwear insert 300. The protective material 322 may be disposed on a bottom portion 322A of the removable footwear insert 300 or other suitable location.

FIG. 4 illustrates a cross-sectional side perspective view along line 2-2 of FIG. 2 of a heel cup 400, in accordance with one embodiment of the present invention. The heel cup 400 may include a first side 410, a second side 420 and a bottom 430. The first side 410 may correspond to the arch support (FIG. 2, 220). The second side 420 may be directly across the arch support (FIG. 2, 220) and may be shorter than the arch support (FIG. 2, 220). The bottom 430 may be formed from the insole (FIG. 2, 210).

FIG. 5 illustrates an exploded side perspective view of a removable footwear insert 500, in accordance with one embodiment of the present invention. The removable footwear insert 500 may include an upper layer 510, a lower layer 520 and an adhesive 530. The upper layer 510 may include a cushion material 512 that provides comfort to a user wearing the removable footwear insert 500. The cushion material 512 may be disposed on the upper layer 510 or other suitable location. The lower layer 520 may be protective material 522 to provide protection to a user wearing the removable footwear insert 500. The protective material 522 may be disposed on the lower layer 520 or other suitable location. The adhesive 530 may be disposed on a top portion 520A of the lower layer 520 or a bottom portion 510A of the top layer 510 to fasten the upper layer 510 and the lower layer 520 together.

Different moldable urethanes like EVA may be utilized for different firmness for the arch support to make the arch support stiff with three firmness settings; low firmness, medium firmness and heavy firmness. All firmness settings may be flexible at the insole. The insole may be comfortable, flexible, light-weight, creates a barrier against hot and cold temperatures and may be non-conductive unlike other protective insoles that may be made with a stainless steel plate or that may be constructed with a stainless steel plate incorporated in the sole of the footwear.

The insole may also hold a multiple layer protective material, such as non-metallic, puncture resistant and midsole material or SWEN-FLEX® material, puncture resistant insole materials or LENZI EGISTO PS5 ES L-PROTECTION® material, Terylene Cotton or TC cotton material or cut, abrasion, penetration-resistant protective apparel or TURTLE SKIN® that may be coupled together. The multiple layer protective material, the SWEN-FLEX® material, puncture resistant insole materials or LENZI EGISTO PS5 ES L-PROTECTION® material, Terylene Cotton or TC cotton material or cut, abrasion, penetration-resistant protective apparel or TURTLE SKIN® may be a fabric but may be any type of suitable material. The LENZI EGISTO PS5 ES L-PROTECTION® material, TC cotton material or TURTLE SKIN® may be non-conductive and have at least three or more layers of fabric, with a double-faced weft, made of relatively high wear resilient polyester fibers that may be coupled together by a thermoplastic film or an adhesive resin. Each of the layers of the material may be treated by a coating of polyurethane and/or acrylic resin that may be enriched with micronized ceramic materials in the form of silicates, such as aluminum silicate.

Moldable closed cell foams may be utilized to make the SWEN-FLEX® material and the LENZI EGISTO PS5 ES L-PROTECTION® material to hold the orthotic shape of the removable footwear insert with or without the heel cup. The moldable closed cell foams may come in different suitable colors, thicknesses and firmness depending on the relative firmness of the arch support and heel cup that may be desired by a user. The moldable closed cell foams may help distribute the weight of a user's body evenly over the entire area of a user's foot and sole. As previously described, EVA may be one of the closed cell foams made from ethylene vinyl acetate and blended copolymers and has a high level of chemical cross-linking, that may result in a semi-rigid product with a fine uniform cell structure that may be suitable for utilization in a wide variety of environments and applications. Benefits of EVA and other types of closed cell foams may include relatively good impact and vibration absorption, relatively good weather and chemical resistance including splash resistance to oils and fuels, relatively good acoustic and thermal insulation properties, relatively good buoyancy with low water absorption and relatively good suitability for thermo-forming and thermo-molding.

An open cell urethane material may be utilized as a cushioning and shock absorption material and also helps to maintain the orthotic shape of the removable footwear insert when using the SWEN-FLEX® and/or the Lenzi Egisto. Open cell urethane material may be available in a wide variety of colors, thicknesses, densities and surface textures to accommodate almost any activity, from everyday utilization to the rigorous demands of high-impact sports and exercise. Open cell urethane material may have a maximum retention of comfort and flexibility and may be made without plasticizers, which means the open cell urethane material will not shrink or become brittle and crack with age. Open cell urethane material may retain a like-new softness and flexibility, which may result in a high degree of impact absorption with more shock absorption and less impact to feet and joints. In side-by-side drop weight tests, open cell urethane material outperformed vinyl sponge, neoprene sponge, sponge rubber, LATEX® foam and other solid viscoelastic material. Open cell urethane material may form permeable layers that form a breathable layer to help feet stay dry and cool and draw water vapor and perspiration away. Open cell urethane material may also have excellent compression set resistance which enables durable, long-term performance for gasketing, sealing and cushioning. Open cell urethane material may also have low-out gassing and non-fogging and contain no plasticizers or residual chemicals to contaminate any device the open cell urethane material forms. Open cell urethane material may not become brittle and crumble and may be non-corrosive to metal and may be inherently flame retardant without the utilization of additives. Many of the open cell urethane material may meet flammability requirements of UL HBF and MVSS 302. Engineered open cell urethane material may also offer a wide modulus in the range of approximately 2 to 90 psi @ 25% deflection for more design versatility requirements. Open cell urethane material also may have good chemical resistance, may be easy to fabricate, die-cut cleanly and work with a broad range of adhesives and may have a broad range of formulas and thicknesses in the range of approximately 0.012 inches to 0.500 inches (i.e., 0.43 mm to 12.7 mm).

A thermoplastic hot melt film adhesive may be utilized to couple the insole, the multiple layer protective material, the SWEN-FLEX®, the Lenzi Egisto, the TC cotton material or TURTLE SKIN® and the open cell urethane material may be heat activated in the approximate range of 140 to 340 degrees Fahrenheit. A second adhesive may include a HM 8545 adhesive that may also be utilized as a fastener. A third adhesive such as a pressure activated adhesive (no number) may also be applied and couple the insole, multiple layer protective material, SWEN-FLEX®, Lenzi Egisto, TC cotton material or TURTLE SKIN® and the open cell urethane material together and may be heat activated in the approximate range of 140 to 400 degrees (Fahrenheit) depending on what specific previously mentioned materials may be utilized. A rubber welt may also be utilized as a cushioning material.

FIGS. 6A-6C illustrates a flow chart of a first method for manufacturing a removable footwear insert 600, in accordance with one embodiment of the present invention. The first layer of the removable footwear insert 600 may be a protective material or fabric. A layer of adhesive contact cement that may be specifically chemically formulated to couple open and/or closed celled urethanes and or polyurethanes to the protective materials and fabrics may be then applied 610. An additional adhesive may be put on top of a SWEN-FLEX® material, or Lenzi Egisto or other protective materials or fabrics 620. A layer of thermoplastic hot melt film may be then placed on top of the protective material 630 and a layer of moldable urethane may be placed on top of the thermoplastic hot melt film 640. A layer of thermoplastic hot melt film may be placed on top of the moldable urethane 650 so that a layer of colored urethane may be placed on top of the thermoplastic hot melt film 660 which may be on top of the moldable urethane. Then a layer of thermoplastic hot melt film may be placed on top of the colored urethane 670 so that a layer of materials, fabrics, amarelle or moisture resistant fabric and logo may be compressed together and heated to activate the thermoplastic hot melt film which molds and couples all layers to produce an orthotic removable puncture resistant insole that may be trimmed to fit any footwear 680 forming an assemblage.

Other thicknesses of urethanes may be utilized to hold the protective material or materials to an orthotic shape, although the thickness of one embodiment of the insole may be approximately ¼ inch or other suitable thickness. The entire assemblage may be then put in an orthotic mold, then pressed, cut and heated to hold all layers of material or fabrics together 690. Other thicknesses of moldable urethane's or other moldable materials that may be well known in the art may be utilized to hold the protective materials to the orthotic shape. A logo may also be disposed on top of the removable footwear insert if desired by a user 692. The moldable urethane and the urethane may also be utilized to hold the protective material or fabric to the orthotic shape 694. The moldable urethane may also be placed on top of the thermoplastic hot melt film which may be on top of the protective material and then a layer of thermoplastic hot melt film may be placed on top of the moldable urethane 612. Then the urethane may be placed on top of the thermoplastic hot melt film which may be on top of the moldable urethane 614. A layer of thermoplastic hot melt film may be placed on top of the sized and colored urethane and then fabric that may be of any suitable color may be placed on top of the thermoplastic hot melt film which may be on top of the sized and colored urethane 616. Other thicknesses of moldable urethane's other types may be utilized to hold the protective material or fabric to the orthotic shape. It may be then all put in an orthotic mold, then pressed, cut and heated to hold the layers of material and fabrics together 618.

FIGS. 7A-7C illustrates a flow chart of a second method for fitting a removable footwear insert 700, in accordance with one embodiment of the present invention. A layer of adhesive may be put on top of the protective materials 710 and then the adhesive may be put onto a layer of any size and color of urethane 720. The protective materials and urethane may be then heated to approximately 400 degrees (F.) 730 where both adhesive sides may be then sandwiched together and may be then pressed with a roll pin type action and may be then dried 740. After drying, the protective materials and urethane will be stamped out into the shape of a flat non-orthotic insole that may be trimmed to fit into any piece of footwear to cover and protect 100% of the user's sole 750. This may be an improvement over many stainless steel plated insoles that may only cover and protect approximately 85% of the user's sole. Other suitable thicknesses of suitable moldable urethane's or other moldable materials that may be well known in the art may be utilized to hold the protective material or fabric to the orthotic shape of the insole. Urethane foam may also be injected into an orthotic mold, cured and taken out and a layer of adhesive may be applied on the bottom of the molded urethane foam 760. Adhesive may be then put on top of the protective material and the molded urethane may be placed on top of the protective material 770 and additional adhesive may be placed on top of the molded urethane and moisture resistant material or other types of material heated and pressed to hold all of the layers of material and adhesive together 780. A logo may also be disposed on top of the material 790. Adhesive may also be placed on top of the protective material 712 and a moisture resistant material may be placed on top of the protective material 714 and may be heated and pressed together to couple the adhesive and protective material together 716.

The removable footwear insert may come in a plurality of styles. The first style may be a flat protective insert without an orthotic or an orthopedic insole and no flat cushion adhered to it on either side. The insert may come in two precut sizes. One size may be a men's size thirteen that may be trimmed down to any size. The other size may be a men's size sixteen that may be trimmed down to a men's size thirteen and a half. Either size may be trimmed to fit by the end user. The other sizes may be manufactured to be precut to any size. This may be done with a press cutting machine that has sized forged dies in the shape of footwear insoles that may be attached to the top plate of the cutting machine and when the button may be pushed the plate with the sized forged dies comes down cutting the protective material into one or more sizes. The insert may be placed underneath the original footwear insole or on top of the original footwear insole or may replace the original footwear insert or insole. The company and product logo may be either stamped or hot melted in the middle of the insert on the top side.

The second style may be also a flat protective insert without an orthotic or an orthopedic insole and without a flat cushion adhered to it on either side. The bottom of the protective material may be facing upward and then an adhesive may be sprayed on or rolled. Then it may be covered with a non-adhesive wax paper or plastic that will not adhere to the adhesive so that it would be a peel and stick concept. Then the sheet of protective material may be placed into a press cutting machine that has sized forged dies in the shape of footwear insoles that may be attached to the top plate of the cutting machine and when the button may be pushed and the plate with the sized forged dies comes down cutting the protective material. The insert may come in two precut sizes. One size may be a men's size thirteen that may be trimmed down to any size. The other size may be a men's size sixteen that may be trimmed down to a men's size thirteen and a half. Either size may be trimmed to fit by the end user for 100% protection. The other sizes may be manufactured to be precut to any size. Then the end user may peel the non-adhesive paper or plastic off the bottom and place the insert underneath the original insole. This will allow the protective insert to be coupled to the inner sole of the footwear to reduce slippage and/or movement. The end user may utilize it as a replacement insert for the footwear and be protected from unforeseen dangers of sharp objects penetrating the sole of the footwear injuring the foot sole of the end user. The company and product logo may be either stamped or hot melted on the top of the fabric and in the middle of the insert.

The third style may be also a flat protective insert without an orthotic or orthopedic insole and without a flat cushion adhered to it on either side. Spraying or rolling an adhesive on the top of the sheet of protective material then covering it with a non-adhesive wax paper or plastic that does not adhere to the adhesive. The sheet of protective material may be flipped over on the other side and do the same process so that it would be a peel and stick concept. Then the sheet of protective material may be placed into a press cutting machine that has sized forged dies in the shape of footwear insoles that may be attached to the top plate of the cutting machine and when the button may be pushed the plate with the sized forged dies comes down cutting the protective material. The insert may come in two precut sizes. One size may be a men's size thirteen that may be trimmed down to any size. The other size may be a men's size sixteen that may be trimmed down to a men's size thirteen and a half. Either size may be trimmed to fit by the end user for protection over the entire sole of a user's sole. The other sizes may be manufactured to be precut to any size. Then the end user may peel the non-adhesive paper or plastic off the bottom and place the insert underneath the original insole. This may allow the protective insert to be coupled to the inner sole of the footwear to reduce slippage and/or movement. Then the end user may peel-off the wax paper or plastic from the top of the protective insert that may be already in the footwear and place's the original insole back into the footwear on top of the adhesive protective insert which will couple together to reduce slippage and/or movement. The end user could utilize it as a replacement insert for the footwear and be protected from unforeseen dangers of sharp objects penetrating the sole of the footwear injuring the foot sole of the end user. The company and product logo may be either stamped or hot melted in the middle of the insert on the top side.

The fourth style may be the flat protective insert without an orthotic or an orthopedic insole but with a flat cushion that may be adhered to the top of the protective materials while adhering a cushion material such as PORON™, rubber, EVA, Gel-Coat, polyurethane, urethane, etc. to the sheet of protective materials. The top side of the protective materials may be sprayed or rolled with an adhesive then the cushion material may be laid on the top of the adhesive that may be on top of the protective materials. After some time passes, then the sheet of protective material with the cushion on the top side may be placed into the press cutting machine that has sized forged dies in the shape of footwear insoles that may be attached to the top plate of the cutting machine and when the button may be pushed the plate with the sized forged dies comes down cutting the size(s). The protective insert with the cushion on top may either be manufactured without an adhesive on the bottom that would be utilized to replace the original footwear insert. An adhesive may also be sprayed or rolled to the bottom of the protective insert.

The process of manufacturing the protective insert with an adhesive on the bottom may be that the protective material may be flipped where the bottom may be facing upward and the cushion may be facing downward. Then an adhesive may be sprayed or rolled onto the material and covered with a non-adhesive wax paper or plastic that will not adhere to the adhesive so that it would be a peel and stick concept. Then the sheet of protective material may be sled into the press cutting machine that has sized forged dies in the shape of footwear insoles that may be attached to the top plate of the cutting machine and when the button may be pushed the plate with the sized forged dies comes down cutting the size(s). This would allow the end user to remove the original insole of the footwear, peel the non-adhesive wax paper or plastic off the bottom of the protective insert and place it onto the inner shoe sole of the footwear and press down. This will allow the protective insert to be coupled to the inner sole of the footwear to reduce slippage and/or movement. The insert may come in two precut sizes. One size may be a men's size thirteen that may be trimmed down to any size. The other size may be a men's size sixteen that may be trimmed down to a men's size thirteen and a half. Either size may be trimmed to fit by the end user for 100% protection. The other sizes may be manufactured to be precut to any size. The end user could utilize it as a replacement insert for the footwear and be protected from unforeseen dangers of sharp objects penetrating the sole of the footwear injuring the foot sole of the end user. The company and product logo may be either stamped or hot melted in the middle of the insert on the top side.

The fifth style may be a premade orthotic or orthopedic shaped insole made of polyurethane, rubber, EVA, PORON™, urethane or other suitable material. A layer of different types of fabric materials such as hypo-allergenic fabric, anti-fungus, water proof, nylon fabric that comes in different colors and may be utilized in all military footwear and meets all military specifications or other types and styles of fabrics may be adhered with adhesive to the top of the premade orthotic or orthopedic insole. The company and product logo may be either stamped or hot melted in the middle of the insert on the top side.

The protective material may be placed into the press cutting machine that has sized forged dies in the shape of footwear insoles that may be attached to the top plate of the cutting machine and when the button may be pushed the plate with the sized forged dies comes down cutting the size(s). The protective inserts may also be cut to the shape of the footwear insole by using a laser machine. The sheet of protective material may be placed on top of the cutting table of the laser machine and then the sizes may be added to a computer program of the machine and the machine tells the laser what and how to cut the protective material. After the sheet of protective inserts may be cut out, they may be either placed in a sized insole mold and sprayed or rolled or sprayed with an adhesive and then placed into a sized insole mold and then the orthotic or the orthopedic insole may be placed on top of the adhesive that may be on top of the protective insert.

Adhesive may also be sprayed or rolled to the bottom of the protective insert. The process of manufacturing the protective insert with an adhesive on the bottom may be that the protective material may be flipped where the bottom may be facing upward. Then an adhesive may be spayed or rolled onto the material and covered with a non-adhesive wax paper or plastic that will not adhere to the adhesive producing a peel and stick concept. Then the sheet of protective material may be sled into the press cutting machine that has sized forged dies in the shape of footwear insoles that may be attached to the top plate of the cutting machine and when the button may be pushed the plate with the sized forged dies comes down cutting the size(s). The insert may come in two precut sizes. One size may be a men's size thirteen that may be trimmed down to any size. The other size may be a men's size sixteen that may be trimmed down to a men's size thirteen and a half. Either size may be trimmed to fit by the end user for 100% protection. The other sizes may be manufactured to be precut to any size. This method would have to be done before the orthotic or the orthopedic insole may be adhered to the top of the protective material insert. This would allow the end user to remove the original insole of the footwear, peel the non-adhesive wax paper or plastic off the bottom of the protective insert and place it onto the inner shoe sole of the footwear and press down. This will allow the protective insert to be coupled to the inner sole of the footwear to reduce slippage and/or movement. The end user could utilize it as a replacement insert for the footwear and be protected from unforeseen dangers of sharp objects penetrating the sole of the footwear injuring the foot sole of the end user.

While the present invention has been related in terms of the foregoing embodiments, those skilled in the art will recognize that the invention may be not limited to the embodiments described. The present invention can be practiced with modification and alteration within the spirit and scope of the appended claims. Thus, the description is to be regarded as illustrative instead of restrictive on the present invention.

Claims

1. A removable puncture protective footwear insert, comprising:

an insole that includes an arch support, said insole is made of a cellular foam product that covers an entire bottom of a user's foot;

a multiple layer protective material with a plurality of layers, wherein said layers may be coupled together and held within said insole; and

a cushioning and shock absorption material that helps maintains an insole shape.

2. The insert according to claim 1, further comprising a heel cup.

3. The insert according to claim 1, wherein said cellular foam product is ethylene vinyl acetate.

4. The insert according to claim 1, wherein said multiple layer protective material is a fabric.

5. The insert according to claim 1, wherein said multiple layer protective material is a puncture proof material.

6. The insert according to claim 5, wherein a thermoplastic hot melt film adhesive couples said insole, said multiple layer protective material, said puncture proof material, said cambrelle material and said cushioning and shock absorption material together.

7. The insert according to claim 1, wherein a second adhesive couples said insole, said multiple layer protective material, said puncture proof material, said TC cotton material or cambrelle material and said cushioning and shock absorption material.

8. The insert according to claim 7, wherein said second adhesive is heat activated.

9. The insert according to claim 8, wherein said second adhesive is heat activated in the range of 140 and 400 degrees Fahrenheit.

10. The insert according to claim 1, wherein said cushioning and shock absorption material is made of open cell urethane.

11. A removable puncture protective footwear insert, comprising:

an insole that includes an arch support and a heel cup, said insole is made of a cellular foam product that covers an entire bottom of a user's foot;

a multiple layer protective puncture proof material with a plurality of layers, wherein said layers may be coupled together and held within said insole;

a cushioning and shock absorption material that helps maintain an insole shape; and

a thermoplastic hot melt film adhesive that couples said insole, said multiple layer protective material, said puncture proof material, said cambrelle material and said cushioning and shock absorption material together.

12. The insert according to claim 11, wherein said cellular foam product is ethylene vinyl acetate.

13. The insert according to claim 11, wherein said multiple layer protective material is a fabric.

14. The insert according to claim 11, wherein a second adhesive couples said insole, said multiple layer protective material, said puncture proof material, said TC cotton material or cambrelle material and said cushioning and shock absorption material.

15. The insert according to claim 14, wherein said second adhesive is heat activated.

16. The insert according to claim 15, wherein said second adhesive is heat activated in the range of 140 to 400 degrees Fahrenheit.

17. The insert according to claim 11, wherein said cushioning and shock absorption material is made of an open cell urethane.

18. The insert according to claim 11, wherein the insert is a flat protective insert without an orthopedic insole and without a flat cushion adhered to either side of the insert.

19. The insert according to claim 18, wherein the flat protective insert is a premade orthotic insole.

20. The insert according to claim 19, wherein the insert is made of material selected from the group consisting of polyurethane, rubber, ethylene vinyl acetate, cellular urethane foam or urethane.