SOCK ORTHOTIC

A sock orthotic includes a sock portion that surrounds and engages at least a portion of a foot, and an orthotic portion that can be situated substantially adjacent to a plantar aspect of the foot. The orthotic portion is integrally affixed to the sock portion to avoid slippage. The sock portion defines a lower opening and an upper opening relative to the plantar aspect, and the orthotic portion is affixed to the sock portion at a perimeter of the lower opening defined by the sock portion.

Skip to: Description  ·  Claims  · Patent History  ·  Patent History
Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit under 35 U.S.C. § 119(e) to U.S. Prov. App. No. 62/785,671, filed Dec. 27, 2018, which is hereby incorporated by reference as if fully set forth herein.

BACKGROUND OF THE INVENTION Field of the Invention

The present disclosure relates in general to a sock orthotic, and more specifically, to a sock with an attached orthotic insole on the plantar aspect of the foot providing comfort, structural support, and an all-day orthotic benefit, as the sock orthotic can be worn with or without shoes.

Description of the Related Art

For thousands of years, humans have been walking with or without footwear. Footwear was born of necessity to navigate harsh terrain or to protect from the elements. The human foot contains 26 bones, 33 joints (20 of which are actively articulated), and more than a hundred muscles, tendons, and ligaments. Humans have discovered through the years that this complex makeup can give rise to a wide variety of foot-related issues. Some of these issues are genetic, while others stem from improper structural footwear that humans choose to wear.

Today, many foot-related issues arise from the wide variety of footwear necessary to complete the many and varied daily tasks in which we engage: work, leisure, athletics, etc. The only viable solutions currently available to treat ailments of the foot are (i) to wear a shoe that puts the foot into proper anatomical position, or (ii) to add to the shoe orthotic insoles that provide or increase the structural support not otherwise built into the shoe. Both of these solutions require the ailing person to wear a shoe. As a result, there has arisen a pressing need for a solution to foot-related ailments that is effective in the absence of a shoe.

Myriad products currently exist for the treatment of various ailments of the foot and ankle. In terms of sheer number, available options are greatly concentrated in the shoe insole market, and, in particular, in the market for over-the-counter orthotic insoles and custom orthotics. For purposes of this disclosure, references to “shoe insoles” relate to over-the-counter orthotic insoles and custom-made orthotics that are placed in a pair of shoes. Shoe insoles can be used for comfort in scenarios of excessive standing or physical activity, act as a preventative measure to foot pain by providing structural support where needed, or help treat a wide-variety of physical ailments, such as plantar fasciitis.

For some users, placing a shoe insole into a pair of shoes suffices to mitigate foot-related issues for relatively long periods of time and is therefore a sufficient and annoyance-free solution to their ailments. For others, however, this traditional, shoe-centered paradigm is impractical and counterproductive to the treatment of their various foot and foot-related problems. As an example of the impracticality of constant shoe use, there are many individuals that may spend all or a majority of their time at home, where wearing shoes may be impractical or counter to house or societal norms or rules. These individuals, therefore, face the difficult choice of either (a) bucking these norms or rules and wearing shoes inside the home or (b) foregoing shoes, and the shoe-insole benefits that accompany those shoes, for all or a significant portion of the day. Moreover, even if one is willing or able to wear shoes inside the home, more often than not, the bed, couch, recliner, dinner table, and other areas are strictly off-limits for shoes, which may further limit the availability of shoe insole relief.

Even where shoe use is widely acceptable and unrestricted, shoe insole users may find that the wide-variety of shoe options presents an interaction issue between a user's sock, the shoe, and the shoe insole. In particular, a familiar complaint of many shoe insole users is that the shoe insole does not fit properly inside the shoe. This can happen because of a variety of reasons, including, but not limited to:

    • (a) the user is placing the shoe insole on top of the original base layer insole; therefore, reducing amount of space for the foot to fit in shoe;
    • (b) the shoe insoles length, width or depth may not be ideal for a given pair of shoes; therefore, the shoe insole must be trimmed to fit; or
    • (c) the shoe can be damaged from trying to alter/remove the original base layer insole to make room for a shoe insole.

Any of the above may result in an uncomfortable amalgam of material layers situated at the bottom of the shoe. This painful and annoying side effect is often an unavoidable and unwelcome “price-of-admission” for those seeking treatment or relief to foot-related issues through the use of shoe inserts. Additionally, if a user has to remove the original base layer insole from a pair of shoes to make sufficient room for a shoe insole and the user's foot, as is often the case, the user's only option is to purchase a full-length shoe insole to fill the void.

What is more, shoe insoles simply do not lend themselves to easy footwear changes. With each change of footwear, each shoe insole must be removed from its current shoe and placed into the next pair. If a user desires to avoid this near-constant changing of shoe insoles, the user's only choice is to purchase a pair of shoe insoles for each of his or her many sets of shoes, which can be prohibitively expensive for many users. This annoyance is particularly acute for those who enjoy—or make their living—engaging in certain activities or sports that require relatively frequent shoe changes, and it is not limited to those living a life of luxury or extravagance. Take, for instance, a fairly common daily routine in which a user goes to work, runs to the gym, spends some casual time with the family and then goes to a restaurant for dinner. It would not be uncommon throughout the course of such a routine to use three or four different pairs of shoes, which, based on currently available solutions, requires the user to make a choice among the following unsavory options: (i) forgo the use of shoe inserts altogether and deal with foot pain throughout the day, (ii) change shoe inserts at four different times throughout the day, or (iii) purchase four, separate pairs of costly shoe inserts.

Furthermore, changing shoe insoles can be unsanitary. Due to the types of materials used to create currently available shoe insoles, there is no fast, easy and thoroughly sanitary way to clean them. The norm for shoe insoles is to hand-wash and air dry. This can be very time-consuming, may not disinfect the shoe insoles properly, and leaves the user without a solution to his or her foot problem while the cleaning and drying process is ongoing. Most commonly, users will decide not wash their shoe insoles, either because of the time and difficulty involved or because the shoe insoles may be labeled “odor-resistant” or “anti-bacterial.” By not washing shoes or shoe insoles, a typical pair of high-use shoes can become unclean and develop odors within a relatively short period of time. This, again, leaves the user with a particularly unsavory, and potentially costly, choice—dirty insoles, new insoles, or no insoles.

Therefore, an improved method of receiving all-day foot comfort and structural support is needed to alleviate the above-mentioned downsides to the presently available, shoe-centric market offerings. In addition, other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and embodiments, taken in conjunction with the accompanying figures and the foregoing technical field and background.

The Background section of this document is provided to place embodiments of the present disclosure in technological and operational context, to assist those of skill in the art in understanding their scope and utility. Unless explicitly identified as such, no statement herein is admitted to be prior art merely by its inclusion in the Background section.

SUMMARY

To minimize the limitations in the prior art, and to minimize other limitations that will be apparent upon reading and understanding the present specification, the present disclosure describes sock orthotics, which in general terms is a sock with an attached, non-removable orthotic insole on the plantar aspect of the sock. The orthotic insole portion described by this disclosure is in the same art as a shoe insole, but rather the orthotic insole is attached to a sock, not placed separately into a shoe.

A sock orthotic will be made available as a left and right sock with corresponding right and left orthotic insoles attached on the plantar aspect of the foot. The orthotic insole portion will be thin enough to allow users to slide into a shoe, yet strong enough to provide comfort and structural stability and ultimately keeping user's foot in correct anatomical positioning all hours of the day, with or without shoes.

It is an objective of the sock orthotic to provide orthotic benefit with or without wearing shoes.

It is an objective of the present invention to allow the user to wear the sock orthotic all day and night.

It is an objective present invention to help support the arch region of the foot, helping users with low-arch or high arch pain related issues.

It is an objective of the present invention to support the proper alignment of the bones in the foot to help alleviate pain and/or discomfort in forefoot, mid-foot and rear-foot.

It is another objective of the present invention to provide a plurality of types of socks for different occasions and circumstances.

It is another objective of the present invention to provide a plurality of types of orthotic materials including soft, semi-rigid and rigid materials.

It is another objective of the present invention to be able to be properly washed via standard machine-washing protocol.

Finally, it is another objective of the present invention for the orthotic insole portion not to be intended for removal from the sock.

Briefly described, embodiment of the present disclosure relate to sock orthotics. According to one aspect, a sock orthotic comprises a sock portion configured to surround and engage at least a portion of a foot. Further, an orthotic portion is configured to be situated substantially adjacent to a plantar aspect of the foot. Also, the orthotic portion is affixed to the sock portion.

According to another aspect, the sock portion defines a lower opening and an upper opening relative to the plantar aspect.

According to another aspect, the orthotic portion is affixed to the sock portion at a perimeter of the lower opening defined by the sock portion.

According to another aspect, the sock portion defines an upper opening relative to the planar aspect and comprises a lower portion configured to engage the plantar aspect of the foot.

According to another aspect, the orthotic portion is affixed to the sock portion at a plane defined by the lower portion of the sock portion and an upper surface of the orthotic portion.

According to another aspect, the orthotic portion is affixed to the sock portion via one or more of thread, adhesive, or any other fastener known in the art.

According to another aspect, the sock portion comprises all or part of a male sock, female sock, athletic sock, tube sock, ankle sock, low-cut sock, full-calf sock, full-length sock, full-leg sock, a leg of a pant, dress sock, moisture-wicking sock, compression sock or pant, job-specific sock, sport-specific sock, knee-high sock, or any other sock, pant, and/or any other clothing known in the art.

According to another aspect, the orthotic portion is comprised of lengths such as half (heel cup), ¾ or full length and compromised of functional varieties such as arch-support (low, medium and high support), non-custom made (over-the-counter), custom-made, pre-contoured, soft, semi-rigid, rigid, comfort fit or other orthotics known in the art.

According to another aspect, the sock orthotic further comprises one or more pull-assisting features affixed to the sock portion and/or the orthotic portion configured to assist with pulling the sock orthotic onto place on the foot.

According to another aspect, the sock portion further comprises one or more blister pads and/or compression areas.

According to another aspect, the sock orthotic further comprises an ankle brace or ankle support located intrinsic to or extrinsic to the sock orthotic.

According to one aspect, a method for constructing a sock orthotic comprises obtaining a sock portion of the sock orthotic configured to surround and engage at least a portion of a foot. Further, the method includes obtaining an orthotic portion configured to be situated substantially adjacent to a planar aspect of the foot. Also, the method includes affixing the sock portion to the orthotic portion.

These and other advantages and features of the present disclosure are described herein with specificity so as to make the present disclosure understandable to one of ordinary skill in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the disclosure are shown. However, this disclosure should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Like numbers refer to like elements throughout.

FIG. 1 is an illustration of an example sock orthotic according to example aspects of the present disclosure.

FIG. 2 is an illustration of an example sock portion of a sock orthotic according to example aspects of the present disclosure.

FIG. 3 is an illustration of another example sock orthotic according to example aspects of the present disclosure.

FIG. 4 is an illustration of another example sock portion of a sock orthotic according to example aspects of the present disclosure.

FIG. 5 illustrates a bottom view of the sock orthotic of another aspect of the disclosure showing a pore structure.

FIG. 6 illustrates a bottom view of a sock orthotic with different hardness.

FIG. 7 illustrates a sock orthotic with a chamber inside the orthotic portion.

 DETAILED DESCRIPTION

For simplicity and illustrative purposes, the present disclosure is described by referring mainly to an exemplary embodiment thereof. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be readily apparent to one of ordinary skill in the art that the present disclosure may be practiced without limitation to these specific details.

The physiology of the human foot is complex, and heredity and the strains of human activity give rise to the conditions treated by orthotics. The human foot contains 26 bones, 33 joints (20 of which are actively articulated), and more than a hundred muscles, tendons, and ligaments. The bones of the foot include the tibia, fibula, tarsus: talus, calcaneus, cuneiformes, cuboid, and navicular metatarsus: first, second, third, fourth, and fifth metatarsal bone phalanges. The human foot has two longitudinal arches and a transverse arch maintained by the interlocking shapes of the foot bones, strong ligaments, and pulling muscles during activity. The muscles acting on the foot can be classified into extrinsic muscles, those originating on the anterior or posterior aspect of the lower leg, and intrinsic muscles, originating on the dorsal (top) or plantar (base) aspects of the foot. The nerves of the foot include the medial plantar, lateral plantar, deep fibular and superficial fibular. The arteries of the foot include the dorsalis pedis, medial plantar and lateral plantar.

There are numerous conditions of the foot that can be treated with the invention. These conditions include flat feet, high-arched feet, rheumatoid arthritis, plantar fasciitis (Policeman's Heel), hallax vulgas (bunions) juvenile idiopathic arthritis, plantar's ulcers and for the prevention of foot ulcers in at-risk diabetic feet.

A sock can be defined as a garment for the foot and lower part of the leg, typically knitted from wool, cotton or nylon. An orthotic can be defined as an artificial support or brace for the limbs or spine

As the market currently stands, foot orthotic material types can fall into three categories: soft, semi-rigid and rigid.

Soft orthotic insoles help to protect the foot and work to reduce pressure and minimize shock. Soft orthotics are usually made of soft, compressible materials (i.e. gel or silicone). This type of orthotic is good for any user looking for additional daily comfort and relief.

Semi-rigid orthotics are used to provide control and as well as protection. They are often used by athletes or those who spend a considerable amount of time on their feet. It allows for responsive support of the foot while standing, running or participating in sports. It is constructed of layers of soft materials, reinforced with more rigid materials.

Rigid orthotic devices are designed to control foot function and are generally made of a firm material to prevent a user's foot from moving in a particular direction. This type of orthotic is often used to improve or eliminate pain in the legs, thighs and lower back due to abnormal function of the foot. Rigid orthotics are most-often prescribed by a foot doctor (DPM), and require a casting or mold of the user's foot.

The example embodiments presented by the present disclosure describe a sock orthotic, a novel form of orthotic that addresses many of the problems which exists from shoe insole solutions introduced above. In an aspect, the sock orthotic described herein is made up of a sock portion and an orthotic insole portion that are fixed together, allowing a user to enjoy the benefits of an orthotic insole simply by pulling on a sock, while avoiding the pitfalls that have been traditionally tied to shoe insole orthotics.

In one significant benefit over current market options, by using the sock orthotic introduced in the present disclosure, a user (also may be referred to as “customer,” “patient,” or the like herein) is able to more freely take advantage of the benefits of orthotics throughout the entire day (or any given time period). For instance, unlike a shoe insole, the example sock orthotic embodiments introduced herein allow users to switch from one pair of shoes to another pair without a break in orthotic insole support, which allows for consistent support and increased comfort when altering footwear on the go. Likewise, whereas shoe insole by definition require a shoe to house the shoe insole and therefore limit use in certain locations and situations (e.g., at home, in friends and relatives' homes, in bed, on a couch), a sock orthotic does not have this limitation, freeing the user from arbitrary barriers to use and treatment, and providing the user with the very tangible relief that comes with orthotic insole use throughout the day.

An advantage of the inventive sock/orthotic over orthotics of the conventional art resides in the orthotic being integral with the sock by sewing, gluing, welding, fastening, etc. The snug fit of the sock permits a very precise positioning of the orthotic on the desired feature of the foot, i.e., the arch, the heel, the toes, bunions, etc. This prevents slippage or displacement of the orthotic from its intended position by less than 10 about mm, preferably less than about 5 mm and most preferably by less than about 2 mm. In contrast, when an orthotic is merely placed in the shoe or is removably or temporarily placed in juxtaposition to a sock, substantial slippage or displacement of the orthotic can occur. This slippage or displacement can result in pain or even damage to the underlying bone, tendons and tissue.

The sock portion may include all or part of a male sock, female sock, athletic sock, tube sock, ankle sock, low-cut sock, full-calf sock, full-length sock, full-leg sock, a leg of a pant, dress sock, moisture-wicking sock, compression sock or pant, job-specific sock, sport-specific sock, knee-high sock, or any other sock, pant, and/or any other clothing known in the art.

According to another aspect, the orthotic portion is formed of lengths such as half (heel cup), ¾ or full length and compromised of functional varieties such as arch-support (low, medium and high support), non-custom made (over-the-counter), custom-made, pre-contoured, soft, semi-rigid, rigid, comfort fit or other orthotics known in the art.

FIG. 1 illustrates a non-limiting example of a shoe orthotic 100 according to certain embodiments. As shown, the sock orthotic 100 can include a sock portion 10 affixed to a orthotic portion 14 along a line or plane that can correspond to a plantar aspect 12 of the foot of the user. By affixing the orthotic portion 12 to the sock portion 10, the user can realize the benefits outlined above relative to existing orthotics available on the market.

In an aspect, the sock portion 10 may be configured to surround and engage at least a portion of a user's leg 16 and/or foot 11. Referencing FIG. 2, when assembled into the sock orthotic 100, the sock portion 10 may be somewhat tubular in shape and can have an upper opening 20 (circular opening defined by top of the sock portion 10). Before being affixed to the orthotic portion 14, the sock portion 10 can, in some examples, also have a lower opening 22 defined by the sock portion 10 at an end opposite to the upper opening 20, as an everyday sock would have if the bottom of the sock (i.e., the portion of the sock that engages with the plantar aspect 12) was removed. FIG. 2, therefore, shows an example embodiment wherein the sock portion 10 defines a lower opening 22 and an upper opening 20 relative to the plantar aspect 12. In such examples, the perimeter of the sock portion 10 defining the lower opening 22 may serve as a line along which the sock portion 10 is affixed to the orthotic portion 14. Since the sock is made of soft material, the sock will not maintain its shape when not in use. On the other hand, the sock may be made of a material that is sufficiently rigid so as to maintain its shape when not in use.

In other examples, however, the sock portion 10 may only have the upper opening 20 and the portion of an everyday sock that engages with the plantar aspect 12 may remain. In these instances, the sock portion 10 may be affixed to the orthotic portion 14 along a lower portion constituting a plane (or subset of area therein) that forms the bottom of the sock portion 10 (i.e., the plane of material that would exist if the lower opening 22 did not exist, referencing FIG. 2). Regardless of the exact points or areas of affixation, in some instances, the sock portion 10 and the orthotic portion 14 may be fixed by one or more methods in any given sock orthotic 100, including, but not limited to, thread or any other means for sewing the portions together, an adhesive, or any other fastener or fasteners known in the art. If the sock is made from a polymeric material such as polyester, fastening can be accomplished by welding by either thermal welding or ultrasonic welding.

The thread may be formed from cotton, nylon, silk, linen, polyester, cotton/polyester blends, RAYON (cellulose) or wool. The thread weight may be light (60 wt), thin (50 wt), regular (40 wt), upholstery (30 wt) or heavy (20 wt), the weight being the length of the thread in kilometers required to weigh 1 kilogram. The thread weight may also be expressed in denier, which is how many grams 9,000 meters of the thread weighs. The preferred thread weights or 40 wt or 30 wt. The adhesive may be casein glue, rubber cement, phenolics, polyvinyl acetate, acrylic, urethane, epoxy, polyimide or cyanoacrylate. A combination of sewing and adhesive may be used to affix the orthotic to the sock. The orthotic may be attached to the sock with a fastener such as VELCRO (material having complemental parts which adhere to each other when pressed together), a zipper, buttons or clips.

Returning to the sock portion 10, any type of sock known in the art may be repurposed or otherwise used to serve as this portion of sock orthotic 100. For instance, the sock portion 10 can include elastic, cotton, polyester, a mixture thereof, or more modern textile materials like polyester microfiber used in socks or other clothing or otherwise known in the art. In addition, the sock portion 10 can be constructed of all or part of a male sock, female sock, athletic sock, tube sock, ankle sock, low-cut sock, full-calf sock, full-length sock, full-leg sock, a leg of a pant, dress sock, moisture-wicking sock, compression sock or pant, job-specific sock, sport-specific sock, knee-high sock, or any other sock, pant, and/or any other clothing known in the art. The sock portion may not maintain shape while not being worn.

Likewise, although specific orthotics for the sock orthotic 100 are envisioned, the orthotic portion 14 can include all or part of any orthotic element known in the art, and therefore may include or comprise of lengths such as half (heel cup), ¾ or full length and compromise of functional varieties such as arch-support (low, medium and high support), non-custom made, custom-made, pre-contoured, soft, semi-rigid, rigid, comfort fit or other orthotics known in the art.

In addition to the elements of the sock orthotic 100 mentioned previously, the sock orthotic 100 of some example embodiments can include further optional elements. For example, in some instances, as shown in the example of FIG. 1, the sock orthotic 100 can include a heel portion 18, which can include pull-assisting material 19 that can serve as a pull-assisting feature to aid the user in putting on the sock orthotic 100. The pull-assisting material 19 of the heel portion 18 can be affixed to the sock portion 10 and/or orthotic portion 14 and can be comprised of a more rigid material than the sock portion 10 and/or one or more other aspects such that a user can “grasp” the pull-assisting material with his or her hand or another gripping instrument and exert an upward pulling force thereon to assist the user in putting the sock orthotic 100 into place on their foot (and leg in some instances). The pull-assisting material 19 can be formed as a loop at the top of the sock.

In addition, although not explicitly shown in the figures, the sock portion 10 and/or orthotic portion 14 can further optionally include one or more blister pads and/or compression areas (e.g. compression pads on mid-foot, heel, calf, etc.) to increase comfort for the user. Furthermore, in some examples, the sock orthotic 100 can also optionally include an ankle brace or ankle support located intrinsic to or extrinsic to the sock orthotic 100 (i.e., attached to or simply placed over the sock orthotic 100 to assist in supporting the user's ankle joint).

The sock and/or orthotic can be fitted with sensors to measure such variables as pressure, temperature, moisture, ammonia, etc. These sensors can be configured to communicate with an external device such as a computer, smart phone, etc., which can communicate via the internet. These variables can be analyzed to configure the optimum performance of the orthotic or for treatment of the associated condition.

The orthotic can be soft orthotic insoles help to protect the foot and work to reduce pressure and minimize shock. Soft orthotics are usually made of soft, compressible materials (i.e., gel or silicone). This type of orthotic is good for any user looking for additional daily comfort and relief.

Semi-rigid orthotics are used to provide control and as well as protection. They are often used by athletes or those who spend a considerable amount of time on their feet. It allows for responsive support of the foot while standing, running or participating in sports. It is constructed of layers of soft materials, reinforced with more rigid materials. Suitable flexible materials include polyurethane, gel, foam, memory foam, urethane, ethylene-vinyl acetate, polyethylene, synthetic rubber, silicone, neoprene, and ethyl vinyl acetate. The memory foam can be viscoelastic polyurethane foam, or low-resilience polyurethane foam, where the foam bubbles or ‘cells’ are open, effectively creating a matrix through which air can move. Higher-density memory foam softens in reaction to body heat, allowing it to mold to a warm foot in a few minutes.

Rigid orthotic devices are designed to control foot function and are generally made of a firm material to prevent a user's foot from moving in a particular direction. This type of orthotic is often used to improve or eliminate pain in the legs, thighs and lower back due to abnormal function of the foot. Rigid orthotics are most-often prescribed by a foot doctor (DPM), and require a casting or mold of the user's foot.

Other materials to form the orthotic and associated layers can include leather, plastic, polyester, non-woven polyester, nylon, cotton, suede, canvas, elastic, rubber, vinyl, fabric, coronet, gel, neoprene, felt, cork, bamboo fiber, silk, silicon, synthetic fabric, urethane, ethylene-vinyl acetate, polyurethane, polyethylene, or a synthetic rubber.

In a preferred embodiment the orthotic can be formed from a reinforced elastomer. The reinforcement can be carbon or carbon fiber. Reinforcement fibers other than carbon fibers can be used, such as glass, aramid, or nylon fibers. The elastomer can be thermoplastic or light curable. The light curable resins can be uv curable, and can be based on free radical curing acrylic compounds (acrylates). These can include acrylated epoxies, acrylated polyesters, acrylated urethanes or acrylated silicones. The light curable resins are suitable for 3D printers. For example, the elastomer can be printed only a carbon fiber lattice or mat, and then exposed to uv light to form the orthotic portion. Alternately, the carbon can be incorporated into the resin itself before forming. 3D printing is not the only option. Molding technology can also be used.

The carbon can be carbon black or activated carbon. Carbon fibers (alternatively CF, graphite fiber or graphite fiber) are fibers about 5-10 micrometers in diameter and are composed mostly of carbon atoms. Carbon fibers have several advantages including high stiffness, high tensile strength, low weight, high chemical resistance, high temperature tolerance and low thermal expansion.

The carbon can also be nanocarbon. Carbon nanostructures including carbon black, carbon nanotubes, graphite or graphene have attracted a tremendous interest as fillers for elastomeric compounds. The preparation methods of nanocomposites that have a strong impact on the state of filler dispersion and thus on the properties of the resulting composites, are briefly described. At the same filler loading, considerable improvement in stiffness is imparted to the host polymeric matrix by the carbon nanomaterials with regard to that provided by the conventional carbon fibers or carbon black particles. It is mainly attributed to the high aspect ratio of the nanostructures rather than to strong polymer-filler interactions. The orienting capability of the anisotropic fillers under strain as well the formation of a filler network, have to be taken into account to explain the high level of reinforcements.

The sock and/or orthotic can incorporate an antimicrobial material such as copper and its alloys, a quaternary ammonium compound such as dimethyloctadecyl (3-trimethoxysilyl propyl) ammonium chloride (Si-QAC), tributyl tin, phenyl-diazenyl(phenols), N-halamine materials or an antimicrobial peptide. Antimicrobial treatment can be with nanomaterials such as titanium dioxide, organosilane, silver, zinc oxide, copper, magnetite, magnesium oxide, gold, gallium or carbon nanotubes.

The sock and/or orthotic can incorporate an odor absorbing material such as activated carbon, silica gel or a zeolite. The activated carbon may have a surface area in excess of 3,000 m2 per gram. Powdered activated carbon is formed from granules less than 1.0 mm in size with an average diameter between 0.15 and 0.25 mm. Thus they present a large surface to volume ratio with a small diffusion distance. Activated carbon (R1) is defined as the activated carbon particles retained on a 50-mesh sieve (0.297 mm). Granular activated carbon (GAC) has a relatively larger particle size compared to powdered activated carbon and consequently, presents a smaller external surface. A 20×40 carbon is made of particles that will pass through a U.S. Standard Mesh Size No. 20 sieve (0.84 mm) (generally specified as 85% passing) but be retained on a U.S. Standard Mesh Size No. 40 sieve (0.42 mm) (generally specified as 95% retained). A 50-mesh sieve (0.297 mm) is the minimum GAC size. The most popular carbons are the 12×40 and 8×30 sizes because they have a good balance of size, surface area, and head loss (energy loss) characteristics. Silica gel has a surface area of about 800 m2 per gram. The hydroxy (OH) groups on the surface of silica can be functionalized to enhance the odor absorbing properties. The zeolites can be either natural or organic. Zeolites are especially effective in absorbing ammonium. Zeolite chemical compositions may have the formula: (Mn+)2/nO.Al2O3.xSiO2.pH2O, M represents a metal ion (usually Na in the artificial synthesis), n represents a metal ion valence, x represents the number of moles of SiO2, also known as silica to alumina ratio, p represents the number of moles of water. The most basic structure of the crystalline zeolite backbone is the tetrahedra SiO4 and AlO4, through the binding of common oxygen atoms to form crystals with three-dimensional network structure. This combination forms, constitutes cavities and channels of molecular level and uniform pore size. An example of the mineral formula of a zeolite is: Na2Al2Si3O10.2H2O

Turning to FIGS. 3 and 4, additional example embodiments are presented. In some examples, such as the example embodiment presented in FIG. 3, the orthotic portion 14 can be attached to the inside of the sock portion 10. In other words, in such examples, the bottom surface of the sock can serve as the exterior surface of the sock orthotic 100 (i.e., to make contact with the ground or footwear directly). In some instances, an outer perimeter of the orthotic portion 14 can be affixed to the sock portion 10 along an interior surface of the sock portion. In this and other examples, an additional layer of material 15, such as the sock material itself or some other material type, could be added to the sock orthotic 100 at the upper surface of the orthotic portion 14. In these examples, the additional layer of material 15 establishes a buffer between the user's foot and the orthotic portion 14.

In other examples, such as the example embodiment illustrated in FIG. 4, the orthotic portion 14 can be affixed to the bottom surface of the sock portion 10, such that the bottom surface of the sock portion 10 itself can serve as a buffer between the user's foot and the orthotic portion 14. In these examples, an additional layer of material 15 can be affixed to the orthotic portion 14 and/or the sock portion 10, forming an enclosure containing the orthotic portion 14 or a “sandwich” stack with the sock portion 10, the orthotic portion 14, and the additional layer of material 15 at the bottom surface of the sock orthotic 100 forming the layers of the stack. In FIGS. 3 and 4, the green portion represents the orthotic portion 14 and the purple portion is the additional layer of material 15.

FIG. 5 illustrates a bottom view of the sock orthotic of another aspect of the disclosure showing a pore structure or a perforation structure 24. The pores can penetrate through the orthotic in order to permit the foot to breathe. There can also be a layer of material between the pore and the foot. In another embodiment, the pores do not penetrate through the entire structure of the orthotic portion 14. The pores can have a circular cross section or any other appropriate cross section, including square, rectangular, oval, rhomboidal, star, triangular, etc. The pores can be distributed in an evenly spaced pattern or in a non-even pattern. The spacing and diameter of the pores can also vary where, for example, the pores associated with the insole of the foot can be larger or smaller than the pores associated with the heel of the foot or the toes. The pores can have a diameter of 1 mm to 10 mm, preferably between 3 and 6 mm and most preferably about 5 mm. The pores can also be micro-pores having a pore size of greater than 20 per linear centimeter.

In an additional aspect, the sock orthotic can have regions of different hardness, as is illustrated in FIG. 7. With a normal foot, when a person walks with a normal gait. Under such circumstances, the foot will initially contact the ground in the region of the calcaneus and will push away from the ground in the region of the big toe. The major forces exerted on the foot during walking occur at the calcaneus region which is subjected to an impact when the foot contacts the ground; the big toe which pushes the foot away from the ground; and the fifth and first metatarsal heads where the direction of loading changes. Accordingly, the sole of the sock orthotic can have different hardness corresponding to the different forces applied to the foot during walking, the greatest softness 30, 32 will be at the toes and the center of the heel. An intermediate level of softness 34, 36 will be at the arch and the periphery of the heel. A moderate level of hardness 38 would lie along the sole, with the highest level of hardness 40 being at the center of the sole.

In an embodiment, the orthotic portion 14 can have an inner chamber 42 that contains deodorizing material 44. Pores 24 have access to the inner chamber 42. The deodorizing material may be a bag of silica gel or activated carbon. If granulated activated carbon is used as the deodorizing material, the pores can be of a size smaller of the activated carbon so that the activated carbon does not leak out of the orthotic portion 14. The thin structure of the pores will promote laminar flow of air, which will increase contact with the deodorizing material 44. A deodorizing material such as powdered activated carbon will adhere to the sides of the pores due to Van der Waals forces, and the walls of the pores will induce laminar flow of air near the walls, which will result in superior contact between the activated carbon and the air flow.

Furthermore, in an aspect of the present disclosure, exemplary methods of assembling the sock orthotic 100 and its various embodiments described above. For instance, in an aspect, such a method can include a method for assembling or constructing a sock orthotic, which can include:

    • (a) obtaining a sock portion of the sock orthotic configured to surround and engage at least a portion of a foot;
    • (b) obtaining an orthotic portion configured to be situated substantially adjacent to a plantar aspect of the foot; and
    • (c) affixing the sock portion to the orthotic portion, among other aspects which would be understood or envisioned by one of ordinary skill in the art, including those features described above, in reference to the examples and drawing figures.

In addition, the invention envisions a method for treating one or more bodily ailments by wearing a sock orthotic 100, wherein the sock orthotic includes a sock portion configured to surround and engage at least a portion of a foot, and an orthotic portion configured to be situated substantially adjacent to a plantar aspect of the foot, wherein the orthotic portion is affixed to the sock portion. Of course, this is not meant to constitute the limit of the features of the sock orthotic 100 covered under such a method, but would also include any and all example aspects which would be understood or envisioned by one of ordinary skill in the art, including those features described above, in reference to the examples and drawing figures.

The sock orthotic of the disclosure can also include a transdermal analgesic or pain relief patch as part of the additional layer of material 15. The patch can contain counterirritant materials such as capsaicin, methyl salicylate, camphor, or menthol, which are thought to mask pain signals by causing other sensations (itching, warmth, or cooling) in the areas they are applied to. The patch can also contain a COX 2 inhibitor such as naproxen or ibuprofen. A topical treatment for nerve pain can include lidocaine.

The manufacture of the orthotic itself is a multi-step process. The first step is to have the podiatrist take a non-weight bearing cast of the foot. The most common method of taking this cast is by using plaster. Wet plaster strips are wrapped around the foot. The hollow, “negative foot mold” is then sent off to the orthotics lab. The lab will fill in the cast and discard the shell. The resulting “positive cast” looks like the foot. After the cast has dried, the cast will be sent to the lab, where a positive cast will be made. Once the positive cast has been constructed, the lab constructs the orthotics through the following steps: 1) under extreme heat, the individual cast is pressed against a sheet of graphite or plastic material, and 2) a cover made of comfortable yet durable material is attached to the harder heel and arch structure. For your custom made orthotic insoles to provide optimum results, they must be constructed from materials that can resist the various forces and motions you put on your feet. In this sense, the materials need to be rigid enough to control for irregular injury-producing motion while still flexible and comfortable enough to be compatible with your activities. There are two main types of materials used for the rigid foundation of the orthotic:

    • Plastics—Most plastics come from the polyolefin family. Polypropylene is the most common plastic used. Material thickness often ranges from ⅛″ to ¼″. The Flexibility of plastics have a wide spectrum, ranging from very flexible to relatively rigid.
    • Graphite—The graphite family is lighter and thinner than plastics, Material thickness is half that of plastic ( 1/16″ to ⅛″), Graphite also has a wide range of flexibility and rigidity.

Cushioning materials such as Neoprene and open- and closed-cell forms are often used to complement the harder plastics or graphite and provide added comfort. The most common materials used to cover the plastic or graphite arch-support and heel cup come from the polyethylene foam family. These are closed-cell forms best for total-contact, pressure-reducing orthotics. Individual materials may include: ethyl-vinyl acetates, crepes/neoprene, silicones or graphite.

Orthotics can also be manufacture by scanning the foot with a laser scanner. The scanned information can be used to produce 3D printed orthotics in a fraction of the time as compared to the casting method of producing orthotics. Another approach is to use a computerized system that works by slipping an arch with computer chips built in, into the shoe. As the subject begins to walk and run the device makes a mini-movie that gathers data and scans showing how pressure is going through the foot. These computer scans are used to create a multi-layered custom orthotics device made for you're the specific foot shape and to target the specific problem.

The present disclosure displays many advantages.

One advantage is ease of use. The user is able to switch from one type of a shoe to another without removing shoe-insert orthotic. This allows for same consistent arch support and comfort from shoe to shoe. The user can also be indoors and not have to wear shoes to have orthotic-type support.

Other advantages is that there is no need to wear shoes to get arch support and comfort. The sock orthotic can be worn 24 hours per day. The orthotic does not slip in the shoe. There is no need to transfer the orthotic from shoe to shoe. The sock orthotic relieves pain and relives tires and/or achy feet

Moreover, those skilled in the art will recognize that other embodiments may be carried out in ways that deviate from those specifically set forth herein without departing from essential characteristics described by this disclosure. The present embodiments are thus to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.

Throughout the specification and the embodiments, the following terms take at least the meanings explicitly associated herein, unless the context clearly dictates otherwise. Relational terms such as “first” and “second,” and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The term “or” is intended to mean an inclusive “or” unless specified otherwise or clear from the context to be directed to an exclusive form. Further, the terms “a,” “an,” and “the” are intended to mean one or more unless specified otherwise or clear from the context to be directed to a singular form. The term “include” and its various forms are intended to mean including but not limited to. References to “one embodiment,” “an embodiment,” “example embodiment,” “various embodiments,” and other like terms indicate that the embodiments of the disclosed technology so described may include a particular function, feature, structure, or characteristic, but not every embodiment necessarily includes the particular function, feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment” does not necessarily refer to the same embodiment, although it may. The terms “substantially,” “essentially,” “approximately,” “about” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art, and in one non-limiting embodiment the term is defined to be within 10%, in another embodiment within 5%, in another embodiment within 1% and in another embodiment within 0.5%. A device or structure that is “configured” in a certain way is configured in at least that way, but may also be configured in ways that are not listed.

INDEX OF REFERENCE NUMERALS

NUMERAL DESCRIPTION 100 Sock orthotic 10 Sock portion 11 Foot 12 Plantar aspect 14 Orthotic portion 15 Additional layer of material 16 Leg 18 Heel portion 19 Pull-assisting material 20 Upper opening 22 Lower opening 24 Pores or perforations 30 Greatest softness 32 Greatest softness 34 Intermediate level of softness 36 Intermediate level of softness 38 Moderate level of hardness 40 Hardest level of hardness 42 Inner chamber 44 Deodorizing material

Claims

1. A sock orthotic, comprising:

a sock portion configured to surround and engage at least a portion of a foot; and
an orthotic portion configured to be situated substantially adjacent to a plantar aspect of the foot, wherein the orthotic portion is affixed to and is integral to the sock portion so as to inhibit slippage or displacement of the orthotic portion.

2. The sock orthotic of claim 1, wherein the sock portion defines a lower opening and an upper opening relative to the plantar aspect.

3. The sock orthotic of claim 2, wherein the orthotic portion is affixed to the sock portion at a perimeter of the lower opening defined by the sock portion.

4. The sock orthotic of claim 1, wherein the sock portion defines an upper opening relative to the plantar aspect and comprises a lower portion configured to engage the plantar aspect of the foot.

5. The sock orthotic of claim 1, wherein the orthotic portion is affixed to the sock portion at a plane defined by the lower portion of the sock portion and an upper surface of the orthotic portion.

6. The sock orthotic of claim 1, wherein the orthotic portion is affixed to the sock portion via one or more of thread, adhesive, welds or a fastener.

7. The sock orthotic of claim 1, wherein the sock portion comprises all or part of a male sock, female sock, athletic sock, tube sock, ankle sock, low-cut sock, full-calf sock, full-length sock, full-leg sock, a leg of a pant, dress sock, moisture-wicking sock, compression sock or pant, job-specific sock, sport-specific sock or knee-high sock.

8. The sock orthotic of claim 1, wherein the orthotic portion comprises of lengths including half (heel cup), ¾ or full length and comprise functional varieties including arch-support of low, medium or high support, non-custom made that is over-the-counter, custom-made, pre-contoured, soft, semi-rigid, rigid or comfort fit.

9. The sock orthotic of claim 1, further comprising one or more pull-assisting features affixed to the sock portion and/or the orthotic portion configured to assist with pulling the sock orthotic onto place on the foot.

10. The sock orthotic of claim 1, wherein the sock portion further comprises one or more blister pads and/or compression areas.

11. The sock orthotic of claim 1, further comprising an ankle brace or ankle support located intrinsic to or extrinsic to the sock orthotic.

12. The sock orthotic of claim 1, wherein the slippage is less than about 5 mm.

13. The sock orthotic of claim 1, further comprising an odor absorbing material or an antimicrobial material.

14. The sock orthotic of claim 13, wherein the odor absorbing material is at least one selected from the group consisting of activated carbon, silica gel and zeolite.

15. The sock orthotic of claim 13, wherein the antimicrobial material is at least one selected from the group consisting of activated copper, copper alloys, a quaternary ammonium compound, dimethyloctadecyl (3-trimethoxysilyl propyl) ammonium chloride, tributyl tin, phenyl-diazenyl(phenols), N-halamine materials and antimicrobial peptides, or is a nanomaterial selected from the group consisting of titanium dioxide, organosilane, silver, zinc oxide, copper, magnetite, magnesium oxide, gold, gallium and carbon nanotubes.

16. The sock orthotic of claim 1, wherein the orthotic portion is formed from carbon reinforced elastomer.

17. A method for constructing a sock orthotic, comprising:

obtaining a sock portion of the sock orthotic configured to surround and engage at least a portion of a foot;
obtaining an orthotic portion configured to be situated substantially adjacent to a planar aspect of the foot; and
affixing the sock portion to the orthotic portion, wherein the orthotic portion is affixed to and is integral to the sock portion so as to inhibit slippage or displacement of the orthotic portion.

16. The method of claim 17, wherein the sock portion defines a lower opening and an upper opening relative to the plantar aspect, and the orthotic portion is affixed to the sock portion at a perimeter of the lower opening defined by the sock portion.

19. The method of claim 17, wherein the orthotic portion further comprises an odor absorbing material or an antimicrobial material.

20. A method for treating one or more bodily ailments by having a patient in need thereof wear a sock orthotic,

the sock orthotic comprising: a sock portion configured to surround and engage at least a portion of a foot; and an orthotic portion configured to be situated substantially adjacent to a plantar aspect of the foot, wherein the orthotic portion is affixed to the sock portion, wherein the orthotic portion is affixed to and is integral to the sock portion so as to inhibit slippage or displacement of the orthotic portion.
Patent History
Publication number: 20200205483
Type: Application
Filed: Dec 12, 2019
Publication Date: Jul 2, 2020
Inventor: Thomas John Burns (Emmitsburg, MD)
Application Number: 16/712,144
Classifications
International Classification: A41B 11/00 (20060101); A41B 11/02 (20060101);