US20090145003A1

US20090145003A1 - Single-layered arch support insole to be inserted into shoe

Info

Publication number: US20090145003A1
Application number: US12/270,934
Authority: US
Inventors: Hwi Jin KIM
Original assignee: Umi System Co
Current assignee: Umi System Co
Priority date: 2007-12-05
Filing date: 2008-11-14
Publication date: 2009-06-11
Also published as: WO2009072797A1; KR100874150B1

Abstract

Provided is an arch support insole to be inserted into a shoe. The insole should satisfy tasks for a wearer as follows: (1) improvement of wearing feeling by maximally reducing the thickness of the insole, (2) reduction of fatigue on walking by maximally preventing transmission of shocks, and (3) sufficient support of the arch of the wearer by maintaining an original shape of the arch support part. In addition, these tasks should be solved by a minimum number of manufacturing processes and minimum cost. The arch support insole includes an insole main body having a portion or the entire of an arch support part curvedly projecting upward to support the arch of a wearer's foot, and a heel support part coupled to a rear part of the insole main body, wherein the insole main body and the heel support part are formed of a single layer by dual injection, the insole main body is formed of a material having hardness higher than that of the heel support part, and a plurality of honeycomb-shaped projections are formed downward at a bottom surface of the curved arch support part.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of Korean Patent Applications No. 10-2007-0125416 and No. 10-2008-0021299 filed with the Korea Intellectual Property Office on Dec. 5, 2007 and Mar. 7, 2008, respectively, the disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates to a single-layered arch support insole to be inserted into a shoe.
2. Description of the Related Art
[Related Prior Art Documents]
1. Korean Utility Model Registration No. 20-0428449 B
2. Korean Utility Model Registration No. 20-0390153 B
3. Korean Utility Model Registration No. 20-0395056 B
4. Korean Patent Laid-open Publication No. 2003-0093618 A
5. Korean Utility Model Registration No. 20-0431315 B
6. U.S. Pat. No. 6,976,322 B
In general, an insole corresponds to the shape of the sole of a foot to form a curved shape such that the insole is bent upward at its outer periphery to surround the sole of a foot to feel comfort when a user wears shoes. In addition, the sole is formed of a material that can absorb shock on walking to absorb a portion of shock generated when the foot contacts the ground, thereby reducing fatigue of the foot and probability of damage to the foot.
The insole for absorbing shock on walking and increasing softness is formed of thermoplastic rubber (TPR) such as neoprene rubber (NR), styrene butadiene rubber (SBR), butadiene rubber (BR), chloroprene rubber (CR), and so on.
However, since the heel receives shock on walking larger than toes of a foot, when the insole formed of the thermoplastic rubber is worn for a long time, the heel of a shoe is damaged such that the heel of the shoe is sunk.
In order to solve the problems, Korean Utility Model Registration No. 20-0428449 that describes an insole having different densities at front and rear parts thereof to prevent the heel of the sole from being sunk and Korean Utility Model Registration No. 20-0390153 that describes an insole overshoe for correcting a foot including a shock-absorbing cushion formed at the heel thereof have been disclosed. The prior arts disclose a multi-layered insole further including a shock-absorbing cushion or a foam resin to reduce shock applied to the heel and prevent the heel of the insole from being sunken.
Meanwhile, since pressure distribution in the front and rear parts of the insole during walking is uneven, the insole is formed of polyurethane to appropriately absorb the entire pressure (see Korean Utility Model Registration No. 20-0395056). However, since the insole formed on polyurethane only has insufficient resilience, shock from the ground may be periodically applied to the heel by the weight of the user such that the entire weight of the user's body is not uniformly distributed to the front and rear parts of the insole to press the muscles and blood vessels.
While Korean Patent Laid-open Publication No. 2003-0093618 as one of the related prior art documents discloses a midsole of a shoe, other than the arch support insole to be inserted into the shoe, the midsole also has a multi-layered structure.
Meanwhile, U.S. Pat. No. 6,976,322 B and Korean Utility Model Registration No. 20-0431315 disclose an arch support insole including a plurality of ribs laterally projecting from the arch support insole to prevent deformation of the arch support part due to a load. However, since the ribs disclosed in the above documents are formed in one direction only, it is difficult to evenly distribute the weight of the user. In addition, when a user wears the shoes having the insoles for a long time, repeated fatigue loads in longitudinal/lateral directions may cause both ends of the ribs to be separated or removed from a bottom surface of the arch support part.

SUMMARY OF THE INVENTION

The multi-layered structure of insole formed of thermoplastic rubber has a large thickness of the entire insole to degrade wearing feeling. In addition, addition of unnecessary processes upon manufacturing increases the number of manufacturing processes and manufacturing cost. Further, the insole formed of a single material having no resilience to support the pressure periodically receives shock applied from the ground to the heel to give fatigue on walking for a long time. Furthermore, long-term use of the insole causes deformation of the arch support part to make it impossible to sufficiently support the arch of the wearer's foot.
That is, the insole should satisfy tasks for a wearer as follows: (1) improvement of wearing feeling by maximally reducing the thickness of the insole, (2) reduction of fatigue on walking by maximally preventing transmission of shocks, and (3) sufficient support of the arch of the wearer by maintaining an original shape of the arch support part. In addition, these tasks should be solved by a minimum number of manufacturing processes and minimum cost.
In order to solve the problems, the present invention provides an arch support insole to be inserted into a shoe including: an insole main body having an arch support part curvedly projecting upward to support the arch of a wearer's foot, and a heel support part coupled to a rear part of the insole main body, wherein the insole main body and the heel support body is formed of a single layer through dual injection. The insole main body having the arch support part may be formed of plastic having hardness higher than that of plastic forming the heel support part.
In addition, the arch support insole may further include an anti-slip part coupled to a front part of the insole main body.
Further, the anti-slip part may have the same hardness as the heel support part.
Therefore, it is possible to minimally maintain the thickness of a “single-layered” insole to improve wearing feeling and more effectively and securely maintain the arch support part. In addition, it is possible to maintain the arch support part or the anti-slip part softer than the arch support part, wherein the heel support part or the anti-slip part should require comfort, other than stiffness. Further, since the insole is manufactured by a dual injection process, it is possible to solve problems that the number of manufacturing processes and manufacturing cost are increased due to addition of unnecessary processes. Furthermore, it is also possible to increase durability of the insole, in comparison with a process of using adhesive, and so on.
Meanwhile, the present invention also provides an arch support insole to be inserted into a shoe including: an insole main body having a portion or the entire of an arch support part curvedly projecting upward to support the arch of a wearer's foot; and a heel support part coupled to a rear part of the insole main body, wherein the insole main body and the heel support part are formed of a single layer by dual injection, and a plurality of honeycomb-shaped projections are formed downward at a bottom surface of the curved arch support part.
In addition, the insole main body may be formed of a material having hardness higher than that of the heel support part.
Further, the arch support insole may further include an anti-slip part coupled to a front part of the insole main body.
Furthermore, the heel support part, the anti-slip part, and the honeycomb-shaped projections may be integrally formed with each other to surround the insole main body by dual injection.
In addition, the heel support part, the anti-slip part, and the honeycomb-shaped projections may be formed of the same material.
Further, the honeycomb-shaped projections and the insole main body may be formed of the same material.
Therefore, as described above, it is possible to minimally maintain the thickness of a “single-layered” insole to improve wearing feeling and more effectively and securely maintain the arch support part. In addition, it is possible to maintain the arch support part or the anti-slip part softer than the arch support part, wherein the heel support part or the anti-slip part should require comfort, other than stiffness. Further, since the insole is manufactured by a dual injection process, it is possible to solve problems that the number of manufacturing processes and manufacturing cost are increased due to addition of unnecessary processes. Furthermore, it is also possible to increase durability of the insole, in comparison with a process of using adhesive, and so on. In particularly, the projections formed at a position corresponding to the bottom surface of the arch support part curvedly projecting upward to support the arch of the wearer's foot employs a honeycomb structure, i.e., a hexagonal structure, to effectively prevent the arch support part from being buckled, by ideally and evenly distributing the weight of the wearer, even though repeated fatigue loads are generated due to the long-term use.
Meanwhile, the present invention also provides an arch support insole including: an insole main body having an arch support part curvedly projecting upward to support the arch of a wearer; and a heel support part configured to support the heel of the wearer's foot, wherein a plurality of honeycomb-shaped projections project downward from a position only corresponding to a bottom surface of the curved arch support part.
In addition, the present invention also provides an arch support insole including: an arch support part curvedly projecting upward to support the arch of a wearer's foot; and a peripheral part coupled to the arch support part as a single layer to surround the arch support part by dual injection, wherein the arch support part is formed of a material having hardness higher than that of the peripheral part, and a plurality of honeycomb-shaped projections project downward from a position corresponding to a bottom surface of the curved arch support part. Preferably, the honeycomb-shaped projections and the arch support part, or the honeycomb-shaped projections and the peripheral part may be formed of the same material.
That is, as described above, the projections formed at a position corresponding to the bottom surface of the arch support part curvedly projecting upward to support the arch of the wearer's foot employs a honeycomb structure, i.e., a hexagonal structure, to effectively prevent the arch support part from being buckled or deformed, by ideally and evenly distributing the weight of the wearer, even though repeated fatigue loads are generated due to the long-term use. In addition, according to use purposes, the insole may be formed by dual injection such that a minimal part corresponding to the arch support part is formed of a material having high hardness, and the other part is formed of a relatively soft material. As a result, it is possible to feel comfort and minimize fatigue on walking, in addition to the arch support and buckling prevention purposes.
Further, the plurality of honeycomb-shaped projections may have the size that is gradually reduced from the front part to the rear part of the insole main body to effectively prevent deformation and buckling of the rear part of the arch support part due to general load concentration to the rear part of the insole by the weight of the wearer.

BRIEF DESCRIPTION OF THE DRAWINGS

These and/or other aspects and advantages of the present general inventive concept will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:

FIG. 1 is a perspective view of an insole in accordance with a first embodiment of the present invention;

FIG. 2 is a plan view of the in accordance with the first embodiment of the present invention;

FIG. 3 is a perspective view of an insole in accordance with a second embodiment of the present invention;

FIG. 4 is a plan view of the insole in accordance with the second embodiment of the present invention;

FIG. 5 is a perspective view of an insole in accordance with a third embodiment of the present invention;

FIG. 6 is a plan view of the insole in accordance with the third embodiment of the present invention;

FIG. 7 is a bottom view of the insole in accordance with the third embodiment of the present invention; and

FIG. 8 is a side view of the insole in accordance with the third embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, exemplary embodiments of the present invention will be described with reference to the accompanying drawings.

First Embodiment

FIG. 1 is a perspective view of an insole in accordance with the first embodiment of the present invention, and FIG. 2 is a plan view of the in accordance with the first embodiment of the present invention.
The insole 10 in accordance with the first embodiment of the present invention includes an insole main body 11 corresponding to the shape of sole of a foot, except toes, and a heel support part 12 surrounding the heel of the foot. The insole main body 11 and the heel support part 12 is formed of a single layer and fabricated by plastic materials having different hardness.
In general, the insole formed of a plastic material such as polypropylene or nylon is manufactured by a plastic molding technology. In general, plastic molding methods are classified into various methods such as injection molding, press molding, transfer molding, rotary molding, thermal molding, blow molding, film blowing, extrusion, calendaring, fiber spinning, and so on. Among them, the injection molding, pressing molding, transfer molding, and rotary molding are methods of pushing a plastic material into a cavity formed between two closed molds to form molding products.
The insole 10 in accordance with the present invention may be manufactured by dual injection. The dual injection uses two kinds of resin or two colors of resin. A mold is configured to perform dual injection using two injection apparatuses and an injector having a rotary mechanism installed on a movable plate or a core or a slide structure. A primary mold product is initially formed by the mold, and secondary resin is filled between the primary mold product and a secondary cavity to form a final mold product. Since the primary and secondary cavities are precisely exchanged, the dual injection is widely used for design variation in various applications without shape restriction.
The dual injection can produce various designs of products through a single molding process at low cost, in comparison with the conventional injection in which injection is performed two times to form two parts and then the two parts are melted to each other and processed by a secondary process such as a painting process.
The injection molding is classified into an insert method in which two operators use two injectors to inject products through two molds, or a two-color method in which one operator use a single injector to inject products through two linkage molds. In some embodiments of the present invention, a two-color dual injection molding may be used to reduce costs including molding cost, personal expenses, operation costs of the injector, and so on. In addition, it is possible to improve productivity through simultaneous injection and simultaneously inject two kinds of plastics having different hardness.
The insole 10 in accordance with the first embodiment of the present invention includes the insole main body 11 and the heel support part 12 formed of a single layer using the two-color method among the dual injection. A first plastic material is injected into a first cavity to primarily form the insole main body 11. Then, a second plastic material is filled into a second cavity to form the heel support part 12 to thereby form the insole main body 11 and the heel support part 12 as a single layer.
More specifically, first, the first plastic material is inserted into the first cavity to primarily form the insole main body 11. The first plastic material is mixture of polybutylene terephthalate (PBT) and polyethylene terephthalate (PET).
Then, the second plastic material is filled into the second cavity to form the heel support part 12 to thereby form the insole main body 11 and the heel support part 12 as a single layer. The second plastic material is a synthetic material of nylon and glass fiber.
Hardness of the manufactured insole 10 is measured using a rubber/plastic durometer used to measure hardness of hard rubber, hard plastic, ebonite, and so on. When the rubber/plastic durometer uses a rubber/plastic durometer of ASKER Co., the hardness of the insole main body 11 is D type 90, and the hardness of the heel support part 12 is D type 70.
As a result, it is possible to minimally maintain the thickness of a “single-layered” insole to improve wearing feeling and more effectively and securely maintain the arch support part. In addition, it is possible to maintain the arch support part or the anti-slip part softer than the arch support part, wherein the heel support part or the anti-slip part should require comfort, other than stiffness. Further, since the insole is manufactured by a dual injection process, it is possible to solve problems that the number of manufacturing processes and manufacturing cost are increased due to addition of unnecessary processes. Furthermore, it is also possible to increase durability of the insole, in comparison with a process of using adhesive, and so on.

Second Embodiment

FIG. 3 is a perspective view of an insole in accordance with the second embodiment of the present invention, and FIG. 4 is a plan view of the insole in accordance with the second embodiment of the present invention.
The insole 20 in accordance with the second embodiment of the present invention further includes an anti-slip part 13 to prevent slippage of a front part of the insole 20. The heel support part 12 and the anti-slip part 13 has hardness different from the insole main body 11 such that the heel support part 12 smoothly wraps the heel and the anti-slip part 13 minimize movement of the insole 20 when the insole 20 is inserted into a shoe. The second embodiment is similar to the first embodiment, except the above description, and thus, overlapping description thereof will not be repeated.
In a manufacturing method thereof, similar to the first embodiment, a first plastic material is inserted into a first cavity to primarily form the insole main body 11, and then, a second plastic material is filled into a second cavity to form the heel support part 12 and the anti-slip part 13, thereby forming the insole main body 11, the heel support part 12, and the anti-slip part 13 as a single layer.
Here, it is more preferable for machining of the insole that the anti-slip part 13 has the same hardness as the heel support part 12, but not limited thereto.

Third Embodiment

FIG. 5 is a perspective view of an insole in accordance with the third embodiment of the present invention, FIG. 6 is a plan view of the insole in accordance with the third embodiment of the present invention, FIG. 7 is a bottom view of the insole in accordance with the third embodiment of the present invention, and FIG. 8 is a side view of the insole in accordance with the third embodiment of the present invention. Meanwhile, in this embodiment, description overlapping the aforementioned embodiments will not be repeated.
The insole 30 in accordance with the third embodiment of the present invention, which is characterized by an arch support part different from the first and second embodiments, generally includes an insole main body 11 configured to include a portion or the entire of an arch support part curvedly projecting upward to support the arch of a wearer's foot, and a heel support part 12 coupled to a rear part of the insole main body. The insole main body 11 and the heel support part 12 is formed of a “single layer” by dual injection, and the insole main body 11 is formed of a material having hardness higher than that of the heel support part 12.
In particular, a plurality of honeycomb-shaped projections 15 project downward from a position corresponding to a bottom surface of the curved arch support part 11 a.
The honeycomb-shaped projections 15 is formed at only the bottom surface of the curved arch support part 11 a, and has a hexagonal shape.
Here, while the number and size of the honeycomb structures is not limited, it is preferable that the size of the honeycomb structures is gradually reduced from the front part to the rear part of the insole main body, as shown in FIGS. 5 to 8. That is, with reference to an apex of the arch support part, the size of the honeycomb is increased toward the front part corresponding to the toe part, and the size of the honeycomb is reduced toward the rear part corresponding to the heel part. Since the weight of the wearer is generally concentrated to the rear part of the insole, it is possible for the insole in accordance with the present invention to more effectively prevent deformation and buckling of the rear part of the arch support part against the concentrated load.
The projected hexagonal structures have the same thickness, and the height of the hexagonal structures is tapered toward the insole part except the outer part of the insole and the arch support part.
That is, it is difficult to evenly distribute the weight of the wearer using the conventional rib structure, and long-term wearing of the wearer applies repeated longitudinal/lateral fatigue loads to both ends of the ribs to separate or remove the both ends from the bottom surface of the arch support part. In order to solve the problems, the projections formed at a position corresponding to the bottom surface of the arch support part employ a “honeycomb” structure, i.e., a hexagonal structure.
Therefore, in addition to effects of the aforementioned embodiment, in particular, the projections formed at a position corresponding to the bottom surface of the arch support part curvedly projecting upward to support the arch of the wearer's foot employ a “honeycomb” structure, i.e., a hexagonal structure, such that the weight of the wearer can be ideally and uniformly distributed to effectively prevent the arch support part from being buckled even though repeated fatigues are generated due to long-term use.
Meanwhile, the arch support insole of the embodiment may further include an anti-slip part 13 coupled to a front part of the insole main body. In order to improve coupling power of the insole main body 11 to the other insole parts 12 and 13, it is more preferable that the heel support part 12, the anti-slip part 12, and the honeycomb-shaped projections 15 are configured to be integrally formed with each other (see the connection part designated by reference numeral 14) to surround the insole main body 11 through dual injection. Of course, when the anti-slip part 13 is omitted, the heel support part 12 and the honeycomb-shaped projections 15, except the anti-slip part, may be integrally connected to each other to surround the insole main body 11 through dual injection.
In addition, in the arch support insole of the embodiment, in consideration of forming of the insole, the heel support part 12, the anti-slip part 13 and the honeycomb-shaped projections 15 may be formed of the same material. In consideration of prevention of deformation of the arch support part 11 a, the honeycomb-shaped projections 15 and the insole main body 11 may be formed of the same material.

Fourth Embodiment

The fourth embodiment has basically the same basic concept as the aforementioned embodiments, this embodiment relates to an arch support insole capable of increasing comfort of shoes according to requirements of a wearer. That is, different from the third embodiment, the insole is dual injected such that only the arch support part 11 a is formed of a relatively hard material and the other part except the arch support part is formed of a relatively soft material to improve cushion thereof.
Therefore, the arch support insole of the embodiment includes an arch support part 11 a curvedly projecting upward to support the arch of a wearer's foot, and a peripheral part coupled to the arch support part as a single layer to surround the arch support part 11 a through dual injection, wherein the arch support part 11 a is formed of a material having hardness higher than that of the peripheral part, and a plurality of honeycomb-shaped projections 15 project downward from only a position corresponding to a bottom surface of the curved arch support part.
Here, the peripheral part corresponds to all the other parts of the insole, except the arch support part (i.e., the insole main body of the aforementioned embodiment corresponds to the arch support part itself). The plurality of honeycomb-shaped projections 15 and the arch support part 11 a may be formed of the same material, or the plurality of honeycomb-shaped projections 15 and the peripheral part may be formed of the same material.
As described above, according to use purposes, the insole may be formed by dual injection such that a minimal part corresponding to the arch support part is formed of a material having high hardness, and the other part is formed of a relatively soft material. As a result, it is possible to feel comfort and minimize fatigue on walking, in addition to the arch support and buckling prevention purposes.

Fifth Embodiment

An arch support insole of the embodiment is especially appropriate to orthopedic treatment, which is different from the aforementioned embodiments formed of a single layer formed of two different materials through dual injection in that the insole is formed of a single layer formed of a single material having relatively high hardness.
For this purpose, an arch support insole in accordance with another embodiment of the present invention includes an insole main body 11 configured to include an arch support part 11 a curvedly projecting upward to support the arch of a wearer's foot, and a heel support part 12 configured to support the heel of the wearer's foot, wherein a plurality of honeycomb-shaped projections 15 project from a position corresponding to a bottom surface of the curved arch support part.
Namely, the present embodiment is concentrated to correction or treatment of the arch of a patient, rather than wearing comfort or fatigue. Other effects and descriptions overlapping the above descriptions will not be repeated.
While this invention has been described with reference to exemplary embodiments thereof, it will be clear to those of ordinary skill in the art to which the invention pertains that various modifications may be made to the described embodiments without departing from the spirit and scope of the invention as defined in the appended claims and their equivalents.

Claims

1. An arch support insole to be inserted into a shoe comprising:

an insole main body including an arch support part curvedly projecting upward to support an arch part of a wearer's foot; and

a heel support part coupled to a rear part of the insole main body,

wherein the insole main body and the heel support body are formed of a single layer through dual injection.

2. The arch support insole according to claim 1, wherein the insole main body including the arch support part is formed of plastic with hardness higher than that of plastic forming the heel support part.

3. The arch support insole according to claim 2, further comprising an anti-slip part coupled to a front part of the insole main body.

4. The arch support insole according to claim 3, wherein the anti-slip part has the same hardness as the heel support part.

5. An arch support insole to be inserted into a shoe comprising:

an insole main body including at least a portion of an arch support part curvedly projecting upward to support the arch of a wearer's foot; and

a heel support part coupled to a rear part of the insole main body,

wherein the insole main body and the heel support part are formed of a single layer by dual injection, and

a plurality of honeycomb-shaped projections are formed downward at a bottom surface of the curved arch support part.

6. The arch support insole according to claim 5, wherein the insole main body is formed of a material having hardness higher than that of the heel support part.

7. The arch support insole according to claim 5, further comprising an anti-slip part coupled to a front part of the insole main body.

8. The arch support insole according to claim 7, wherein the heel support part, the anti-slip part, and the honeycomb-shaped projections are integrally formed with each other to surround the insole main body by dual injection.

9. The arch support insole according to claim 8, wherein the heel support part, the anti-slip part, and the honeycomb-shaped projections are formed of the same material.

10. The arch support insole according to claim 5, wherein the honeycomb-shaped projections and the insole main body are formed of the same material.

11. An arch support insole to be inserted into a shoe comprising:

an insole main body including an arch support part curvedly projecting upward to support the arch of a wearer; and

a heel support part configured to support the heel of the wearer's foot,

wherein a plurality of honeycomb-shaped projections projecting downward from a position only corresponding to a bottom surface of the curved arch support part.

12. The arch support insole according to claim 11, wherein the plurality of honeycomb-shaped projections have the size that is gradually reduced from the front part to the rear part of the insole main body.

13. An arch support insole to be inserted into a shoe comprising:

an arch support part curvedly projecting upward to support the arch of a wearer's foot; and

a peripheral part coupled to the arch support part as a single layer to surround the arch support part by dual injection,

wherein a plurality of honeycomb-shaped projections project downward from a position corresponding to a bottom surface of the curved arch support part.

14. The arch support insole according to claim 13, wherein the arch support part is formed of a material having hardness higher than that of the peripheral part.

15. The arch support insole according to claim 13, wherein the honeycomb-shaped projections and the arch support part are formed of the same material.

16. The arch support insole according to claim 13, wherein the honeycomb-shaped projections and the peripheral part are formed of the same material.

17. The arch support insole according to claim 1, wherein the dual injection is a two-color forming method.

18. The arch support insole according to claim 5, wherein the dual injection is a two-color forming method.

19. The arch support insole according to claim 5, wherein the plurality of honeycomb-shaped projections have the size that is gradually reduced from the front part to the rear part of the insole main body.

20. The arch support insole according to claim 13, wherein the plurality of honeycomb-shaped projections have the size that is gradually reduced from the front part to the rear part of the insole main body.