Molded foot support

Abstract

There is provided a foot support conforming to a user's foot. The foot support includes a supportive member defining a front portion, a rear portion and an arch portion for engagement against the foot plantar arch. The rear portion has a concave periphery formed for partial resting abutment of the person's heel. The supportive member is fabricated from thermoplastic material formed to shape in a custom application. Preferred materials are thermoplastic materials providing easily formable shapes that soften or react at a low temperature between and are capable of being molded and shaped with hand pressure to the bottom of the foot while the foot is in a non-weight bearing position. Subsequently the thermoplastic material hardens retaining the molded shape. In a second embodiment, a footbed assembly having a cushioning top layer overlaying the upper surface of the molded supportive member is provided. The invention also contemplates a method for custom forming the supportive member.

1 . A foot support for fitting inside footwear and conforming to a person's foot comprising; 
 at least one customizable and supportive member wherein said supportive member softens significantly at an elevated but non-scalding temperature so that said supportive member loses its material memory and is easily pliable by the user to take on a desired three-dimensional surface; and    when cooled to normal use temperatures, said supportive member retains the desired three-dimensional surface and provides support and comfort to the user's foot when used inside a shoe.    
   
   
       2 . The foot support according to  claim 1  wherein said foot support further comprises an assembly of members.  
   
   
       3 . The foot support according to  claim 2  wherein said assembly includes at least one member made of textile, leather or synthetic materials to provide comfort against the skin.  
   
   
       4 . The foot support according to  claim 2  wherein said assembly includes at least one member is made of foam to cushion the foot against the rigid supportive member.  
   
   
       5 . The foot support according to  claim 1  wherein said supportive member includes a cut out in the heel portion and recesses to provide extra shock-absorption and comfort to the user's foot.  
   
   
       6 . The foot support according to  claim 1  wherein said supportive member is a thermoplastic material.  
   
   
       7 . The foot support according to  claim 1  wherein said supportive member changes color and opacity when heated to it softening temperature.  
   
   
       8 . The foot support according to  claim 6  wherein said thermoplastic material is softened by placing said material in heated water.  
   
   
       9 . The foot support according to  claim 6  wherein the softening temperature of said thermoplastic material is between 120° F. and 180° F.  
   
   
       10 . The foot support according to  claim 6  wherein said thermoplastic material in a softened state permanently deforms under a load of 15 psi.  
   
   
       11 . The foot support according to  claim 1  wherein the desired surface shape and detail of said supportive member is formed by molding to the user's foot in a non-weight bearing position.  
   
   
       12 . The foot support according to  claim 1  wherein said supportive member is formed by molding to the user's foot in a weight bearing position.  
   
   
       13 . The foot support according to  claim 1  wherein the desired surface shape said supportive member is created to form a corrective effect on the posture or shape of user's foot.  
   
   
       14 . The foot support according to  claim 1  wherein said supportive member is created to form an accommodative effect for the posture or shape of the user's foot.  
   
   
       15 . The foot support according to  claim 1  wherein normal use temperatures are between −20° F. and 125° F.  
   
   
       16 . The foot support according to  claim 1  wherein said thermoplastic material, when cooled, will not permanently deform under 25 psi at normal use temperatures.  
   
   
       17 . The foot support according to  claim 1  where material, when cooled, has a flexural modulus of from about 300 to about 500 MPa at normal use temperatures.  
   
   
       18 . The foot support according to  claim 1  wherein said foot support comprises: 
 a monolithic resilient supportive member defining inner and outer lateral sides defining an arch portion between a front portion and a rear portion conforming to the arch of the person's foot;    said front portion integrally frontwardly extending from said arch portion for complementary engagement near the metatarsal plantar region of the foot;    said rear portion having a concave periphery for partial resting abutment of the person's heel onto said sides for complementary engagement around said heel; and    said monolithic resilient supportive member being formed of a softened thermoplastic material that that is conformed directly to the person's foot while said foot is in a non-weight bearing position.    
   
   
       19 . The foot support according to  claim 18  wherein said thermoplastic material is selected from the group consisting of poly(ethyleneadipate), poly (epsilon-caprolactone), polyvinyl stearate, cellulose acetate, butyl rubber and ethyl cellulose poly (propylene oxide) containing co-monomers, trans polyisoprene and cis polyisoprene based thermoplastic materials, and polycaprolactone based materials.  
   
   
       20 . The foot support according to  claim 18  wherein said thermoplastic material is poly (epsilon-caprolactone).  
   
   
       21 . The foot support according to  claim 18  wherein said thermoplastic material is a polysilicone.  
   
   
       22 . The foot support according to  claim 18  wherein said front portion has a plurality of frontwardly facing arcuate concavities.  
   
   
       23 . The foot support according to  claim 18  wherein said resilient supportive member has a hole in the heel area.  
   
   
       24 . The foot support according to  claim 18  wherein said resilient supportive member has a plurality of ruts on the bottom surface.  
   
   
       25 . The foot support according to  claim 18  further comprising a second member positioned on top of said resilient supportive member to provide a cushioning layer to cushion the foot.  
   
   
       26 . The foot support according to  claim 18  wherein said second member is ethylene vinyl acetate.  
   
   
       27 . A footbed assembly comprising 
 at least one customizable and supportive air-curable member wherein said supportive member is initially in a soft and unhardened state, said supportive member being easily pliable by the user to take on a desired three-dimensional surface;    whereby exposure to air allows said supportive member having said desired three-dimensional surface to harden and establish a material memory in said three-dimensional surface and provides support and comfort to the user's foot.    
   
   
       28 . The footbed assembly according to  claim 27  further comprising a member made of textile, leather or synthetic to provide comfort against the skin.  
   
   
       29 . The footbed assembly according to  claim 27  further comprising a member made of foam to cushion the foot against the rigid supportive member.  
   
   
       30 . The footbed assembly according to  claim 27  wherein said supportive member includes ruts and dimples to provide extra shock-absorption and comfort.  
   
   
       31 . The footbed assembly according to  claim 27  wherein said supportive member is a thermoset plastic.  
   
   
       32 . The footbed assembly according to  claim 27  wherein said supportive member is a multi-component member.  
   
   
       33 . The footbed assembly according to  claim 31  wherein said supportive member changes color and/or opacity when it reaches its hardened state.  
   
   
       34 . The footbed assembly according to  claim 31  wherein said thermo set material, in softened state, permanently deforms under a load of 15 psi.  
   
   
       35 . The footbed assembly according to  claim 27  wherein the desired surface of said supportive member is provided by the user's foot in a non-weight-bearing position.  
   
   
       36 . The footbed assembly according to  claim 27  wherein the desired surface of said supportive member is created to form a corrective effect on the user's foot.  
   
   
       37 . The footbed assembly according to  claim 31  wherein said thermo set material, when hardened, will not permanently deform under 25 psi at normal use temperatures.  
   
   
       38 . The footbed assembly according to  claim 27  wherein said supportive member, when cooled, has a flexural modulus of from 300 to about a 500 MPa at normal use temperatures.  
   
   
       39 . A footbed assembly comprising: 
 at least one customizable and supportive plastic member wherein said supportive member is initially in a soft and unhardened state, said supportive member being easily pliable by the user to take on a desired three-dimensional surface;    whereby mixture with a catalyst allows said supportive member having said desired three-dimensional surface to harden and establish a material memory in said three-dimensional surface and provides support and comfort to the user's foot.    
   
   
       40 . Footwear that comprises: 
 an item selected from the group consisting of shoes, boots, skates and ski boots; and    a footbed assembly comprising at least one customizable and supportive member wherein said supportive member is initially in a soft and unhardened state, said supportive member being easily pliable by the user to take on a desired three-dimensional surface, whereby said supportive member is allowed to harden and establish a material memory in said three-dimensional surface and provides support and comfort to the user's foot.    
   
   
       41 . The footwear according to  claim 40  wherein said footbed assembly includes at least one member made of textile, leather or synthetic components to provide comfort against the skin.  
   
   
       42 . The footwear according to  claim 40  wherein said footbed assembly includes at least one member is made of foam to cushion the foot against the rigid supportive member.  
   
   
       43 . The footwear according to  claim 40  wherein said supportive member includes cut outs and dimples to provide extra shock-absorption and comfort to the user's foot.  
   
   
       44 . The footwear according to  claim 40  wherein said supportive member is a thermoplastic material.  
   
   
       45 . The footwear according to  claim 40  wherein said supportive member changes color and opacity when heated to it softening temperature.  
   
   
       46 . The footwear according to  claim 44  wherein said thermoplastic material is softened by placing said material in heated water.  
   
   
       47 . The footwear according to  claim 44  wherein the softening temperature of said thermoplastic material is between 120° F. and 180° F.  
   
   
       48 . The footwear according to  claim 44  wherein said thermoplastic material in a softened state permanently deforms under a load of 15 psi.  
   
   
       49 . The footwear according to  claim 40  wherein the desired surface shape and detail of said supportive member is formed by molding to the user's own foot in a non-weight-bearing position.  
   
   
       50 . The footwear according to  claim 40  wherein the desired surface shape and detail said supportive member is formed by molding to the user's foot in a weight bearing position.  
   
   
       51 . The footwear according to  claim 40  wherein said supportive member is created to form a corrective effect on the posture or shape of user's foot.  
   
   
       52 . The footwear according to  claim 40  wherein said supportive member is created to form an accommodative effect for the posture or shape of the user's foot.  
   
   
       53 . The footwear according to  claim 40  wherein normal use temperatures are between −20° F. and 125° F.  
   
   
       54 . The footwear according to  claim 40  wherein said thermoplastic material, when cooled, will not permanently deform under 25 psi at normal use temperatures.  
   
   
       55 . The footwear according to  claim 40  where material, when cooled, has a flexural modulus of from about 300 to about 500 MPa at normal use temperatures.  
   
   
       56 . The footwear according to  claim 40  wherein said foot support comprises: 
 a monolithic resilient supportive member defining inner and outer lateral sides defining an arch portion between a front portion and a rear portion conforming to the arch of the person's foot;    said front portion integrally frontwardly extending from said arch portion for complementary engagement near the metatarsal plantar region of the foot;    said rear portion having a concave periphery for partial resting abutment of the person's heel onto said sides for complementary engagement around said heel; and    said monolithic resilient supportive member being formed of a softened thermoplastic material that that is conformed directly to the person's foot while said foot is in a non-weight bearing position.    
   
   
       57 . The footwear according to  claim 56  wherein said thermoplastic material is selected from the group consisting of poly(ethyleneadipate), poly (epsilon-caprolactone), polyvinyl stearate, cellulose acetate, butyl rubber and ethyl cellulose poly (propylene oxide) containing co-monomers, trans polyisoprene and cis polyisoprene based thermoplastic materials, and polycaprolactone based materials.  
   
   
       58 . The footwear according to  claim 56  wherein said thermoplastic material is poly (epsilon-caprolactone).  
   
   
       59 . The footwear according to  claim 56  wherein said thermoplastic material is a polysilicone.  
   
   
       60 . The footwear according to  claim 56  wherein said front portion has a plurality of frontwardly facing arcuate concavities.  
   
   
       61 . The footwear according to  claim 56  wherein said resilient supportive member has a hole in the heel area.  
   
   
       62 . The footwear according to  claim 56  wherein said resilient supportive member has a plurality of ribs on the bottom surface.  
   
   
       63 . The foot support according to  claim 56  further comprising a second member positioned on top of said resilient supportive member to provide a cushioning layer to cushion the foot.  
   
   
       64 . The foot support according to  claim 56  wherein said second member is ethylene vinyl acetate.  
   
   
       65 . A process for customizing a footbed assembly comprising: 
 placing a supportive member from said footbed assembly in a forming tray that can contain both the footbed and 500 ml of hot water;    filling said forming tray with water at a temperature between 120° F. and 180° F., and said supportive member and allowing the internal temperature of said supportive member to rise until said member reaches a pliable state;    removing said supportive member from said forming tray and shaping said supportive member to the user's foot or other corrective shape;    allowing said supportive member to cool to a hardened state; and    re-assembling said shaped supportive member into said footbed assembly.