Cushioning device with ventilation

Abstract

An insole for a shoe is characterized by a cushioning device that circulates air between a plastic bottom layer and a soft, porous upper layer. The air is directed to designated areas of the insole via vertical apertures, which circulate air to and over the foot of a user. The bottom layer is formed with air capturing structures that when collapsed expel air that is forced through the apertures and to the surface of the user's foot. The bottom layer and the upper layer are separated by a porous middle layer that may be foam or other light weight but breathable material.

We claim: 
     
         1 . A multi-layer cushioning device adapted to conform to a human body part comprising:
 a bottom layer formed of a material selected from plastic and thermoset, the bottom layer having a lower surface including a plurality of uniformly spaced apart dome shaped structures extending substantially a length and a width of the lower surface;   a middle layer on top of the bottom layer; and   a top layer having a plurality of vertical apertures that extend through the middle layer and through the bottom layer.   
     
     
         2 . The multi-layer cushioning device of  claim 1  further comprising an upwardly extending lateral protrusion, the upwardly extending lateral protrusion comprising column-shaped vertical recesses on an outer surface for communicating air thereinthrough. 
     
     
         3 . The multi-layer cushioning device of  claim 2  wherein an upper edge of the lateral protrusion is an arc. 
     
     
         4 . The multi-layer cushioning device of  claim 1  wherein the middle layer comprises a foam. 
     
     
         5 . The multi-layer cushioning device of  claim 1  wherein the middle layer comprises air. 
     
     
         6 . The multi-layer cushioning device of  claim 1  wherein the bottom layer is adhered to the top layer with a thermally activated adhesive. 
     
     
         7 . The multi-layer cushioning device of  claim 1 , wherein the dome shaped structures are inverted. 
     
     
         8 . The multi-layer cushioning device of  claim 1 , wherein the device is shaped to the contour of a human foot. 
     
     
         9 . The multi-layer cushioning device of  claim 1 , wherein the dome shaped structures are resilient and return to an original shape once compressed. 
     
     
         10 . The multi-layer cushioning device of  claim 1  further comprising a lip extending around a periphery thereof. 
     
     
         11 . The multi-layer cushioning device of  claim 1 , wherein the dome shaped structures are selected to collapse when stepped upon, expelling air away from the bottom layer. 
     
     
         12 . The multi-layer cushioning device of  claim 1 , wherein the dome shaped structures extend approximately one half way into the middle layer. 
     
     
         13 . The multi-layer cushioning device of  claim 1 , wherein the bottom layer is a plastic mesh. 
     
     
         14 . The multi-layer cushioning device of  claim 1  further including a non-stretch moderator adjacent to the bottom layer. 
     
     
         15 . The multi-layer cushioning device of  claim 1 , further comprising a deodorizing material dispersed when the dome-shaped structures are compressed. 
     
     
         16 . The multi-layer cushioning device of  claim 1 , wherein the cushioning device can be individually tuned by adjusting the size, shape, and thickness of the dome shaped structures. 
     
     
         17 . The multi-layer cushioning device of  claim 1 , wherein at least one layer includes chitin. 
     
     
         18 . A method for fabricating a shoe insert comprising:
 fabricating a bottom layer from a plastic material that is formed into a negative mold of the insert;   heating an interfacing layer and placing the interfacing layer over the bottom layer while the bottom layer is still heated from the molding operation;   applying an adhesive to a plurality of attachment points to create an instant and permanent bond between the plastic bottom layer and the interfacing layer; and   applying air pressure to the interfacing layer to bond it to the plastic bottom layer.   
     
     
         19 . The method for fabricating a shoe insert of  claim 18 , wherein the plastic bottom layer is formed by selecting a sheet of plastic material and securing the sheet into a clamping frame, and then placing the clamping frame and sheet in a temperature controlled oven until a melting point is reached, whereupon the sheet of material is placed in a negative mold and cured. 
     
     
         20 . The method for fabricating a shoe insert of  claim 19 , further comprising adding a foam layer between the bottom layer and the interfacing layer comprising:
 heating a foam material and then positioning the foam material over the plastic bottom layer;   lowering the interfacing layer onto a negative mold containing the bottom layer and the foam material;   pressing the interfacing layer to the bottom layer at attachment points to trap the foam material therebetween using air pressure; and   pressing an edge of the foam material into the bottom layer while the bottom layer is in a melted state.