Orthotic shell

Abstract

An orthotic shoe insert having a contoured body adapted to support a location of a wearer's foot between a heel and a medial arch, the body being constructed of a semi-rigid material and including a rear concave end and a forward extending and medial arch supporting edge. The body exhibits a three dimensional shape and perimeter defining outer profile adapted for being inserted into the wearer's shoe. Corresponding methods for forming an orthotic shoe insert can include either providing a thermoplastic material in an unformed lay-flat sheet of varying thickness and rigidity, then applying a heat source to the material to assisting in forming the material into a three dimensional shape including a concave rear and heel supporting end and a forward extending and medial arch supporting end. Other methods include pre-placing scrim layers within opposing surfaces of mating die halves and post-injecting a plasticized material in fluidic state in order to form the insert.

I claim: 
     
         1 . An orthotic shoe insert, comprising:
 a contoured body adapted to support a location of a wearer's foot between a heel and a medial arch, said body being constructed of a semi-rigid material and including a rear concave portion bounded by a raised heel edge and a forward extending and medial arch supporting edge; and   said body exhibiting a three dimensional shape and perimeter defining outer profile adapted for being inserted into the wearer's shoe.   
     
     
         2 . The insert as described in  claim 1 , said body having a specified shape and size and being constructed of a polypropylene/polyethylene blend material. 
     
     
         3 . The insert as described in  claim 1 , further comprising at least one scrim layer applied to either an upper and/or lower surface of said body. 
     
     
         4 . The insert as described in  claim 3 , said scrim layer further comprising any of a foam, fabric or leather material. 
     
     
         5 . The insert as described in  claim 1 , said body having a specified shape and size and varying in at least one of thickness and density between said rear concave end and said forward extending edge. 
     
     
         6 . A method for forming an orthotic shoe insert, comprising the steps of:
 providing a semi-rigid and thermoplastic material as a lay-flat sheet of varying thickness;   applying a heat source to said material; and   forming the material into a three dimensional shape including a rear concave portion bounded by a raised heel edge and a forward extending and medial arch supporting edge.   
     
     
         7 . The method as described in  claim 6 , further comprising the step of applying the heat source through the use of any of a hot air gun, hot water, convection oven, conventional oven, infrared or targeted microwave generated heat. 
     
     
         8 . The method as described in  claim 6 , said step of forming into a three dimensional shape further comprising providing any of a die, stamping or closed mold in which one or both of cavity defining die surfaces can be heated to facilitate forming and setting of the material into the desired shape. 
     
     
         9 . The method as described in  claim 6 , further comprising the step of providing said material in at least one of a liquid or semi-molten form in a combined polypropylene and/or polyethylene scrim blend extrusion. 
     
     
         10 . The method as described in  claim 8 , further comprising the step of applying at least one scrim layer to either an upper and/or lower surface of said formed material. 
     
     
         11 . The method as described in  claim 10 , said step of applying said scrim layer further comprising extruding upper and lower scrim layers against opposite sides of said semi rigid and thermoplastic material. 
     
     
         12 . The method as described in  claim 6 , further comprising the step of said material varying in at least one of thickness or rigidity between said rear concave end and said forward extending end. 
     
     
         13 . The method as described in  claim 10 , further comprising the step of pre-positioning upper and lower scrim layers into cavity defining surfaces of said die prior to or during three dimensional forming. 
     
     
         14 . The method as described in  claim 13 , further comprising the step of pre-cutting said scrim layers to match a profile of the three dimensional formed material. 
     
     
         15 . The method as described in  claim 13 , further comprising the step of trimming said scrim layers to match a contour of the three dimensionally formed material. 
     
     
         16 . A method for forming an orthotic shoe insert, comprising the steps of:
 providing upper and lower dies, each including a mating and recessed interior;   placing at least one scrim layer into at least one of said die recessed cavities; and   upon closing said dies, infilling a fluidic plasticized material in order to fill a cavity defined by opposing interior surfaces of said dies and between said scrim layers.   
     
     
         17 . The method as described in  claim 16 , further comprising the step of said scrim layer exhibiting any of a foam, fabric or leather material. 
     
     
         18 . The method as described in  claim 16 , further comprising the step of pre-positioning upper and lower scrim layers into upper and lower recess cavity defining surfaces of said dies prior to three dimensional forming. 
     
     
         19 . The method as described in  claim 16 , further comprising the step of pre-cutting said scrim layers to match a profile of the three dimensional formed material. 
     
     
         20 . The method as described in  claim 16 , further comprising the step of provided said scrim layers in a tautened sheet form and subsequently edge trimming to match a contour of the three dimensionally formed material.