Weighted shoe insole and method for making the same

Abstract

A weighted insole assembly, comprising a top thermoformable material layer, a bottom thermoformable material layer, and a weighted unit encapsulated between the top and bottom thermoformable material layers, the weighted unit including a heavy filler material and having a specific gravity between about 2.0 and about 4.0.

What is claimed is: 
     
         1 . A weighted insole assembly, comprising:
 a top thermoformable material layer;   a bottom thermoformable material layer; and   a weighted unit encapsulated between the top and bottom thermoformable material layers, the weighted unit including a heavy filler material and having a specific gravity between about 2.0 and about 4.0.   
     
     
         2 . The weighted insole assembly of  claim 1 , wherein the top and bottom thermoformable material layers have a larger surface area than the weighted unit encapsulated therebetween. 
     
     
         3 . The weighted insole of  claim 2 , wherein the top and bottom thermoformable material layers are joined together in an outer peripheral section of the insole assembly. 
     
     
         4 . The weighted insole of  claim 3 , wherein the outer peripheral section extends upwardly and forms a concave section adapted to fit a user's heel. 
     
     
         5 . The weighted insole of  claim 4 , wherein the weighted unit is substantially flat. 
     
     
         6 . The weighted insole of  claim 4 , wherein the outer peripheral section tapers in a direction from the heel toward the front of the insole. 
     
     
         7 . The weighted insole of  claim 3 , wherein the weighted unit is substantially flat. 
     
     
         8 . The weighted insole of  claim 3 , wherein the weight provided by the weighted unit is distributed substantially evenly. 
     
     
         9 . The weighted insole of  claim 3 , wherein the weighted unit has a substantially uniform thickness. 
     
     
         10 . The weighted insole of  claim 3 , wherein the weighted unit has a non-uniform thickness. 
     
     
         11 . The weighted insole of  claim 3 , wherein the top and bottom thermoformable material layers directly contact each other in the outer peripheral section of the insole assembly. 
     
     
         12 . The weighted insole of  claim 3 , further comprising a raised arch portion. 
     
     
         13 . The weighted insole of  claim 12 , wherein the top thermoformable material layer is thicker in the area of the raised arch portion. 
     
     
         14 . The weighted insole assembly of  claim 1 , wherein the top thermoformable material layer is fabricated from at least one of a thermoplastic synthetic resin foam, a thermosetting resin foam and a rubber material foam. 
     
     
         15 . The weighted insole assembly of  claim 14 , wherein the thermoplastic synthetic resin foam is selected from at least one of an ethylene-vinyl acetate copolymer and a cross-linked polyethylene. 
     
     
         16 . The weighted insole assembly of  claim 14 , wherein the thermosetting resin foam is polyurethane. 
     
     
         17 . The weighted insole assembly of  claim 14 , wherein the rubber material foam is selected from at least one of a butadiene rubber and a chloroprene rubber. 
     
     
         18 . The weighted insole assembly of  claim 1 , wherein the specific gravity of the weighted unit is between about 2.5 and about 3.5. 
     
     
         19 . The weighted insole assembly of  claim 1 , wherein the specific gravity of the weighted unit is between about 2.7 and about 3.2. 
     
     
         20 . The weighted insole assembly of  claim 1 , further comprising a fabric layer. 
     
     
         21 . The weighted insole assembly of  claim 20 , wherein the fabric layer includes an agent configured to inhibit bacterial, microbial or fungal growth, the agent being selected from at least one of antimicrobial polymerizable compositions containing an ethylenically unsaturated monomer, di-functional or tri-functional antimicrobial monomers and polymerization initiators, silver containing antimicrobial agents comprising carboxymethylcellulose, crosslinked compounds containing silver or silver salts of carboxymethylcellulose, organic solvent-soluble mucopolysaccharides consisting of ionic complexes of at least one mucopolysaccharide and a quaternary phosphonium, antibacterial antithrombogenic compositions comprising organic solvent-soluble mucopolysaccharides and organic polymeric materials, antibacterial antithrombogenic compositions comprising organic solvent-soluble mucopolysaccharides and inorganic antibacterial agents, and silver, copper or zinc components. 
     
     
         22 . The weighted insole assembly of  claim 1 , wherein the bottom thermoformable material layer is fabricated from an elastomeric material selected from one or more of natural rubbers, synthetic polyisoprenes, butyl rubbers, halogenated butyl rubbers, polybutadienes, styrene-butadiene rubbers, nitrile rubbers, hydrogenated nitrile rubbers, chloroprene rubbers, polychloroprenes, neoprene, baypren, ethylene propylene rubbers, copolymers of ethylene and propylene, ethylene propylene diene rubbers, terpolymers of ethylene, propylene and a diene-component), epichlorohydrin rubbers, polyacrylic rubbers, silicone rubbers, fluorosilicone Rubbers, fluoroelastomers, perfluoroelastomers, polyether block amides, chlorosulfonated polyethylenes and ethylene-vinyl acetate copolymers. 
     
     
         23 . The weighted insole assembly of  claim 1 , wherein the top thermoformable material layer has a durometer hardness of from about 30 Shore C to about 70 Shore C. 
     
     
         24 . The weighted insole assembly of  claim 1 , wherein the bottom thermoformable material layer has a durometer hardness of from about 60 Shore C to about 90 Shore C. 
     
     
         25 . The weighted insole assembly of  claim 1 , wherein the bottom thermoformable material layer has a durometer hardness of from about 70 Shore C to about 80 Shore C. 
     
     
         26 . The weighted insole assembly of  claim 1 , wherein the heavy filler material includes at least one of copper oxide, zinc oxide, calcium oxide, lead oxide, tin oxide, antimony oxide, iron oxide, copper carbonate, magnesium carbonate, calcium carbonate, barium carbonate, zinc carbonate, cadmium carbonate, copper sulfide, barium sulfide, zinc sulfide, cadmium sulfide, iron sulfide, cobalt sulfide, lead sulfide, copper hydroxide, magnesium hydroxide, calcium hydroxide, barium hydroxide, aluminum hydroxide, cobalt hydroxide and lead hydroxide. 
     
     
         27 . A method for fabricating a weighted insole assembly, the method comprising:
 creating a cavity in a first thermoformable material layer;   inserting a weighted unit in the cavity of the first thermoformable material layer;   placing the thermoformable material layer and the weighted unit into a mold;   introducing a second thermoformable material layer into the mold;   encapsulating the weighted unit between the first thermoformable material layer and the second thermoformable material layer by heating the mold and applying pressure;   removing a weighted insole assembly blocker from the mold; and   cutting the weighted insole assembly blocker.   
     
     
         28 . The method of  claim 27 , further comprising attaching a fabric layer. 
     
     
         29 . The method of  claim 28 , wherein the fabric layer includes an agent configured to inhibit bacterial, microbial or fungal growth, the agent being selected from at least one of antimicrobial polymerizable compositions containing an ethylenically unsaturated monomer, di-functional or tri-functional antimicrobial monomers and polymerization initiators, silver containing antimicrobial agents comprising carboxymethylcellulose, crosslinked compounds containing silver or silver salts of carboxymethylcellulose, organic solvent-soluble mucopolysaccharides consisting of ionic complexes of at least one mucopolysaccharide and a quaternary phosphonium, antibacterial antithrombogenic compositions comprising organic solvent-soluble mucopolysaccharides and organic polymeric materials, antibacterial antithrombogenic compositions comprising organic solvent-soluble mucopolysaccharides and inorganic antibacterial agents, and silver, copper or zinc components. 
     
     
         30 . The method of  claim 27 , wherein the first thermoformable material layer is fabricated from at least one of a thermoplastic synthetic resin foam, a thermosetting resin foam and a rubber material foam. 
     
     
         31 . The method of  claim 30 , wherein the thermoplastic synthetic resin foam is selected from at least one of an ethylene-vinyl acetate copolymer and a cross-linked polyethylene. 
     
     
         32 . The method of  claim 30 , wherein the thermosetting resin foam is polyurethane. 
     
     
         33 . The method of  claim 30 , wherein the rubber material foam is selected from at least one of a butadiene rubber and a chloroprene rubber. 
     
     
         34 . The method of  claim 27 , wherein the weighted unit includes a heavy filler material that includes at least one of copper oxide, zinc oxide, calcium oxide, lead oxide, tin oxide, antimony oxide, iron oxide, copper carbonate, magnesium carbonate, calcium carbonate, barium carbonate, zinc carbonate, cadmium carbonate, copper sulfide, barium sulfide, zinc sulfide, cadmium sulfide, iron sulfide, cobalt sulfide, lead sulfide, copper hydroxide, magnesium hydroxide, calcium hydroxide, barium hydroxide, aluminum hydroxide, cobalt hydroxide and lead hydroxide 
     
     
         35 . The method of  claim 27 , wherein the specific gravity of the weighted unit is between about 2.0 and about 4.0. 
     
     
         36 . The method of  claim 27 , wherein the specific gravity of the weighted unit is between about 2.5 and about 3.5. 
     
     
         37 . The method of  claim 27 , wherein the specific gravity of the weighted unit is between about 2.7 and about 3.2. 
     
     
         38 . The method of  claim 27 , wherein the second thermoformable material layer is fabricated from an elastomeric material selected from one or more of natural rubbers, synthetic polyisoprenes, butyl rubbers, halogenated butyl rubbers, polybutadienes, styrene-butadiene rubbers, nitrile rubbers, hydrogenated nitrile rubbers, chloroprene rubbers, polychloroprenes, neoprene, baypren, ethylene propylene rubbers, copolymers of ethylene and propylene, ethylene propylene diene rubbers, terpolymers of ethylene, propylene and a diene-component), epichlorohydrin rubbers, polyacrylic rubbers, silicone rubbers, fluorosilicone Rubbers, fluoroelastomers, perfluoroelastomers, polyether block amides, chlorosulfonated polyethylenes and ethylene-vinyl acetate copolymers. 
     
     
         39 . The method of  claim 27 , wherein the first thermoformable material layer has a durometer hardness of from about 30 Shore C to about 70 Shore C. 
     
     
         40 . The method of  claim 27 , wherein the second thermoformable material layer has a durometer hardness of from about 60 Shore C to about 90 Shore C. 
     
     
         41 . The method of  claim 27 , wherein the second thermoformable material layer has a durometer hardness of from about 70 Shore C to about 80 Shore C. 
     
     
         42 . An insole assembly training kit, the kit including:
 a pair of weighted insoles, each weighted insole having a weighted unit with a heavy filler material; and   a pair of non-weighted insoles, each non-weighted insole having at least one flexible layer.   
     
     
         43 . The insole assembly training kit of  claim 42 , wherein the specific gravity of the weighted unit is between about 2.0 and about 4.0. 
     
     
         44 . The insole assembly training kit of  claim 42 , wherein at least one of the pair of weighted insoles and the pair of non-weighted insoles further includes a fabric layer attached thereto. 
     
     
         45 . The insole assembly training kit of  claim 44 , wherein the fabric layer includes an agent configured to inhibit bacterial, microbial or fungal growth, the agent being selected from at least one of antimicrobial polymerizable compositions containing an ethylenically unsaturated monomer, di-functional or tri-functional antimicrobial monomers and polymerization initiators, silver containing antimicrobial agents comprising carboxymethylcellulose, crosslinked compounds containing silver or silver salts of carboxymethylcellulose, organic solvent-soluble mucopolysaccharides consisting of ionic complexes of at least one mucopolysaccharide and a quaternary phosphonium, antibacterial antithrombogenic compositions comprising organic solvent-soluble mucopolysaccharides and organic polymeric materials, antibacterial antithrombogenic compositions comprising organic solvent-soluble mucopolysaccharides and inorganic antibacterial agents, and silver, copper or zinc components. 
     
     
         46 . The insole assembly training kit of  claim 42 , wherein the at least one flexible layer is fabricated from at least one of a thermoplastic synthetic resin foam, a thermosetting resin foam and a rubber material foam. 
     
     
         47 . The insole assembly training kit of  claim 46 , wherein the thermoplastic synthetic resin foam is selected from at least one of an ethylene-vinyl acetate copolymer and a cross-linked polyethylene. 
     
     
         48 . The insole assembly training kit of  claim 46 , wherein the thermosetting resin foam is polyurethane. 
     
     
         49 . The insole assembly training kit of  claim 46 , wherein the rubber material foam is selected from at least one of a butadiene rubber and a chloroprene rubber. 
     
     
         50 . The insole assembly training kit of  claim 42 , wherein the heavy filler material includes at least one of copper oxide, zinc oxide, calcium oxide, lead oxide, tin oxide, antimony oxide, iron oxide, copper carbonate, magnesium carbonate, calcium carbonate, barium carbonate, zinc carbonate, cadmium carbonate, copper sulfide, barium sulfide, zinc sulfide, cadmium sulfide, iron sulfide, cobalt sulfide, lead sulfide, copper hydroxide, magnesium hydroxide, calcium hydroxide, barium hydroxide, aluminum hydroxide, cobalt hydroxide and lead hydroxide 
     
     
         51 . The insole assembly training kit of  claim 42 , wherein the specific gravity of the weighted unit is between about 2.0 and about 4.0. 
     
     
         52 . The insole assembly training kit of  claim 42 , wherein the specific gravity of the weighted unit is between about 2.5 and about 3.5. 
     
     
         53 . The insole assembly training kit of  claim 42 , wherein the specific gravity of the weighted unit is between about 2.7 and about 3.2. 
     
     
         54 . The insole assembly training kit of  claim 42 , wherein the at least one flexible layer is fabricated from an elastomeric material selected from one or more of natural rubbers, synthetic polyisoprenes, butyl rubbers, halogenated butyl rubbers, polybutadienes, styrene-butadiene rubbers, nitrile rubbers, hydrogenated nitrile rubbers, chloroprene rubbers, polychloroprenes, neoprene, baypren, ethylene propylene rubbers, copolymers of ethylene and propylene, ethylene propylene diene rubbers, terpolymers of ethylene, propylene and a diene-component), epichlorohydrin rubbers, polyacrylic rubbers, silicone rubbers, fluorosilicone Rubbers, fluoroelastomers, perfluoroelastomers, polyether block amides, chlorosulfonated polyethylenes and ethylene-vinyl acetate copolymers. 
     
     
         55 . The insole assembly training kit of  claim 42 , wherein the at least one flexible layer has a durometer hardness of from about 30 Shore C to about 70 Shore C. 
     
     
         56 . The insole assembly training kit of  claim 42 , wherein the at least one flexible layer has a durometer hardness of from about 60 Shore C to about 90 Shore C. 
     
     
         57 . The insole assembly training kit of  claim 42 , wherein the at least one flexible layer has a durometer hardness of from about 70 Shore C to about 80 Shore C.