Customized orthopedic sole insert and method

Abstract

A customizable sole insert for a shoe, the sole insert comprising: a top layer having a first plurality of holes through the top layer; a middle layer having a conforming and curable hardening material; a bottom layer having a second plurality of holes through the bottom layer; wherein the top layer, middle layer, and bottom layers are fastened together by a fastener; wherein a fluid applied to the middle layer causes the middle layer to cure; wherein the middle layer conforms to a plantar aspect area or sole of a foot of a user. Further comprising: a top cover attached to to a top outside surface of the top layer; and, a bottom cover attached to a bottom outside surface of the bottom layer. The customizable sole insert has a method for constructing the sole insert and a method for activating the sole insert.

1 . A customizable sole insert for a shoe, the sole insert comprising:
 a top layer having a first plurality of holes through the top layer;   a middle layer having a conforming and curable hardening material;   a bottom layer having a second plurality of holes through the bottom layer;   wherein the top layer, middle layer, and bottom layers are fastened together by a fastener;   wherein a fluid applied to the middle layer causes the middle layer to cure; wherein the middle layer conforms to a plantar aspect area or sole of a foot of a user.   
     
     
         2 . The sole insert of  claim 1 , further comprising: a top cover attached to to a top outside surface of the top layer; and, a bottom cover attached to a bottom outside surface of the bottom layer; wherein the top cover and the bottom cover are made of a cloth material; wherein the cloth material is at least one of a cotton material, a denim material, a felt material, a linen material, a nylon material, a polyester material, a silk material, a satin material, a twill material, a wool material, and a yarn material. 
     
     
         3 . The sole insert of  claim 1 , wherein the first plurality of holes allow for the fluid to pass through the top layer to contact the middle layer, wherein the fluid is moisture produced by a user's foot. 
     
     
         4 . The sole insert of  claim 1 , wherein the second plurality of holes allow for the fluid to pass through the bottom layer to contact the middle layer, wherein the fluid is water applied by a user. 
     
     
         5 . The sole insert of  claim 1 , wherein the conforming and curable hardening material is at least one of potting compounds, epoxy, resins, fiberglass, fiberglass resin, polyurethane casting, and hydroxypropyl methyl-cellulose. 
     
     
         6 . The sole insert of  claim 1 , wherein the top layer is made from a cushion material; wherein the cushion material compresses under a foot of a user; wherein the cushion material partly decompress when the foot of the user is removed from the sole insert. 
     
     
         7 . The sole insert of  claim 1 , wherein the bottom layer is conformable to the middle layer. 
     
     
         8 . The sole insert of  claim 1 , wherein the bottom layer has a protruding rim. 
     
     
         9 . The sole insert of the  claim 8 , wherein the protruding rim is attachable to a perimeter of the top layer by the fastener, wherein the fastener is at least one of an adhesive, a glue, an epoxy, and stitching. 
     
     
         10 . The sole insert of  claim 1 , further comprising: at lease one additional padding positioned below the top layer or above the bottom layer. 
     
     
         11 . The sole insert of  claim 10 , wherein the at least one additional padding acts as a heel support. 
     
     
         12 . A method for manufacturing a customizable sole insert, the method comprising:
 forming a bottom layer having a protruding rim on a perimeter of the bottom layer; wherein the protruding rim forms a cavity in the bottom layer;   applying an adhesive in the cavity of the bottom layer;   inserting a middle layer within the cavity of the bottom layer; wherein the middle layer hardens when contacted by a fluid;   applying the adhesive to the protruding rim and a top surface of the middle layer;   sandwiching a top layer onto the protruding rim and the top surface of the middle layer;   wherein the top layer and the bottom layer have a first and second set of plurality of holes.   
     
     
         13 . The method for manufacturing a customizable sole insert  12 , wherein the method further comprises: applying the adhesive to at least one of an outer surface of the top and bottom layers; covering at least one of the top and bottom layers with a cover; wherein the cover is made from a permeable cloth material; and, placing the sole insert into a moisture proof packaging. 
     
     
         14 . The method for manufacturing a customizable sole insert  12 , wherein the method further comprises: inserting at least one additional padding below the top layer and above the bottom layer. 
     
     
         15 . A method for activating a customizable sole insert, the method comprising:
 selecting a sole insert from a selection of inserts; wherein the selection of inserts are based on various shoe sizes, widths, arch heights and categories of use;   applying a fluid to a first plurality of holes in a top layer; wherein the fluid passes through the top layer via the first plurality of holes to contact a middle layer;   rotating the sole insert so that an outer surface of a bottom layer faces in the up direction;   applying the fluid to a second plurality of holes in the bottom layer; wherein the fluid passes through the bottom layer via the second plurality of holes to contact the middle layer;   inserting the sole insert into a shoe;   placing a foot of a user into the shoe applying a downwards force on the sole insert for a first period of time; wherein the downwards force molds the middle layer;   removing the foot of the user from the shoe and leaving the sole insert in the shoe for a second period of time.   
     
     
         16 . The method for activating the customizable sole insert  15 , wherein the fluid is water; wherein the fluid is applied by a sponge, a paper towel, or a cloth. 
     
     
         17 . The method for activating the customizable sole insert  16 , wherein the first period of time is at least 5 minutes; wherein the second period of time is at least 10 minutes. 
     
     
         18 . The method for activating the customizable sole insert  15 , wherein the fluid is ambient moisture produced by the foot of the user; wherein the ambient moisture is produced when the foot is inserted into the shoe and the user walks for the first period of time with the insert placed in the shoe. 
     
     
         19 . The method for activation the customizable sole insert  18 , wherein the first period of time is is at least 30 minutes; wherein the second period of time is 4 hours. 
     
     
         20 . The method for activating the customizable sole insert  15 , wherein the middle layer is made from polyurethane casting material and hydroxypropyl methyl-cellulose; wherein contact from the fluid causes the polyurethane casting material and hydroxypropyl methyl-cellulose to harden.