Fiber-foam shoe insoles, and a method of manufacturing the same

Abstract

This document discloses antistatic shoe insoles that include a flexible foam layer and antistatic filaments of textile material interspersed throughout the foam layer and extending passed or exposed at the surface of the shoe insole and methods of making such an antistatic shoe insole. The antistatic filaments are needle punched through the foam layer. The antistatic filaments may be any suitable antistatic material blended with any felt fiber such as wool fiber, cotton fiber, polyester fiber, or the like.

1 - 11 . (canceled) 
     
     
         12 . A method of manufacturing a shoe insole, the method comprising:
 positioning a fabric layer on a top surface of a flexible foam body; and   embedding a plurality of filaments from the fabric layer into the flexible foam body such that the plurality of filaments form a mechanical bond between the fabric layer and flexible foam body.   
     
     
         13 . The method of  claim 12 , wherein embedding the plurality of filaments includes oscillating a plurality of needles, each including downwardly extending barbs, through the fabric layer and into the flexible foam body. 
     
     
         14 . The method of  claim 13 , wherein oscillating the plurality of needles causes the barbs to grab hold of portions of the fabric layer to form the plurality of filaments. 
     
     
         15 . The method of  claim 13 , wherein oscillating the plurality of needles includes causing the plurality of needles to penetrate the flexible foam body by a depth of between about 12 mm to about 15 mm. 
     
     
         16 . The method of  claim 13 , wherein oscillating the plurality of needles moving the plurality of needles downwardly through the fabric layer and through the flexible foam body such that the plurality of filaments extends from the top surface of the flexible foam body passed the bottom surface thereof. 
     
     
         17 . The method of  claim 12 , wherein embedding the plurality of filaments in the flexible foam body includes causing at least a portion of the plurality of filaments to be entangled within the flexible foam body. 
     
     
         18 . The method of  claim 12 , wherein the fabric layer is configured to directly contact a user's foot when the shoe insole is worn by a user. 
     
     
         19 . The method of  claim 12 , wherein the fabric layer includes a non-woven fabric formed with a conductive material. 
     
     
         20 . The method of  claim 12 , wherein the flexible foam body is an open-cell polyurethane foam. 
     
     
         21 . The method of  claim 12 , wherein the flexible foam body is a closed-cell EVA foam. 
     
     
         22 . The method of  claim 12 , wherein the fabric layer is not coupled to the flexible foam body by an adhesive. 
     
     
         23 . The method of  claim 12 , wherein the fabric layer comprises a blend of polyester fabric with steel fibers. 
     
     
         24 . The method of  claim 12 , wherein an end portion of the plurality of filaments are exposed exteriorly from a bottom surface of the flexible foam body. 
     
     
         25 . The method of  claim 12  further comprising cutting the bonded fabric layer and flexible foam body into the shape of a shoe insole. 
     
     
         26 . The method of  claim 12 , wherein the fabric layer includes a natural textile fabric. 
     
     
         27 . The method of  claim 12 , wherein the fabric layer includes at least one of cotton, wool, jute, hemp, polylactic acid, and bionylon. 
     
     
         28 . A method of manufacturing a shoe insole, the method comprising:
 positioning a fabric layer including a non-woven fabric on a top surface of a flexible foam body;   oscillating a plurality of needles, each including downwardly extending barbs, through the fabric layer and into the flexible foam body causing a plurality of filaments from the fabric layer to form a mechanical bond between the fabric layer and flexible foam body; and   cutting the bonded fabric layer and flexible foam body into the shape of a shoe insole.   
     
     
         29 . The method of  claim 28 , wherein oscillating the plurality of needles moving the plurality of needles downwardly through the fabric layer and through the flexible foam body such that the plurality of filaments extend from the top surface of the flexible foam body passed the bottom surface thereof. 
     
     
         30 . The method of  claim 28 , wherein embedding the plurality of filaments in the flexible foam body includes causing at least a portion of the plurality of filaments to be entangled within the flexible foam body. 
     
     
         31 . The method of  claim 28 , wherein the fabric layer is configured to directly contact a user's foot when the shoe insole is worn by a user. 
     
     
         32 . The method of  claim 28 , wherein the non-woven fabric is formed with a conductive material.