Electrostatic discharge insole

Abstract

The present invention discloses an advanced insole for electrostatic discharge footwear. The insole features a base foam layer and a fabric top cover with conductive threads woven into the cover material, providing electrical flow paths from a wearer's foot to the base foam layer. An electrostatic discharge chemical additive is incorporated into the base foam layer, creating polarity channels for an electrical pathway within the foam layer. The insole is designed in a 3D supportive shape for increased foot comfort and interface, including a heel cup and arch support. The edges adjacent the toe region are beveled to accommodate various footwear, and the bottom surface of the base foam layer includes molded-in structures that provide varying degrees of cushioning to different regions of the foot. This novel insole design enhances comfort while ensuring efficient electrostatic discharge, proving advantageous in various footwear applications.

1 . An insole for electrostatic discharge footwear comprising:
 a base foam layer having a unitary body with a contoured upward-facing shape to follow the shape of a wearer's foot;   a fabric top cover having conductive threads woven into the cover material, overlaying the base foam layer and providing electrical flow paths from a foot of a wearer to the base foam layer; and   an electrostatic discharge chemical additive added to the base foam layer, creating polarity channels for an electrical pathway within the foam layer.   
     
     
         2 . The insole of  claim 1 , wherein the fabric top cover is constructed of a breathable knit material. 
     
     
         3 . The insole of  claim 1 , wherein the fabric top cover is a woven material. 
     
     
         4 . The insole of  claim 1 , wherein the fabric top cover is a non-woven material. 
     
     
         5 . The insole of  claim 1 , wherein the base foam layer is constructed of polyurethane closed-cell foam, the foam having a durometer in the range of  41   c  to  47   c  on the Asker c scale. 
     
     
         6 . The insole of  claim 1 , wherein the electrostatic discharge chemical additive is added to a liquid polyurethane material before it is molded, foamed, and cured. 
     
     
         7 . The insole of  claim 1 , further comprising a semi-rigid support member along at least a portion of a bottom of the base foam layer, the semi-rigid support member providing additional heel and arch support to the base foam layer. 
     
     
         8 . The insole of  claim 7 , wherein the support member includes a conductive material. 
     
     
         9 . The insole of  claim 7 , wherein the support member covers less than half of a lower surface area of the base foam layer. 
     
     
         10 . An insole for an electrostatic discharge footwear, the insole being formed in a 3D supportive shape for a foot for increased comfort and foot interface, comprising:
 a base foam layer; and   a fabric top cover having conductive threads woven into the cover material, overlaying the base foam layer and providing electrical flow paths from a foot of a wearer to the base foam layer.   
     
     
         11 . The insole of  claim 10 , wherein the  3 D supportive shape comprises a heel cup and an arch support. 
     
     
         12 . The insole of  claim 10 , wherein the edges adjacent the toe region of the insole are beveled to accommodate various footwear. 
     
     
         13 . The insole of  claim 10 , wherein the thickness of the region of the insole beneath the ball and toes of the foot is reduced to accommodate various footwear. 
     
     
         14 . The insole of  claim 10 , wherein the bottom surface of the base foam layer includes molded-in structures that provide relatively more or less cushioning to the foot in various regions of the foot. 
     
     
         15 . The insole of  claim 14 , wherein the molded-in structures comprise ridges and recesses. 
     
     
         16 . A method for creating an insole for an electrostatic discharge footwear, the method comprising:
 providing a base foam layer with a conductive additive;   providing a fabric top cover having conductive threads woven into the cover material; and   overlaying the fabric top cover on the base foam layer to provide electrical flow paths from a foot of a wearer to the base foam layer.   
     
     
         17 . The method of  claim 16 , wherein the fabric top cover is constructed of a breathable knit material. 
     
     
         18 . The method of  claim 16 , wherein the fabric top cover is a woven material. 
     
     
         19 . The method of  claim 16 , wherein the base foam layer is constructed of polyurethane closed-cell foam having a specific gravity between 0.31 to 0.35 to provide contoured foot support. 
     
     
         20 . The method of  claim 16 , wherein the electrostatic discharge chemical additive is added to a liquid polyurethane material before it is molded, foamed, and cured. 
     
     
         21 . The method of  claim 16 , wherein the additive is conductive particles such as carbon powder. 
     
     
         22 . The method of  claim 16 , further comprising forming the insole into a 3D supportive shape for a foot for increased comfort and foot interface. 
     
     
         23 . The method of  claim 22 , wherein the 3D supportive shape comprises a heel cup and an arch support. 
     
     
         24 . The method of  claim 22 , wherein the edges adjacent the toe region of the insole are beveled to accommodate various footwear. 
     
     
         25 . The method of  claim 22 , wherein the thickness of the region of the insole beneath the ball and toes of the foot is reduced to accommodate various footwear. 
     
     
         26 . The method of  claim 22 , wherein the bottom surface of the base foam layer includes molded-in structures that provide relatively more or less cushioning to the foot in various regions of the foot. 
     
     
         27 . Footwear having electrostatic discharge properties, the footwear comprising:
 an upper to surround at least a portion of the foot of a wearer;   an outsole engaged to the upper, the outsole having electrostatic discharge properties embedded therein;   an insole comprising:
 a cushion member having conductive material therein, the conductive material allowing transmission of static electricity from the top of the cushion member to the bottom of the cushion member; 
 a cover material fixed to the cushion member, the cover material being a fabric, the fabric having fabric threads;
 wherein the fabric includes conductive threads extending through the fabric from top to bottom, the conductive threads being integrated with the fabric threads. 
 
   
     
     
         28 . The footwear of  claim 27 , further comprising:
 a midsole secured to a top of the outsole, the midsole having electrostatic discharge properties embedded therein; and   a last board secured to a top of the midsole, the last board having electrostatic discharge properties for discharging static electricity from the insole to the midsole;
 wherein the insole rests on the midsole. 
   
     
     
         29 . The footwear of  claim 28 , wherein the cushion member comprises a closed-cell foam having an additive providing electrostatic discharge properties, the cushion member having an upper surface contour substantially following the bottom contour of a foot. 
     
     
         30 . The footwear of  claim 29 , further comprising a semi-rigid support member along at least a portion of a bottom of the cushion member, the semi-rigid support member providing additional heel and arch support to the cushion member. 
     
     
         31 . The footwear of  claim 28 , wherein the last board includes a thread extending therethrough from top to bottom, the thread being conductive.