Rapidly formable personalized insole and method of manufacturing the same

Abstract

The present application provides a kind of personalized insole capable of rapid prototyping and its manufacturing method, which comprises an outer cover layer, at least one opening and closing component, a plurality of particles and at least one negative pressure auxiliary component. The outer cover layer is made of a gas-impermeable structure, which is provided with the particles and the negative pressure auxiliary component, and an air passage. When the whole or part of the foot sole is stepped on the outer cover layer, the particles can displace and complete shaping according to the three-dimensional configuration of the foot sole due to the pressure applied by the foot sole. At the same time, the negative pressure auxiliary component reduces its occupied volume, so that the air in the outer cover layer can be discharged outside the outer cover layer through the air passage. Then, the air passage is hermetically sealed by the opening and closing component. In this way, the user can easily and quickly complete the personalized insole conforming to the three-dimensional configuration of his / her foot sole without using any special equipment.

Description

Technical Field

[0001] This invention relates to insole structure, and more particularly to a personalized insole that can be rapidly molded according to the three-dimensional shape of an individual's foot and has a negative pressure assist component inside. Background Technology

[0002] When people wear shoes, insoles are placed inside to absorb shock and cushion the feet, reducing foot pain and other ailments caused by prolonged standing or walking, while also providing better comfort. Generally, under normal circumstances, the foot should have a noticeably high arch (i.e., the concave arch on the inside of the foot), and the talus and calcaneus should be in a straight line and perpendicular to the ground. However, due to congenital or acquired factors, the three-dimensional structure of each person's foot will vary. For example, some people born with flat feet will have a low or even no arch; or, when young children stand too early or maintain incorrect posture for a long period, they are prone to pronation of the foot.

[0003] Currently, insoles are often mass-produced with a uniform shape, rather than being tailored to individual foot conditions. Therefore, users often choose softer insoles, which deform more easily when stepped on, providing a more comfortable feel. However, softer insoles often lack support, which can lead to abnormal tightness in the foot muscles over time. For individuals with flat feet or high arches, this can exacerbate existing lower limb fascia problems. Therefore, it is better to choose insoles that provide adequate foot support.

[0004] As mentioned earlier, due to the differences in the three-dimensional structure of each person's foot, mass-produced insoles obviously cannot meet everyone's needs. However, currently, custom-made insoles are usually for orthopedic purposes, and their production time is not only several weeks long but also very expensive. Furthermore, the production process is complex and requires a lot of specialized equipment and tools, making it impractical for the general public. In view of this, the inventor has designed an orthopedic insole that can be quickly custom-made, which is briefly described below. Please refer to [link / reference]. Figure 1A As shown, the corrective insole 10 includes an inner covering layer 11, a plurality of particles 12, and an outer covering layer 13. The inner covering layer 11 is itself a breathable material and is filled with the particles 12. Then, the inner covering layer 11 and the particles 12 can be placed together into the airtight outer covering layer 13. Furthermore, the outer covering layer 13 is provided with an air channel 131, which connects the inside and outside of the outer covering layer 13.

[0005] Please refer to the following: Figure 1A As shown, in manufacturing, the orthotic insole 10 is first placed in the shaping groove 151 of a support fixture 15 (e.g., a shoe mold table). Then, a professional (e.g., a rehabilitation therapist) can assist the user in adjusting the foot position so that the foot can step onto the top surface of the orthotic insole 10 in the correct posture (i.e., the posture required for correction). Simultaneously, the particles 12 are shaped into the desired corrective state. After completing the aforementioned shaping process, a professional can connect the air channel using specialized vacuum equipment (e.g., a vacuum pump, valve, vacuum gauge, pipes, connectors, etc.) and perform a vacuuming operation on the orthotic insole 10. This ensures that the particles 12 are shaped into a state where they are tightly pressed together and cannot move further. Then, the air channel 131 is sealed airtight, thus shaping the orthotic insole 10 (e.g., a shoe mold table). Figure 1B (As shown).

[0006] Although the orthotic insole 10 conceived by the inventor has a much shorter personalized production time (less than 10 minutes) and a much lower price compared to well-known orthotic insoles, it is still insufficient for widespread use by the general public. The main reason is that the orthotic insole 10 requires not only specialized vacuuming and shaping auxiliary equipment (such as shoe mold tables, vibration tables, sealing machines, etc.), but also professional assistance, which ordinary users cannot provide themselves. Therefore, users who need it can only purchase it from a few specialized places, such as foot orthotics clinics or insole specialty stores. In addition, in order to make the orthotic insole 10 have good corrective ability, a large number of particles 12 need to be placed inside to shape it into the state required for correction. This situation also makes the overall production cost of the orthotic insole 10 higher than that of ordinary insoles.

[0007] For the general public, the insoles they use do not necessarily need to be strictly corrective, but rather focus on comfort and daily health care. Therefore, given the aforementioned issues (such as the need for specialized equipment, specialty stores / venues, professional services, and higher costs), the willingness of the general public to purchase and use the corrective insole 10 will be greatly reduced. Thus, how to effectively solve the aforementioned problems and provide more suitable products for the general public has become an important issue of this invention.

[0008] Public content

[0009] Given the many shortcomings of familiar insoles, the inventor, drawing on years of practical experience and after numerous research, trials, and experiments, has finally designed a personalized insole capable of rapid prototyping and its manufacturing method, hoping to effectively solve the aforementioned problems.

[0010] One object of the present invention is to provide a rapidly moldable personalized insole that can be placed inside a shoe or become part of the shoe structure for a user's foot to step on. The personalized insole includes an outer covering layer, multiple particles, at least one opening / closing component, and at least one negative pressure assist component. The outer covering layer is made of an airtight structure, and its planar configuration can match the overall or partial planar configuration of the foot. It has an air channel connecting the inside and outside of the outer covering layer. The top surface of the layer has at least a partial area made of an elastic or flexible airtight material or structure; the opening and closing component enables the air passage to be in a unidirectional outward exhaust state, or to switch the air passage to a bidirectional conduction state and a bidirectional non-conducting state; the particles can be directly or indirectly filled into the outer covering layer, giving the outer covering layer a predetermined thickness, and the particles can move within the outer covering layer; each of the negative pressure auxiliary components is located within the outer covering layer, and has at least one air-containing space within it, which is subjected to external pressure. In this state, the air inside is expelled, and when the external force is removed, its own restoring force also forces it to absorb external air. When the whole or part of the foot steps on the outer covering layer, these particles can be shaped (i.e., formed) by displacement with the three-dimensional structure of the whole or part of the foot. The air inside the outer covering layer will be discharged to the outside of the outer covering layer through the air channel due to the pressure applied by the whole or part of the foot. The negative pressure auxiliary component will also be affected by the aforementioned pressure and reduce its occupied volume. The air inside it will also be discharged to the outside of the outer covering layer through the air channel. When the air channel is sealed, the pressure applied by the foot is removed. The negative pressure auxiliary component will expand due to its own restoring force and absorb the residual air between these particles to generate negative pressure, so that these particles are fixed in a state of close contact with each other and not easy to shift, thus obtaining the personalized insole. In this way, the user can easily and quickly complete the personalized insole that conforms to the three-dimensional structure of their own foot without using any special equipment.

[0011] Another object of the present invention is to provide a method for manufacturing a rapidly prototyping personalized insole, wherein the personalized insole can be placed inside a shoe for a user to step on. The manufacturing method first performs a filling operation, which, according to the design of the personalized insole, positions at least one opening / closing component and at least one negative pressure assist component at predetermined positions on an outer covering layer, and then fills a plurality of particles into the outer covering layer to give the outer covering layer a predetermined thickness, and allows the particles to move within the outer covering layer. After the aforementioned placement and filling work is completed, the filling port is sealed with an airtight seal to complete the filling operation. The outer covering layer is an airtight structure, its planar shape matching the overall or partial planar shape of the foot, and it has an air channel connecting the inside and outside of the outer covering layer. The opening and closing component allows the air channel to be in a unidirectional outward exhaust state, or to switch between a bidirectional conducting state and a bidirectional non-conducting state. The negative pressure auxiliary component has at least one air-containing space within it, which is used when subjected to external force... Under pressure, the air inside is expelled. When the external force is removed, its own restoring force forces it to absorb external air. Then, a shaping process is performed. When the entire foot or part of the foot is stepped on the outer covering layer, the particles can be shaped by the displacement of the entire or part of the foot's three-dimensional structure. The air inside the outer covering layer is expelled outside the outer covering layer through the air channel due to the pressure applied by the entire or part of the foot. The negative pressure assist component is also affected by the aforementioned pressure and its occupied volume is reduced. The air inside it is also expelled outside the outer covering layer through the air channel. Then, a fixing process is performed to seal the air channel so that air outside the outer covering layer cannot flow into the outer covering layer. When the pressure applied by the foot is removed, the negative pressure assist component expands due to its own restoring force and absorbs the residual air between the particles to generate negative pressure. This causes the particles to be fixed in a state where they are closely attached to each other and not easily displaced, thus resulting in the personalized insole.

[0012] The insoles of this invention represent a significant breakthrough. Users can easily and quickly prepare their own personalized insoles without needing to prepare any professional equipment. This means they can be sold in convenience stores or online. The insoles of this invention have the following advantages:

[0013] (1) The personalized molding of the insoles of the present invention is extremely simple and does not require other tools. Therefore, users can operate by themselves and quickly complete the personalized insoles they need.

[0014] (2) Users can easily obtain insoles, for example, through convenience stores or online shopping;

[0015] (3) Inexpensive;

[0016] (4) Because the three-dimensional shape of the insole is adapted to the user's individual foot shape, it is extremely comfortable to wear;

[0017] (5) Before the heating and solidification process, the insole of the present invention can introduce air into the outer covering layer as needed by the user to reshape the three-dimensional configuration of the insole until the user is satisfied; and

[0018] (6) For daily health care, the insole of the present invention has good effect.

[0019] To facilitate the review committee's further understanding of the purpose, technical features, and effects of this invention, specific embodiments are provided below with accompanying drawings, and detailed explanations are as follows: Attached Figure Description

[0020] Figure 1A This is a schematic diagram of a partial cross-section of a well-known orthotic insole before it is shaped;

[0021] Figure 1B This is a partial cross-sectional diagram of a well-known orthotic insole after it has been shaped.

[0022] Figure 2 This is a partial cross-sectional view of the personalized insole before it is formed according to the first embodiment of the present invention;

[0023] Figure 3A This is a top view schematic diagram of a personalized insole according to the first embodiment of the present invention, which has only one negative pressure auxiliary component;

[0024] Figure 3B This is a top view of the personalized insole of the present invention, which is provided with multiple negative pressure auxiliary components;

[0025] Figure 4 This is a partial cross-sectional schematic diagram of the personalized insole of the first embodiment of the present invention after it has been shaped;

[0026] Figure 5 This is for Figure 3B A schematic diagram of the AA heel section of the molded insole;

[0027] Figure 6 This is a top view schematic diagram of the personalized insole according to the second embodiment of the present invention;

[0028] Figure 7A This is a partial cross-sectional view of the personalized insole before it is formed according to the third embodiment of the present invention;

[0029] Figure 7B This is a partial cross-sectional schematic diagram of the personalized insole after shaping according to the third embodiment of the present invention;

[0030] Figure 7CThis is a partial cross-sectional schematic diagram of the personalized insole after heating and solidification according to the third embodiment of the present invention;

[0031] Figure 8 This is a schematic diagram of the mixing of the particles and bonding materials of the present invention; and

[0032] Figure 9 This is the manufacturing process of the present invention.

[0033] Explanation of reference numerals in the attached figures

[0034] [Well-known]

[0035] 10: Orthopedic insoles

[0036] 11: Inner coating layer

[0037] 12: Particles

[0038] 13: Outer coating

[0039] 131: Air passage

[0040] 15: Support fixture

[0041] 151: Shaping Groove

[0042] [This invention]

[0043] 2: Personalized insoles

[0044] 21: Outer coating layer

[0045] 211: Air passage

[0046] 22: Particles

[0047] 23, 33, 43: Negative pressure auxiliary components

[0048] 24: Opening / closing components

[0049] 25: Inner coating layer

[0050] 26, 36, 46: Air volume space

[0051] 27: Bonding material

[0052] 271: Adhesive Material

[0053] 273: Adsorbent materials

[0054] 431: First check valve

[0055] 432: Second check valve

[0056] 501-505: Steps

[0057] HU: Upper half

[0058] HD; lower half Detailed Implementation

[0059] To make the objectives, technical solutions, and advantages of this invention clearer, the following detailed description of the embodiments of "personalized insoles capable of rapid prototyping and their manufacturing method" disclosed in this invention, in conjunction with specific embodiments and with reference to the accompanying drawings, provides further details. Those skilled in the art can understand the advantages and effects of this invention from the content disclosed in this specification. This invention can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the concept of this invention. Furthermore, it should be stated in advance that the accompanying drawings of this invention are for simple illustrative purposes only and are not depictions based on actual dimensions. In addition, unless the context clearly indicates or defines it, the meaning of "a" or "the" in this invention includes the plural. Moreover, the following embodiments will further describe the relevant technical content of this invention in detail, but the disclosed content is not intended to limit the scope of protection of this invention.

[0060] It should be understood that although terms such as "first," "second," etc., may be used herein to describe various components or signals, these components should not be limited by these terms. These terms are primarily used to distinguish one component from another. Furthermore, directional terms mentioned in other embodiments, such as "up," "down," "front," "back," "left," "right," etc., are only for reference to the accompanying drawings. Therefore, the directional terms used are for illustrative purposes and not for limiting the scope of protection of this invention. In addition, the term "or" as used herein may, as appropriate, include any combination of one or more of the associated listed items.

[0061] This invention discloses a rapidly prototyping personalized insole and its manufacturing method. The primary purpose of this personalized insole is as a general-purpose, pressure-relieving insole. It does not require special auxiliary tools (such as specialized vacuum equipment), and users can easily create personalized insoles that match the three-dimensional shape of their own feet. However, this invention does not exclude its orthotic applications. Please refer to [link to relevant documentation]. Figure 2 As shown, in a first embodiment, the personalized insole 2 includes an outer covering layer 21, a plurality of particles 22, at least one negative pressure assist component 23, and at least one opening and closing component 24. The outer covering layer 21 is made of an airtight material or has an airtight structure, and its periphery is airtightly sealed to form a first receiving space therein. Furthermore, the planar configuration of the outer covering layer 21 can match the overall planar configuration of the foot (e.g., ...). Figure 3AAs shown), and at least a portion of its top surface is made of an elastic or flexible, non-breathable material or structure to form a planar shape conforming to the foot during the manufacturing process described later. However, this is not a limitation. In other embodiments of the invention, the planar shape of the outer covering layer 21 can also match the planar shape of a portion of the foot (e.g., a portion corresponding to the metatarsal bones, midfoot bones, or heel bones), as explained in advance.

[0062] Please refer to the following: Figure 2 As shown, the outer covering layer 21 can be provided with at least one air channel 211, which connects the inside and outside of the outer covering layer 21, allowing air in the first accommodating space to flow out to the outside of the outer covering layer 21 through the air channel 211. Furthermore, in this first embodiment, the particles 22 can be directly filled into the outer covering layer 21 to give the outer covering layer 21 a predetermined thickness and maintain it in a soft state; also, the particles 22 can move within the outer covering layer 21. In addition, the personalized insole 2 also provides an opening and closing component 24, which is airtightly installed on the outer covering layer 21 at a position corresponding to the air channel 211. For example, it can be located inside the air channel 211, or on the inner and / or outer side of the outer covering layer 21. In this first embodiment, such as... Figure 2 As shown, the opening and closing component 24 is located inside the outer covering layer 21. Furthermore, the opening and closing component 24 can cause the air passage 211 to be in a unidirectional outward exhaust state, or it can switch the air passage 211 to a bidirectional conduction state and a bidirectional non-conducting state. In addition, to prevent particles 22 from potentially flowing out of the outer covering layer 21 through the air passage 211, the opening and closing component 24 can also be equipped with a blocking structure (such as a filter screen), which simultaneously prevents particles 22 from flowing out through the air passage 211.

[0063] Please refer to the following: Figure 2 and Figure 3A As shown, to avoid overly complex diagrams, Figure 3A The drawing of particles 22 is omitted. The negative pressure auxiliary component 23 can be located within the outer covering layer 21, and its position and number can be determined according to actual needs, such as... Figure 3A As shown, it can have only a single negative pressure auxiliary component 23; or, as Figure 3BAs shown, the device can have multiple negative pressure auxiliary components 23. These negative pressure auxiliary components 23 are generally located near the bottom surface within the outer covering layer 21, while the particles 22 can be stacked on their top surface. The negative pressure auxiliary component 23 is characterized by generating a restoring force when deformed (shrunken) under external pressure, and returning to its original state when the external pressure disappears. Furthermore, the negative pressure auxiliary component 23 has at least one air-containing space 26. When deformed (shrunken) under external pressure, the air in the air-containing space 26 is expelled; conversely, when the external force disappears, its own restoring force forces it to draw in external air into each of the air-containing spaces 26. For example, in this first embodiment, the negative pressure auxiliary component 23 can be an open-cell porous elastic material (such as foam), and the collective pores or voids on it constitute the air-containing space 26. The term "open" as used above refers to the fact that the gas-bearing space 26 is directly connected to the external space of the negative pressure auxiliary component 23. The "open" in subsequent embodiments is also the same as the aforementioned definition.

[0064] Please refer to the following: Figure 2 and Figure 3A As shown, when the user's foot (whole or part) steps on or applies pressure to the top surface of the outer covering layer 21, the particles 22 are shaped (i.e., formed) by displacement according to the three-dimensional shape of the foot. The air inside the outer covering layer 21 is discharged to the outside of the outer covering layer 21 due to the pressure applied by the foot through the air channel 211. Furthermore, the negative pressure auxiliary component 23 is also affected by the aforementioned pressure and its occupied volume is reduced. The air in its air-containing space 26 is also discharged from the negative pressure auxiliary component 23 and then discharged to the outside of the outer covering layer 21 through the air channel 211. Furthermore, when the user seals the air passage 211 through the opening and closing component 24, preventing air from flowing into the outer covering layer 21 from the atmospheric side and removing the pressure applied by the foot, the negative pressure assist component 23 expands due to its own restoring force and absorbs a relatively large proportion of the residual air between the particles 22, thereby creating negative pressure within the outer covering layer 21. This causes the particles 22 to be fixed in a state of close contact and not easily displaced, resulting in the personalized insole 2 (e.g., Figure 4 (As shown).

[0065] For the user, the molding of the personalized insole 2 mainly involves two stages: "forming" and "setting". In the "forming" stage, the user places their foot on the outer covering layer 21 and applies pressure. During this stage, only air within the outer covering layer 21 is allowed to escape unidirectionally through the air channel 211 to the outside of the outer covering layer 21. In the "setting" stage, the user removes their foot from the outer covering layer 21 to remove the applied pressure. During this stage, air outside the outer covering layer 21 is not allowed to flow unidirectionally through the air channel 211 to the inside of the outer covering layer 21. As mentioned above, the opening and closing component 24 must meet one of the following two conditions:

[0066] 1. Regardless of whether it is the "forming" stage or the "setting" stage, the air passage 211 only exhausts air in one direction; according to the aforementioned conditions, the opening and closing component 24 can be achieved using a check valve, that is, a check valve that only exhausts air in one direction is airtightly connected to the air passage 211 (e.g., located inside or outside the air passage 211); or

[0067] 2. During the "forming" stage, the air channel 211 is bidirectionally open, while during the "setting" stage, the air channel 211 is switched to a bidirectional non-open state. Based on the aforementioned conditions, the opening and closing component 24 can be a plug, airtight tape, valve, or other means to achieve this. Therefore, during the "forming" stage, the air channel 211 is bidirectionally open. After the foot applies pressure to complete the shaping and expel air, and while the foot continues to apply pressure, a plug or airtight tape can be used to manually plug or seal the air channel 211 before removing the pressure from the foot, thus completing the "setting" stage.

[0068] Depending on the usage requirements, the design of this negative pressure auxiliary component 23 can take into account various factors and achieve different effects:

[0069] 1. As shown in Figures 3A and 3B, the position covered or placed by the negative pressure assist component 23 can be: 1-1. covering the entire insole; 1-2. covering the forefoot area; 1-3. covering the arch area; 1-4. covering the heel area; or 1-5. a combination of two or more of the above.

[0070] 2. Based on the material and type of the negative pressure auxiliary component 23, it can be roughly distinguished into the following styles:

[0071] 2-1. An open-cell porous elastic material, such as foam or sponge, which can be a single unit or assembled from multiple independent components; the aforementioned "porosity" refers to the fact that the material itself has many pores or gaps, and the collective of such pores or gaps can be regarded as the air-containing space 26.

[0072] 2-2. An open-cell hollow elastomer, comprising: an open-cell hollow elastic cylindrical tube, an open-cell hollow flat elastomer, an open-cell hollow spherical elastomer, and open-cell hollow elastic particles, etc.; wherein, the open-cell hollow elastic particles refer to the particles filled into the outer covering layer, having a hollow interior, and the hollow interior directly communicating with the outside of the particles, so that in addition to having the function of the particles themselves, they can also be used as the negative pressure auxiliary component;

[0073] 2-3. The double check valve structure is a non-open hollow elastomer, and is provided with a first outlet and a second outlet respectively connecting from the hollow interior to the outside. The first check valve is designed so that the air outside the negative pressure auxiliary component can only flow into the hollow interior (i.e., the air-filled space 26) in one direction, while the second check valve allows the air inside the hollow interior (i.e., the air-filled space 26) to flow out to the outside of the negative pressure auxiliary component in one direction.

[0074] 3. Additionally, please refer to Figure 5 (for Figure 3B As shown in the AA heel cross-section of the molded insole, when the user walks, the particles 22 of the upper part HU of the personalized insole 2 are fixed in a state of close contact and not easy to shift due to the influence of negative pressure, so its overall hardness is high. At the same time, the negative pressure auxiliary component 23 of the lower part HD of the personalized insole 2 can change its volume with external force, so it has a cushioning ability. Therefore, the personalized insole 2, where the negative pressure auxiliary component 23 is provided, not only provides foot support, but also has cushioning.

[0075] 4. Viewed in longitudinal section of the personalized insole 2, as follows: Figure 4 As shown, the negative pressure assist component 23 occupies part of the volume, thus greatly reducing the number of particles 22 used, thereby reducing the production cost of the personalized insole 2, while still being able to be shaped into a three-dimensional shape suitable for the user's foot.

[0076] In the second embodiment of the present invention, the negative pressure auxiliary component used is not limited to block-shaped foam, but can employ an open-cell hollow elastomer, which is illustrated here by a strip-shaped hollow elastic tube, such as... Figure 6 As shown in the multiple hollow elastic tubes (negative pressure auxiliary components 33) above, these open hollow elastic tubes can also be made of breathable materials. Therefore, in addition to the large air-holding space 36 inside the tube itself, multiple small air-holding spaces (i.e., holes and pores) can be added inside the tube wall. The air discharged by the negative pressure auxiliary component 33 can finally pass through the air channel 211 (such as... Figure 6The air is discharged through the air channel 211 in the middle of the right side. In this second embodiment, the opening and closing component 24 is an airtight tape and can be located on the outside of the outer covering layer 21.

[0077] Please refer to the following: Figure 6 As shown, in this second embodiment, a negative pressure auxiliary component 43 with a double check valve structure (such as...) is used. Figure 6 The lower flat, round, non-open hollow elastomer is made of an airtight material or structure and is airtightly connected to a first check valve 431 and a second check valve 432. The first check valve 431 allows only external air from the negative pressure auxiliary component 43 to flow into its hollow interior (i.e., the air-bearing space 46). Figure 6 The arrow above the first check valve 431 points in the direction of the first check valve; the second check valve 432 only allows air inside the hollow interior (i.e., the air-filled space 46) of the negative pressure auxiliary component 43 to flow to the outside, such as... Figure 6 The arrow points below the second check valve 432, and it is airtightly connected to the air passage 211. When the heel of the outer covering layer 21 is repeatedly stepped on, squeezed, and released by external force, the air inside can flow out of the outer covering layer 21 sequentially through the first check valve 431, the air-containing space 46, the second check valve 432, and the air passage 211. It is worth mentioning that when the user continuously steps on the negative pressure auxiliary component 43, a large negative pressure can also be formed in the outer covering layer 21. The first check valve 431 and the second check valve 432 only allow air to flow in one direction. Therefore, any structure that can achieve the aforementioned one-way air flow, such as a duckbill valve or an air check valve, belongs to the first check valve 431 and the second check valve 432 referred to in this invention.

[0078] Please see Figure 7AAs shown, in the third embodiment of the present invention, the particles 22 can be first filled into the second receiving space of an inner covering layer 25, wherein the inner covering layer 25 is made of a breathable material (such as: a breathable fabric or breathable plastic film with elasticity or flexibility), and its planar configuration can match the overall or partial planar configuration of the foot, so that the inner covering layer 25 has a predetermined thickness to maintain a soft state. The particles 22 can move inside the inner covering layer 25, and their particle size will be larger than the breathable pore size of the inner covering layer 25, so that the particles 22 will not detach from the inner covering layer 25 under external pressure. Furthermore, the periphery of the inner covering layer 25 can be sealed, and it, together with the particles 22 inside, can be placed into the outer covering layer 21, that is, the particles 22 are indirectly placed into the outer covering layer 21. Furthermore, the negative pressure auxiliary component 23 and the opening / closing component 24 can be located outside the inner covering layer 25. Thus, during production, the negative pressure auxiliary component 23, the opening / closing component 24, and the inner covering layer 25 can be respectively placed within the outer covering layer 21. This not only simplifies the procedure but also ensures that the negative pressure auxiliary component 23 and the opening / closing component 24 are positioned as intended. In other embodiments of the present invention, the negative pressure auxiliary component 23 can also be installed within the inner covering layer 25 along with the particles 22, as will be explained beforehand.

[0079] Following on, please refer to Figure 7B As shown, when the user's foot steps on the top surface of the outer covering layer 21, the particles 22 in the inner covering layer 25 are shaped by displacement according to the three-dimensional structure of the foot, and the air in the inner covering layer 25 is discharged to the inner covering layer 25 due to the pressure applied by the foot; in addition, the negative pressure auxiliary component 23 will also discharge air under external pressure. The air discharged from the inner covering layer 25 and the negative pressure auxiliary component 23, together with the air originally in the outer covering layer 21, are discharged to the outside of the outer covering layer 21 through the air channel 211. Furthermore, the air passage 211 is sealed by air. When the outer covering layer 21 is no longer under force (i.e., no longer stepped on), the restoring force of the negative pressure auxiliary component 23 will force it to draw in external air, so that the particles 22 that have been shaped in the inner covering layer 25 are fixed in a state of close contact and not easy to shift due to the influence of negative pressure, thus obtaining the personalized insole 2.

[0080] Additionally, please see Figure 7CAs shown, in order to maintain the shaped state of the personalized insole 2 for a long time, it can also be heated after the shaping is completed (i.e., the particles 22 are shaped into a state where they are closely attached to each other and not easily displaced) and the air channel 211 is airtight. The particles 22 can be made of thermoplastic elastomer materials with low melting points or low initial melting temperatures (e.g., 60℃~85℃) (e.g., TPU, TPEE, TPS, TPR, SEBS, etc.), whose melting points or initial melting temperatures are lower than other components of the personalized insole 2 (e.g., outer covering layer 21, negative pressure auxiliary components 23, etc.). That is, when the particles 22 are in a molten state, the other components of the personalized insole 2 can also maintain their integrity and will not melt. Furthermore, the heating operation can be carried out with hot water, an oven, a hair dryer, or a microwave oven, without the need for professional heating equipment, thus improving the convenience for personal use. During the heating process, at least the surface of the particles 22 will be in a molten state, allowing adjacent particles 22 to fuse together and solidify into a long-lasting personalized insole 2. Thus, even if the outer covering layer 21 or the inner covering layer 25 is damaged after prolonged use, the personalized insole 2 can still maintain its original three-dimensional shape of the foot because the particles 22 have been bonded together, effectively extending the service life of the personalized insole 2.

[0081] In addition to using thermoplastic elastomer materials to make the particles 22, in other embodiments of the invention, the particles 22 can also be uniformly mixed with a bonding material 27, so that the bonding material 27 can be uniformly adhered to the surface of each particle 22 (e.g., ...). Figure 8 As shown), the bonding material 27 can be in the form of powder, liquid paste, etc., and includes an adhesive (binder) 271 (e.g., TPU hot melt adhesive, EVA hot melt adhesive, etc.) and / or an absorbent (e.g., infrared absorbing material, electromagnetic wave absorbing material, etc.) 273, wherein the adhesive 271 and the absorbent 273 can be bonded together as shown in the diagram. Figure 8 Generally, the bonding material 27 adheres to the surface of the particles 22 or completely covers the surface of the particles 22. Furthermore, the melting point of the bonding material 27 is lower than the melting point of other components of the personalized insole 2 (such as the particles 22, the outer covering layer 21, the negative pressure auxiliary component 23, etc.), and the bonding material 27 and the particles 22 can be directly or indirectly filled into the outer covering layer 21. When the personalized insole 2 also includes an inner covering layer 25, the particle size of the bonding material 27 can be larger than the pore size of the inner covering layer 25, so that the bonding material 27 can only move within the inner covering layer 25. After heating, the bonding material 27 can melt, fusing adjacent particles 22 together to form a long-lasting personalized insole 2.

[0082] It is worth mentioning that the personalized insole 2 can be repeatedly shaped when not heated. The user simply needs to open the air channel 211 to allow outside air to enter the outer covering layer 21. Furthermore, the number of air channels 211 in this invention is not limited to one; multiple channels can also be used (e.g., ...). Figure 6 As shown), when one of the air passages 211 is occupied (as in the second embodiment, the air passage 211 at the bottom is exclusively occupied by the second check valve 432), the other air passage 211 can be opened to allow outside air to enter the outer covering layer 21. If necessary, the air passage 211 can also be used to fill or remove particles 22.

[0083] The manufacturing process of the personalized insole 2 of the present invention will be described below. Please refer to [link / reference]. Figure 2 and Figure 9 As shown, in step 501, a filling operation is performed. Based on the design of the personalized insole 2, the opening / closing component 24 and the negative pressure assist component 23 are positioned at predetermined locations on the outer covering layer 21. The particles 22 are then directly or indirectly filled into the outer covering layer 21 (for example, the particles 22 can be filled into the inner covering layer 25 first, and then the inner covering layer 25 is installed into the outer covering layer 21), so that the outer covering layer 21 has a predetermined thickness, and the particles 22 can move within the outer covering layer 21 (or the inner covering layer 25). The filling port is then sealed with an airtight seal to complete the filling operation. Afterwards, in step 502, a pre-forming operation can be performed. This operation is typically performed at the factory, i.e., based on a preliminary three-dimensional shape of the sole, the aforementioned… "Preliminary foot three-dimensional model" generally refers to a representative three-dimensional model of the foot, such as one that conforms to the shape of most people's feet or one designed according to the user's desired foot shape. Then, the filled insole is laid flat or placed on a support fixture (i.e., a shoe mold platform). The opening and closing component 24 causes the air channel 211 to be in a unidirectional outward exhaust state or a bidirectional conduction state. The preliminary foot three-dimensional model is placed on the outer covering layer of the insole, and appropriate pressure is applied, causing the particles 22 to move along the foot three-dimensional model and complete the shaping. Then, an air extraction device (such as a vacuum pump) is used to extract air from the outer covering layer 21 through the air channel 211 to achieve a strong shaping (high vacuum) effect. Finally, the air channel is sealed airtight, completing the pre-molding process. This process allows the insole to maintain a representative state for long-term storage and will also facilitate future use by users.

[0084] Additionally, in step 503, a forming operation is performed. When the internal and external air pressures of the outer covering layer 21 are the same or substantially the same, and the opening / closing component 24 causes the air passage to be in a unidirectional outward exhaust state or a bidirectional conduction state, under the condition that the user's entire or partial foot steps on and applies pressure to the outer covering layer 21, the particles 22 can be shaped by displacement according to the overall or partial three-dimensional structure of the foot. Furthermore, the air inside the outer covering layer 21 will be discharged outside the outer covering layer 21 through the air passage 211 due to the pressure applied by the entire or partial foot. Simultaneously, the negative pressure assist component 23 will also be affected by the aforementioned pressure, reducing its occupied volume, and the air inside will also... The air will be discharged outside the outer covering layer 21 through the air channel 211. At this time, the top surface of the outer covering layer 21 will form a three-dimensional shape that matches and conforms to the shape of the user's foot. In step 504, a shaping operation is performed so that the opening and closing component 24 keeps the air channel in a unidirectional outward exhaust state or converts it to a bidirectional non-conducting state, so that the air outside the outer covering layer 21 cannot flow into the outer covering layer 21. After the pressure applied to the foot is removed, the negative pressure assist component 23 will expand due to its own restoring force and absorb the residual air between the particles 22, so that the particles 22 are shaped into a state that is closely attached to each other and not easy to shift due to the influence of negative pressure, so as to obtain the personalized insole 2. Furthermore, in step 505, a heating process is performed to directly or indirectly fuse adjacent particles 22 into a single unit, thereby solidifying a long-lasting personalized insole 2. Also, since some materials release gas during heating, disrupting the original negative pressure state and altering the already shaped state, step 505 can employ a method of simultaneously heating and vacuuming the insole to ensure its three-dimensional structure remains unchanged. In the process of the present invention described above, steps 502 and 505 can be omitted depending on product requirements.

[0085] It is hereby specifically noted that when the opening and closing assembly 24 uses a check valve, it has the following advantages:

[0086] 1. The personalized insole 2 can be directly placed inside the shoe. During stepping or walking, the personalized insole 2 will automatically complete its shaping (forming and setting), eliminating the need for manual shaping and setting on the outside of the shoe before inserting it. The main reason is that if the opening and closing component 24 is a plug, airtight tape, etc., switching between opening and closing the air passage 211 generally requires manual operation, thus needing to be done outside the shoe.

[0087] 2. It conforms to the three-dimensional shape of the sole of the foot during the user's daily activities.

[0088] 3. During daily operations, it will automatically replenish the vacuum (avoiding the problem of micro-leakage).

[0089] 4. It can be molded into personalized insoles that meet special structural requirements. For example, patients with flat feet often desire an insole with a three-dimensional shape that matches the shape of their foot when under slight pressure (or no pressure), or they may desire a specific shape such as a tilt or protrusion in a certain location or direction (e.g., stimulating acupoints). In this case, if an insole with a check valve is used, the outer covering layer can be manually squeezed to allow some air inside the outer covering layer (and / or inner covering layer) to be slowly expelled through the air channel under control. When a slight negative pressure is achieved, the particles will come into contact with each other and remain stationary. However, when pressure is applied to the outer covering layer with fingers, the particles can be easily moved and their three-dimensional shape can be maintained. By using this manual method and comparing it with the foot, and using appropriate tools to assist in shaping if necessary, the shaping process for the specific shape requirement can be completed easily and quickly. Finally, the negative pressure is increased to complete the shaping process, thus creating a personalized insole that meets the specific shape requirement.

[0090] The above description is merely a preferred embodiment of the present invention. The scope of the rights claimed by the present invention is not limited thereto. Equivalent variations that can be easily conceived by those skilled in the art based on the technical content disclosed in the present invention should all be considered within the scope of protection of the present invention.

Claims

1. A personalized shoe insole capable of rapid prototyping, which can be placed in a shoe for the user's foot to step on, characterized in that, The personalized insole comprises: an outer cover layer, which is airtight, has a planar configuration matching the whole or part of the planar configuration of the foot sole, and is provided with an air passage capable of connecting the inside and outside of the outer cover layer, the top surface of the outer cover layer having at least a partial region made of elastic or flexible airtight material or structure; at least one opening and closing component capable of making the air passage in a one-way outward exhaust state or capable of switching the air passage between a two-way conductive state and a two-way non-conductive state; a plurality of particles filled in the outer cover layer, so that the outer cover layer has a predetermined thickness, and the plurality of particles can move in the inside of the outer cover layer when the air pressure inside and outside the outer cover layer is the same or substantially the same; and at least one negative pressure auxiliary component located in the outer cover layer, which is provided with at least one air containing space and stacks the plurality of particles on the top surface, and when the negative pressure auxiliary component is under pressure, the air containing space will become smaller and the air in the air containing space will be exhausted; when the negative pressure auxiliary component is no longer under pressure, the air containing space will restore to the original state and become larger and can suck in air; wherein, when the air pressure inside and outside the outer cover layer is the same or substantially the same, and the opening and closing component makes the air passage in a one-way outward exhaust state or a two-way conductive state, the whole or part of the foot sole is placed on the outer cover layer, and the plurality of particles will displace along the three-dimensional configuration of the whole or part of the foot sole to complete shaping under the pressure applied by the foot sole to the outer cover layer, and the negative pressure auxiliary component will also shrink the air containing space and release air due to the pressure, and the released air together with the air originally in the outer cover layer will be exhausted to the outside of the outer cover layer through the air passage due to the pressure; then the opening and closing component still maintains the one-way outward exhaust state or switches to the two-way non-conductive state, the pressure applied by the foot sole is removed, the negative pressure auxiliary component will have a tendency to restore to the original state and become larger due to its restoring force, and will suck in the residual air in the outer cover layer to form a negative pressure in the outer cover layer, so that the plurality of particles that have completed shaping are formed in a state of closely abutting each other and not easy to displace, so as to obtain the personalized insole.

2. The personalized insole of claim 1, wherein, The opening and closing component can be a one-way check valve, a plug, an airtight tape or a valve.

3. The personalized insole of claim 1, wherein, The negative pressure auxiliary component is an open porous elastomer.

4. The personalized insole of claim 1, wherein, The negative pressure auxiliary component is an open hollow elastomer.

5. The personalized insole of claim 1, wherein, Part or all of the plurality of particles are open hollow elastic particles or porous air-permeable elastic particles, which serve as the negative pressure auxiliary component.

6. The personalized insole of claim 1, wherein, The negative pressure auxiliary assembly is a non-open hollow elastic body made of air-tight material or structure, which is internally provided with the air storage space, and externally provided with a first outlet and a second outlet connected to the air storage space, which are respectively air-tightly connected to a first check valve and a second check valve; wherein the first check valve corresponds to the first outlet, and allows air outside the negative pressure auxiliary assembly to flow into the air storage space in a one-way manner, and the second check valve corresponds to the second outlet, and allows air in the air storage space to flow out and be air-tightly guided into the air passage in a one-way manner, so as to be discharged outside the outer covering layer.

7. The personalized insole of claim 1, wherein, Further comprising an inner covering layer located in the outer covering layer, which is an air-permeable structure, and its planar configuration can match the planar configuration of the whole or part of the foot sole, and the plurality of particles can be filled into the inner covering layer, and the plurality of particles can move in the inner covering layer when the air pressure inside and outside the outer covering layer is the same or substantially the same, and the particle size of the plurality of particles is greater than the air-permeable aperture of the inner covering layer.

8. The personalized insole according to any one of claims 1 to 7, characterized in that, The plurality of particles are made of thermoplastic elastomer material, and the melting point is lower than that of other components of the personalized insole, and in the state that the plurality of particles are closely attached to each other and are not easy to move, heating operation is performed to fuse adjacent particles into one body to solidify the personalized insole.

9. The personalized insole according to any one of claims 1 to 7, characterized in that, Further comprising a bonding material that can be uniformly mixed with the plurality of particles, and the melting point is lower than that of other components of the personalized insole, wherein in the state that the plurality of particles are closely attached to each other and are not easy to move, heating operation is performed to melt the bonding material to fuse adjacent particles into one body to solidify the personalized insole.

10. A method of manufacturing a personalized shoe insole capable of rapid prototyping, characterized by, The following steps are included: A filling operation is performed to place at least one opening and closing assembly and at least one negative pressure auxiliary assembly in an outer covering layer, and fill a plurality of particles into the outer covering layer through a filling port to make the outer covering layer have a predetermined thickness, and the plurality of particles can move in the outer covering layer, wherein the outer covering layer is made of air-tight material or air-tight structure, and its planar configuration can match the planar configuration of the whole or part of the foot sole, and it is provided with an air passage that can communicate the inside and outside of the outer covering layer; the opening and closing assembly can make the air passage in a one-way outward exhaust state, or can make the air passage switch between a bidirectional conductive state and a bidirectional non-conductive state; the negative pressure auxiliary assembly is internally provided with at least one air storage space, and the top surface is stacked with the plurality of particles, and under the condition that the negative pressure auxiliary assembly is under pressure, the air storage space will become smaller, and the air in it will be discharged; under the condition that the negative pressure auxiliary assembly is no longer under pressure, it will recover due to its restoring force, and the air storage space will recover to its original state and become larger, and it will inhale air from the surrounding; after the plurality of particles, the opening and closing assembly and the negative pressure auxiliary assembly are filled and placed in the outer covering layer, the filling port is air-tightly closed to complete the filling operation; In the shaping operation, the plurality of particles are filled into an inner cover layer, and the inner cover layer is installed into the outer cover layer, wherein the particle size of the plurality of particles is greater than the air permeation aperture of the inner cover layer. In the shaping operation, the plurality of particles are filled into an inner cover layer, and the inner cover layer is installed into the outer cover layer, wherein the particle size of the plurality of particles is greater than the air permeation aperture of the inner cover layer.

11. The manufacturing method according to claim 10, wherein The plurality of particles are made of thermoplastic elastomer material, and the melting point thereof is lower than that of other components of the personalized insole, so that after the shaping operation, a heating operation can be performed on the personalized insole to fuse adjacent particles into a whole, thereby solidifying the personalized insole.

12. The manufacturing method according to claim 10, wherein The plurality of particles are mixed with a bonding material, and the melting point of the bonding material is lower than that of other components of the personalized insole, so that after the shaping operation, a heating operation can be performed on the personalized insole to melt the bonding material, thereby fusing adjacent particles into a whole, thereby solidifying the personalized insole.

13. The manufacturing method according to claim 10, wherein The plurality of particles are made of thermoplastic elastomer material, and the melting point thereof is lower than that of other components of the personalized insole, so that after the shaping operation, a heating operation can be performed on the personalized insole to fuse adjacent particles into a whole, thereby solidifying the personalized insole.

14. The manufacturing method according to claim 11, wherein The plurality of particles are mixed with a bonding material, and the melting point of the bonding material is lower than that of other components of the personalized insole, so that after the shaping operation, a heating operation can be performed on the personalized insole to melt the bonding material, thereby fusing adjacent particles into a whole, thereby solidifying the personalized insole.

15. The manufacturing method according to claim 11, wherein In the heating operation, a vacuum operation is simultaneously performed on the personalized insole.

16. The production method according to any one of claims 12 to 15, characterized by, After the personalized insole is formed, the outer cover layer is removed.

17. The production method according to any one of claims 12 to 15, characterized by, After the personalized insole is formed, the outer cover layer is removed.

18. The manufacturing method according to claim 16, wherein ​

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