Manufacturing method of foot orthopedic insole

Abstract

The manufacturing method of the foot orthopedic insole comprises the steps that foot orthopedic equipment is adopted, the foot orthopedic equipment comprises a plurality of electric cylinders distributed in an array mode, the distribution area of the electric cylinders is larger than the area of the foot sole, the electric cylinders are provided with pressure sensors and displacement sensors, and the electric cylinders, the pressure sensors and the displacement sensors are all connected to a controller; the electric cylinders are located in a coordinate system, and the manufacturing method comprises the following steps that S1, a normal foot database is established; s2, shape taking of the orthopedic insole; and S3, according to the shape of the shape-taking data, making the shape-correcting insole. According to the method, the steps are simple, the feeling of a patient is fully considered during shape taking, the force line condition can be seen according to the pressure value of the electric cylinder, and the experience of a maker is not high.

Description

Technical Field

[0001] This invention relates to foot orthotics, and more particularly to a method for manufacturing an orthopedic insole. Background Technology

[0002] Orthotic insoles are an effective method for correcting foot deformities. The two most common types of foot orthotics are flat feet and high arches. In children and adolescents, most flat feet are congenital, with the arch typically forming between 4 and 6 years of age. Studies show a relatively high incidence of flat feet in children. In adults, flat feet are more common in women over 50. Acquired flat feet in adults can be caused by various secondary factors. Initially, the arch is present in a non-weight-bearing state and disappears after weight-bearing, which is reversible flat feet. If joint problems occur and the deformity cannot be corrected, it becomes rigid flat feet. Symptoms include pain and swelling on the inner side of the foot, especially noticeable at the navicular tuberosity, and can lead to gait abnormalities such as outward toeing. In severe cases, it can cause pain and arthritis in the knees and hips. Prevention of flat feet includes exercises to strengthen the intrinsic and extrinsic muscles of the foot, choosing shoes with arch support, and avoiding prolonged standing. Treatment options include non-surgical methods such as insoles and wearing hard-soled shoes; surgery may be necessary in severe cases. There are no authoritative, large-scale statistics on the exact incidence of high arches, but a small percentage are congenital, while the majority develop after age 3 due to neurological disorders. High arches cause excessive pressure on the forefoot, increasing the risk of metatarsal stress fractures by 47%, chronic instability of the lateral ankle ligaments by up to 60%, and also increasing the risk of lumbar disc herniation. Mild deformities can be treated with low-heeled orthotic shoes, while moderate to severe cases often require surgery.

[0003] In medicine, orthotic insoles are often used to improve the condition of patients with non-severe foot deformities. The main methods for manufacturing orthotic insoles are as follows: 1. Handmade method: - Material preparation: Prepare suitable insole materials, such as EVA foam, silicone, leather, etc., as well as tools such as scissors, pencils, rulers, and sandpaper.

[0004] - Measurement and Design: Have the user stand barefoot on a piece of white paper and draw the outline of their foot with a pencil. Measure the length, width, and arch height of the foot. Based on the measurement results and the user's foot problems, design the shape and curvature of the insole material.

[0005] - Cutting and shaping: Cut the insole material into the designed shape with scissors. If the arch support needs to be adjusted, the material can be folded or thickened appropriately. Use sandpaper to smooth the edges of the insole.

[0006] 2. Thermoplastic molding method: - Material selection: Use thermoplastic materials, such as thermoplastic polyurethane (TPU).

[0007] - Heating and softening: Place the thermoplastic material in a heating device and heat it until the material softens. The temperature is generally around 60-80 degrees Celsius.

[0008] - Shaping process: The softened material is placed on the user's foot or foot model and shaped according to the shape of the foot. The material can be made to fit the foot by pressing, stretching, etc. After the material cools down, it will be fixed into the desired shape.

[0009] 3. 3D printing manufacturing method: - Data Acquisition: Acquire three-dimensional data of the user's feet through foot scanners or 3D photography equipment, including gait analysis, pressure testing, etc., to accurately record the shape, size and mechanical characteristics of the feet.

[0010] - Model Design: Import the collected data into 3D design software, adjust and optimize the model according to the user's foot problems and orthopedic needs, and design a 3D model of the orthopedic insole.

[0011] - 3D printing: Select a suitable 3D printing material, such as nylon or resin, import the designed model into the 3D printer, set the printing parameters, and print.

[0012] The existing methods for manufacturing orthotic insoles have the following drawbacks: First, after the foot model is created, doctors modify the model based on their experience and then directly create a 3D model of the orthotic insole, without considering the patient's wearing experience; second, it is impossible to determine whether the insole can achieve the desired correction of the body's alignment after the patient wears it, and observation is required after it is made and worn. If the alignment effect is not good after wearing it, a second correction is needed, which delays the patient's consultation time; third, if the second correction is excessive, the insole will be rendered unusable. Summary of the Invention

[0013] The purpose of this invention is to provide a method for manufacturing orthotic insoles.

[0014] To achieve the objective of this invention, the following technical solution is adopted: A method for manufacturing a foot orthotic insole, comprising using a foot orthotic device, wherein the foot orthotic device includes multiple electric cylinders arranged in an array, the area of ​​which the electric cylinders are distributed is larger than the area of ​​the sole of the foot, each electric cylinder is equipped with a pressure sensor and a displacement sensor, and the electric cylinders, pressure sensors, and displacement sensors are all connected to a controller, the electric cylinders being located in a coordinate system, and the manufacturing method comprising the following: S1: Establishment of a normal foot database; When all the electric cylinders extend to the same height, the surface formed by the electric cylinders is a plane. Select people with normal feet but different foot sizes, and after standing on the array of electric cylinders with both feet, record their weight, foot size, and the pressure value of the electric cylinders at different coordinates. Establish a database of the relationship between weight, foot size, and the pressure value of the electric cylinders at different coordinates in the array. S2: Shape of orthopedic insoles; S21: After the patient is weighed, both feet are placed on the electric cylinder array. The patient's foot position is aligned with the position of normal people with the same foot size when the normal foot database is established. The weight of normal people with the same foot size and the pressure value corresponding to the electric cylinder at different coordinates are found in the database. The pressure value corresponding to the electric cylinder at different coordinates of the patient is calculated. The pressure value corresponding to the electric cylinder at different coordinates of the patient is equal to the pressure value corresponding to the electric cylinder at different coordinates of normal people in the database multiplied by the weight coefficient, where the weight coefficient is the patient's weight divided by the weight of the corresponding normal person in the database. S22: Adjust the extension and retraction of the electric cylinders on different coordinates of the patient's foot so that the pressure value of the electric cylinders on different coordinates moves infinitely closer to the corresponding pressure value of the electric cylinder on that coordinate until the corresponding pressure value is reached or the patient's maximum tolerance limit is reached. S23: After the adjustment is completed, the patient gets off, and the curved surface formed by the upper end of the electric cylinder is shaped into the shape of the orthotic insole, completing one shaping step; S3: Make orthopedic insoles according to the shape of the orthopedic sole based on the shape data.

[0015] Furthermore, after the initial shaping in step S23 is completed, step S24 is also included. Step S24 is to make a trial orthotic insole. The trial orthotic insole is made by one of the following methods: one is to make it by 3D printing; the other is to transfer the data obtained from the initial shaping to a curved mold to form the corresponding shape, and then place the heated plastic plate on the curved mold to press it into a trial orthotic insole. After the trial orthotic insole is made, the patient tries it on. If it fits after the trial, the orthotic insole is made according to the initial shaping result. If it does not fit after the trial, steps S21, S22, S23, and S24 are repeated until it fits. The orthotic insole is made according to the shaping data after the trial is successful.

[0016] Furthermore, in step S21, the patient's foot position is aligned with the position of a normal person with the same foot size when establishing the normal foot database, using one of the following two methods: one is to directly mark the foot position on the electric cylinder plane, and the patient stands according to that position; the other is to achieve this by having the patient stand in any position and then using coordinate transformation.

[0017] The positive and beneficial technical effects of the present invention are as follows: the steps of the present invention are simple, the patient's feelings are fully considered when taking the shape, and the force line can be seen from the pressure value of the electric cylinder. It does not require much experience from the maker. The specific implementation method will be described in detail. Attached Figure Description

[0018] Figure 1 This is a top view of the electric cylinder array of the shaping device.

[0019] Figure 2 This is a front view schematic diagram of the electric cylinder array of the shaping device. Detailed Implementation

[0020] To more fully explain the implementation of the present invention, implementation examples are provided. These implementation examples are merely illustrative of the present invention and do not limit the scope of the present invention.

[0021] Figure 1 shows an electric cylinder. In this invention, the (miniature) electric cylinder with a pressure sensor and located at the sensor is a commercially available product.

[0022] A method for manufacturing a foot orthotic insole includes using a foot orthotic device. The foot orthotic device comprises multiple electric cylinders arranged in an array, with the area of ​​the distributed electric cylinders larger than the area of ​​the sole of the foot. Each electric cylinder is equipped with a pressure sensor and a displacement sensor. The electric cylinders, pressure sensors, and displacement sensors are all connected to a controller. The electric cylinders are located in a coordinate system. The manufacturing method includes the following: S1: Establishment of a normal foot database; All electric cylinders extend to the same height, generally 10-20mm. At this point, the surface formed by the electric cylinders is a plane. Select people with normal foot sizes and stand on the array of electric cylinders with both feet. Record their weight, foot size, and the pressure value of the electric cylinders at different coordinates. Establish a database of the relationship between weight, foot size, and the pressure value of the electric cylinders at different coordinates in the array. S2: Orthopedic insole shaping S21: After the patient is weighed, both feet stand on the electric cylinder array. The patient's foot position is aligned with the position of a normal person with the same foot size when the normal foot database was established. One of the following two methods is used to align the patient's foot position with the position of a normal person with the same foot size when the normal foot database was established: one is to directly mark the foot position on the electric cylinder plane and have the patient stand in that position; the other is to have the patient stand in any position and achieve this through coordinate transformation. Find the weight of normal people with the same foot size and the pressure value of the electric cylinder at different coordinates in the database. Calculate the pressure value that the electric cylinder should correspond to at different coordinates of the patient. The pressure value that the electric cylinder should correspond to at different coordinates of the patient is equal to the pressure value of the electric cylinder corresponding to different coordinates of normal people in the database multiplied by the weight coefficient, where the weight coefficient is the patient's weight divided by the weight of the corresponding normal person in the database. S22: Adjust the extension and retraction of the electric cylinders on different coordinates of the patient's foot so that the pressure value of the electric cylinders on different coordinates moves infinitely closer to the corresponding pressure value of the electric cylinder on that coordinate until the corresponding pressure value is reached or the patient's maximum tolerance limit is reached. S23: After the adjustment is completed, the patient gets off, and the curved surface formed by the upper end of the electric cylinder is shaped into the shape of the orthotic insole, completing one shaping step; S3: Make orthopedic insoles according to the shape of the orthopedic sole based on the shape data.

[0023] As a further optimization, after the initial shaping in step S23, step S4 is also included. Step S4 is to make a trial orthotic insole. The trial orthotic insole is made by one of the following methods: one is to make it by 3D printing; the other is to transfer the data obtained from the initial shaping to a curved mold to form the corresponding shape, and then place the heated plastic plate on the curved mold to press it into a trial orthotic insole. After the trial orthotic insole is made, the patient tries it on. If it fits after the trial, the orthotic insole is made according to the initial shaping result. If it does not fit after the trial, steps S21, S22, S23, and S24 are repeated until it fits. The orthotic insole is made according to the shaping data after the trial fit.

[0024] After a detailed description of the embodiments of the present invention, those skilled in the art will clearly understand that various changes and modifications can be made without departing from the scope and spirit of the above-mentioned patent applications. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention shall fall within the scope of the technical solution of the present invention, and the present invention is not limited to the embodiments of the examples given in the specification.

Claims

1. A method for manufacturing an orthotic insole, characterized in that: The invention includes the use of a foot orthotic device, which comprises multiple electrically driven cylinders arranged in an array. The area of ​​the distributed cylinders is larger than the area of ​​the sole of the foot. Each cylinder is equipped with a pressure sensor and a displacement sensor. The cylinders, pressure sensors, and displacement sensors are all connected to a controller. The cylinders are located in a coordinate system. The manufacturing method includes the following: S1: Establishment of a normal foot database; When all the electric cylinders extend to the same height, the surface formed by the electric cylinders is a plane. Select people with normal feet but different foot sizes, and after standing on the array of electric cylinders with both feet, record their weight, foot size, and the pressure value of the electric cylinders at different coordinates. Establish a database of the relationship between weight, foot size, and the pressure value of the electric cylinders at different coordinates in the array. S2: Shape of orthopedic insoles; S21: After the patient is weighed, both feet are placed on the electric cylinder array. The patient's foot position is aligned with the position of normal people with the same foot size when the normal foot database is established. The weight of normal people with the same foot size and the pressure value of the electric cylinder at different coordinates are found in the database. The pressure value of the electric cylinder at different coordinates of the patient is calculated. The pressure value of the electric cylinder at different coordinates of the patient is equal to the pressure value of the electric cylinder at different coordinates of normal people in the database multiplied by the weight coefficient, where the weight coefficient is the patient's weight divided by the weight of the corresponding normal person in the database. S22: Adjust the extension and retraction of the electric cylinders at different coordinates on the patient's sole, so that the pressure value of the electric cylinders at different coordinates moves infinitely closer to the pressure value that the electric cylinder at that coordinate should correspond to, obtained in step S21, until it reaches the corresponding pressure value or the patient's maximum tolerance limit. There is a difference between the pressure value at the patient's maximum tolerance limit and the corresponding pressure value. S23: After the adjustment is completed, the patient gets off, and the curved surface formed by the upper end of the electric cylinder is shaped into the shape of the orthotic insole, completing one shaping step; S3: Make orthopedic insoles according to the shape of the orthopedic sole based on the shape data.

2. The method for manufacturing an orthotic insole according to claim 1, characterized in that: After the initial shaping in step S23 is completed, step S24 is also included. Step S24 is to make a trial orthotic insole. The trial orthotic insole is made by one of the following methods: one is to make it by 3D printing; the other is to transfer the data obtained from the initial shaping to a curved mold to form the corresponding shape, and then place the heated plastic plate on the curved mold to press it into a trial orthotic insole. After the trial orthotic insole is made, the patient tries it on. If it fits after the trial, the orthotic insole is made according to the initial shaping result. If it does not fit after the trial, steps S21, S22, S23 and S24 are repeated until it fits. The orthotic insole is made according to the shaping data after the trial fit.

3. The method for manufacturing an orthotic insole according to claim 1, characterized in that: In step S21, the patient's foot position is aligned with the position of a normal person with the same foot size when establishing the normal foot database. One of the following two methods is to directly mark the foot position on the electric cylinder plane and have the patient stand at that position; the other is to have the patient stand at any position and achieve this through coordinate transformation.

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