A portable memory material physiotherapy insole customization system

Abstract

This invention discloses a portable memory material therapeutic insole customization system, comprising a box-type portable device, a replaceable module group, a memory material insole, a foot scanning module, and an intelligent terminal control system. The box-type portable device includes a box body and a box lid. A base is provided on the top of the box body, and a heating module is mounted on the base. A fixing seat is provided on the upper side of the base. The replaceable module group includes multiple support modules with adjustable parameters, and the support modules are snapped onto the base. The intelligent terminal control system includes an operating terminal and an AI diagnostic module. The AI ​​diagnostic module is based on data filtering and component adaptation. This invention is portable, enables rapid on-site customization, and ensures a close fit to the user's foot and therapeutic correction function.

Description

Technical Field

[0001] This invention relates to the field of foot care and orthopedic technology, and more specifically to a portable memory material physiotherapy insole customization system. Background Technology

[0002] The feet are the foundation of human movement, and foot conditions such as flat feet, high arches, and plantar fasciitis can cause discomfort and pain when walking. Patients with foot problems often use insoles to relieve pain, and podiatrists frequently recommend using insoles to improve symptoms. However, commercially available insoles only fit an "average" foot shape and cannot provide precise correction for individual foot problems such as asymmetrical arches and calcaneal deformities. Traditional custom-made methods involving repeated fittings and modifications are time-consuming, often requiring several weeks to obtain a satisfactory product.

[0003] Existing customized solutions mainly fall into two categories: one is digital scanning + 3D printing. This solution collects foot data through 3D scanning, generates designs using AI algorithms, and produces insoles through 3D printing. Although designs can be obtained on-site, the equipment is expensive, the printing cycle is long (usually 7-10 days for delivery), and the choice of materials is limited, resulting in high costs. The other is thermoplastic molding. This involves scanning the foot or plaster model and using heated thermoplastic material to create a mold. The molding time is about 10-30 minutes, but the specialized equipment is complex in structure and bulky, requiring vacuum pumps and large heating devices. It is not easy to carry and deploy on-site, and it lacks dynamic load-bearing feedback, resulting in poor fit.

[0004] The existing thermoplastic insole customization system disclosed in CN118941355A has optimized the pretreatment and molding process, but still relies on fixed molding fixtures and lacks portability. Patent CN120258945A proposes multi-dimensional foot feature detection, but it has not formed an efficient integration with rapid prototyping technology and still has problems such as long cycle or complex equipment. Therefore, this invention proposes a portable memory material physiotherapy insole customization system. Summary of the Invention

[0005] The purpose of this invention is to provide a portable memory material physiotherapy insole customization system that is portable, allows for rapid on-site customization, and ensures a close fit to the user's foot and physiotherapy correction function.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A portable memory material physiotherapy insole customization system includes a box-type portable device, a replaceable module group, a memory material insole, a foot scanning module, and an intelligent terminal control system. The box-type portable device includes a box body and a box lid. A base is provided on the top of the box body, and a heating module is installed on the base. A fixing seat is provided on the upper side of the base. The replaceable module group includes multiple support modules with adjustable parameters. The support modules are snapped onto the base. The intelligent terminal control system includes an operating terminal and an AI diagnostic module. The AI ​​diagnostic module is based on data filtering and component adaptation.

[0007] Furthermore, the inner side of the fixed base is provided with a side groove, and a locking block is fixedly provided in the side groove by a spring. The two sides of the side groove are provided with a sliding groove. The locking block is fixedly provided with a slider on both sides and has an inclined surface at the upper end. The slider is locked in the sliding groove and can move. The support module is embedded between the fixed base for positioning.

[0008] Furthermore, the adjustable parameters of the support module include arch height, tilt angle, size, and hardness. The tilt angle includes the calcaneal inversion / exversion angle and the forefoot angle. The module is designed with corresponding support shapes for foot types such as flat feet and high arches.

[0009] Furthermore, the memory material insole has a pre-set curvature before customization, with a radius of curvature of 50-150mm and a thickness of 3-10mm. The differentiated parameters include applicable size, insole thickness, support structure, and the difference in height between the left and right heels.

[0010] Furthermore, the heating module has a heating temperature range of 60–85°C and is electrically connected to the intelligent terminal control system. The operating terminal can set the heating temperature and heating time.

[0011] Furthermore, the foot scanning module includes a three-dimensional foot scanner, a pressure sensing plate, and a gait analyzer, which respectively collect foot morphology, plantar pressure distribution, and gait data.

[0012] Furthermore, the support module is made of a high-strength elastic material with a hardness range of Shore A 30 to 70 degrees and a thickness of 8 to 20 mm. The upper and lower ends of the support module are respectively provided with groove one and groove two, and several ventilation holes are provided in the center. The heating module is installed in groove two, and the memory material insole is installed in groove one.

[0013] Furthermore, the operating terminal of the intelligent terminal control system is equipped with a visual interactive interface, and the AI ​​diagnostic module has a built-in biomechanical model that can adjust the matching algorithm weights according to foot characteristics such as arch type.

[0014] Furthermore, the box is lined with a material that provides both cushioning and support, the side of the box is provided with a handle, and a locking structure is provided between the box and the lid.

[0015] Furthermore, the foot scanning module is located on the top of the housing and on one side of the base. The intelligent terminal control system is electrically connected to the housing. The intelligent terminal control system's operating terminal is used to input user information, and the foot scanning module can acquire foot-related data.

[0016] Beneficial effects: This invention combines various support modules and memory material insoles with AI intelligent analysis to accurately match the specific pathological characteristics of a user's feet. The customization process is directly shaped by the force applied to the foot, resulting in a close fit between the insole and the sole of the foot, providing comfort and better corrective effect. Furthermore, through thermoforming memory insoles and foot-step shaping, a pair of insoles can be customized within tens of minutes, eliminating the need to wait for factory production and transportation, significantly improving efficiency and providing users with immediate physiotherapy assistance. Compared to the traditional 7-10 day delivery cycle of 3D printing, efficiency is significantly improved.

[0017] The compact, lightweight, integrated box design makes it easy to carry to clinics, shopping malls, or homes. The modular and standardized production process allows for reusable support modules and cost-effective use of memory material insoles. This avoids the need for reprinting or customizing complete molds each time, reducing production costs. Users can obtain fully functional, customized insoles without multiple fittings and modifications, offering excellent value for money. Attached Figure Description

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0019] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the cross-sectional structure of the replaceable module group in this invention.

[0020] Reference numerals: 1. Box body; 101. Box lid; 2. Support module; 201. Vent hole; 202. Groove one; 203. Groove two; 3. Fixing base; 301. Side groove; 302. Slide groove; 4. Locking block; 401. Sliding block; 402. Inclined surface; 5. Memory material insole; 6. Base; 7. Handle; 8. Locking structure; 9. Intelligent terminal control system; 10. Spring; 11. Heating module; 12. Foot scanning module. Detailed Implementation

[0021] like Figure 1As shown in this specific embodiment, a portable memory material physiotherapy insole customization system includes a box-type portable device. The box-type portable device serves as the overall carrier, integrating all core functional components. It replaces the expensive 3D printing equipment clusters and traditional thermoplastic molding large tooling, achieving an integrated design, significantly reducing equipment cost and volume, and improving portability. The box-type portable device includes a box body 1 and a box cover 101. The box body 1 is lined with an inner lining material that combines cushioning and support. A handle 7 is provided on the side of the box body 1, and a locking structure 8 is provided between the box body 1 and the box cover 101. Through the portable structural design of the handle 7, the locking structure 8, and the cushioning inner lining, the system is easy to carry and transport, and can be easily deployed in various scenarios such as clinics, shopping malls, and homes, replacing the limitations of traditional customized equipment that is fixed in a specific location.

[0022] The top of the housing 1 is equipped with a base 6, on which a heating module 11 is mounted. The heating module 11 has a heating temperature range of 60-85℃. This temperature range ensures that the memory material can be fully softened to achieve thermoplastic deformation, while avoiding excessive temperature that could damage the material's properties. The parameters are scientifically and reasonably designed. It is electrically connected to the intelligent terminal control system 9. The operating terminal can set the heating temperature and heating time, and supports setting the heating temperature and time through the operating terminal. This adapts to the thermoplastic requirements of different models of memory material insoles 5, improving the system's compatibility and adaptability.

[0023] like Figure 2 As shown, a fixed seat 3 is provided on the upper side of the base 6. A side groove 301 is provided inside the fixed seat 3. A locking block 4 is fixed in the side groove 301 by a spring 10. A sliding groove 302 is provided on both sides of the side groove 301. A slider 401 is fixed on both sides of the locking block 4 and an inclined surface 402 is provided at the upper end. The slider 401 is locked in the sliding groove 302 and can move. Through the combination structure of "side groove 301 + spring 10 + locking block 4 + sliding groove 302 + slider 401", the support module 2 can be quickly embedded and fixed. The operation is convenient and the positioning is accurate, avoiding the displacement of the module during the molding process and improving the customization stability. The inclined surface 402 at the upper end of the locking block 4 reduces the difficulty of module embedding. The cooperation between the slider 401 and the sliding groove 302 ensures the stability of the movement trajectory of the locking block 4. The spring 10 provides continuous clamping force. The overall structure is both practical and reliable, and the module can be replaced without complicated tools.

[0024] like Figure 1As shown, the interchangeable module group contains multiple support modules 2 with adjustable parameters. The support modules 2 are snapped onto the base 6 and positioned between the fixing seats 3. The adjustable parameters of the support modules 2 include arch height, tilt angle, size, and hardness. The tilt angle includes calcaneal inversion / valgus angle and forefoot angle. The modules are designed with corresponding support shapes for foot types such as flat feet and high arches. Through the combination of multi-dimensional adjustable parameters and exclusive support shapes, it breaks through the limitations of traditional custom insoles with their single-shape adjustment, accurately matching different foot pathological characteristics and achieving refined correction for different foot types. To meet the mechanical correction needs, the plantar pressure distribution is optimized through parameter adjustment, such as arch support for flat feet and force line correction for inversion and supination, thus achieving diversified correction functions and overcoming the shortcomings of existing technologies that only focus on shape adaptation. The support module 2 is made of high-strength elastic material with a hardness range of Shore A 30 to 70 degrees and a thickness of 8 to 20 mm, ensuring that the module has both support and elasticity, can withstand foot pressure and is not easily deformed, thus extending its service life. The upper and lower ends of the support module 2 are respectively provided with groove 1 202 and groove 2 203, with several ventilation holes in the center. The heating module 11 is inserted into groove 2 203. The memory material insole 5 features a pre-set curvature with a radius of curvature of 50-150mm and a thickness of 3-10mm. This pre-set curvature radius and thickness range ensures the stability of the material's thermoplastic deformation and its support strength after molding, avoiding fluctuations in the customized effect due to uncertain parameters. Differentiated parameters include applicable size, insole thickness, support structure, and the difference in heel height between the left and right sides. The differentiated design of parameters such as insole thickness and support structure can ensure corrective effect while also catering to the comfort needs of different users. For example, elderly users can choose insoles with moderate softness and cushioning, while athletic users can choose high-support, wear-resistant insoles. The memory material insole 5 is secured within groove 202. The adjustable parameters of the replaceable module group, combined with the differentiated parameters of the memory material insole 5, can provide customized solutions for different foot type correction needs, replacing standardized ready-made insoles and traditional single-form customized insoles, achieving precise correction.

[0025] The foot scanning module 12 is located on the top of the housing 1 and on one side of the base 6. The foot scanning module 12 includes a 3D foot scanner, a pressure sensing plate, and a gait analyzer, which respectively collect foot morphology, plantar pressure distribution, and gait data. The foot scanning module 12 can acquire relevant foot data. Combined with the accurate foot data (morphology, pressure, and gait) collected by the foot scanning module 12, the three types of devices have clear division of labor. The 3D foot scanner ensures the accuracy of morphological data, the pressure sensing plate captures static pressure distribution, and the gait analyzer records dynamic movement characteristics. The data collection is both comprehensive and accurate. The AI ​​diagnostic module selects suitable replaceable modules and insoles, and then the foot is directly pressured and shaped to simulate foot deformation under dynamic load-bearing conditions, ensuring that the insole fits the contour of the foot closely and overcoming the defects of traditional static shaping.

[0026] The intelligent terminal control system 9 has a visual interactive interface on its operating terminal. This interface presents matching results, heating parameters, customization progress, and other information intuitively, improving the user and operator experience. The AI ​​diagnostic module has a built-in biomechanical model that can adjust the matching algorithm weights based on foot characteristics such as arch type, deformity, and pressure distribution, achieving "feature-first" intelligent matching and improving matching accuracy. The built-in biomechanical model makes data interpretation and component matching more consistent with the biomechanical principles of the human foot, ensuring the scientific validity and effectiveness of the correction plan.

[0027] The intelligent terminal control system 9 includes an operating terminal and an AI diagnostic module. The AI ​​diagnostic module is based on a data filtering and adaptation component. The intelligent terminal control system 9 is electrically connected to the housing 1. The operating terminal of the intelligent terminal control system 9 is used to input user information. The user's basic information includes age, weight, height, and gender. This information, combined with foot data, can more comprehensively reflect the user's body characteristics and foot stress, providing richer reference dimensions for AI matching. The user's basic information input into the operating terminal is combined with the foot-related data obtained by the foot data acquisition device to achieve dual data support of "human body characteristics + foot characteristics", thereby improving the accuracy of AI diagnosis.

[0028] Working principle: This invention is based on the core logic of accurate data collection, intelligent algorithm matching, and thermoplastic dynamic molding, and integrates foot biomechanics, AI intelligent diagnosis and shape memory material technology to achieve on-site rapid customization of personalized therapeutic insoles.

[0029] Regarding multidimensional data acquisition, the foot scanning module 12 utilizes a 3D foot scanner, a pressure sensing plate, and a gait analyzer to capture static and dynamic feature data of the user's feet. The 3D foot scanner uses optical imaging technology to acquire the three-dimensional morphological coordinates of the foot with micron-level accuracy, reconstructing static structures such as arch height, heel contour, and forefoot width. The pressure sensing plate uses an array of pressure sensors to collect real-time data on the peak and regional distribution of static pressure distribution on the sole of the foot. The gait analyzer, based on motion capture technology, records changes in foot joint angles, dynamic pressure transfer trajectories, and gait cycle characteristics during walking. These three types of data work together to construct a complete data model of the user's foot structure-pressure-movement, providing a foundation for accurate matching.

[0030] Regarding AI-powered intelligent matching, the AI ​​diagnostic module of the intelligent terminal control system 9 incorporates a foot biomechanical model. This model integrates a database of biomechanical correction parameters corresponding to different foot types (flat feet, high arches, etc.), age groups, and weights. After receiving multi-dimensional collected data, the AI ​​module first identifies key features such as arch type, deformity (e.g., calcaneal valgus angle), and uneven pressure distribution areas through feature extraction algorithms. Then, it adjusts the matching algorithm weights based on the user's basic information (age, weight, etc.). For example, it focuses on "gentle correction and growth adaptation" for adolescent users, "support strength and functional adaptation" for adult users, and "cushioning and comfort" for elderly users. Finally, it selects suitable module parameters (arch height, hardness, tilt angle) and insole models (thickness, support structure, functional type) from the replaceable module group and memory material insole database 5 to ensure the scientific and targeted nature of the correction plan.

[0031] Regarding thermoplastic molding, the memory material insole 5 uses a shape memory polymer material. This material softens and loses its original fixed shape within a temperature range of 60-85℃, exhibiting good plasticity. When the temperature drops to room temperature, the material restores its hardness and fixes a new molded shape. The heating module 11 precisely controls the temperature through a smart terminal, heating the selected memory material insole 5 to a softened state. The user's foot then applies direct pressure to the insole surface. At this time, under the dual action of "mechanical guidance from the lower support module 2" and "pressure shaping from the upper sole," the insole deforms to conform to the dynamic weight-bearing contour of the foot. The support module 2 provides a preset corrective mechanical structure (such as the arch support height required for flat feet), while the sole pressure allows the insole to adapt to the individual's subtle sole texture and stress characteristics. After cooling, a customized insole with both corrective function and high fit is formed.

[0032] Regarding modular support, each support module 2 of the replaceable module group is made of high-strength elastic material. Its hardness (Shore A 30-70 degrees), arch height, tilt angle, and other parameters have been biomechanically optimized to provide a dedicated support structure for different foot problems. The module achieves rapid positioning and fixation through the mechanical structure of side groove 301, spring 10, and locking block 4, ensuring the stability of the module position during the heating and shaping process. Its upper groove 1 202 precisely fits the insole, and its lower groove 203 tightly engages with the heating module 11. This ensures efficient heat transfer to the insole and guides the insole to form a shape that meets the correction requirements through the module's own support strength, achieving the dual functions of shaping guidance and mechanical support.

[0033] Regarding the operating procedure The operation process of this invention is simple and efficient, requiring no full involvement of a professional podiatrist; it can be operated by medical staff, technicians, or personnel with simple training.

[0034] Open the latch 8 of the portable case and lift the case lid 101. Confirm that the foot scanning module 12, intelligent terminal control system 9, and heating module 11 are all powered on. Arrange the replaceable module group and memory material insoles 5 neatly according to their models to avoid confusion. Ensure the operating area is flat and dry, and guide the user to remove foreign objects from the feet (such as shoes, socks, and jewelry) to keep the feet clean and dry, avoiding affecting scanning accuracy and pressure detection results.

[0035] Operators input basic user information, including age, gender, height, weight, and previous foot discomfort (optional), through the visual interactive interface of the intelligent terminal control system 9, to complete user information registration. The user is then guided to stand barefoot in the center of the pressure sensor plate of the foot scanning module 12, maintaining balance. The 3D foot scanner and pressure sensor plate are activated, simultaneously collecting 3D foot morphology data and static pressure distribution data. The data collection process lasts 3-5 seconds. Subsequently, the user is guided to take 5-10 steps in place within the detection area of ​​the gait analyzer to collect dynamic gait data. All data is automatically uploaded to the AI ​​diagnostic module, and the interface displays the collection progress in real time.

[0036] The AI ​​diagnostic module automatically processes the collected data, completing feature recognition and solution matching within 10 seconds. The interface displays the matching results, including the compatible support module 2 number, insole model, suggested heating parameters (temperature and duration), and customization process progress prompts. The operator informs the user of the matching results and correction principle. If the user has special needs (such as requiring high support for sports scenarios), the parameters can be fine-tuned within the system's allowable range. After confirmation, the process proceeds to the next step.

[0037] Based on the matching result, the corresponding support module 2 is retrieved and embedded into the area between the top fixing seats 3 of the housing 1. During embedding, the module presses against the inclined surface 402 of the locking block 4, causing the locking block 4 to compress the spring 10 and retract along the slide groove 302. After the module is fully embedded, the spring 10 returns to its original position, pushing the locking block 4 to clamp the two sides of the module, thus achieving a stable fixation of the module and ensuring no displacement during heating and shaping. The matching memory material insole 5 is then retrieved and laid flat inside the support module 2. The heating temperature is set via the smart terminal, and the heating module 11 is activated. The heating temperature causes the memory material insole 5 to deform through the support module 2. The interface displays the current temperature and remaining heating time in real time. The system automatically issues a prompt sound upon completion of heating.

[0038] The operator guides the user to put on heat-insulating socks and step onto the softened insoles, maintaining a standing posture for 3-8 minutes. During this time, the user can slightly adjust their center of gravity to ensure the insoles fully conform to the foot's contour. The operator can observe the user's posture and assist in adjusting the foot position to ensure the shaping effect. The heating module 11 is then turned off, and the insoles are allowed to cool to room temperature and regain their firmness, completing the shape fixation. The operator assists the user in slowly lifting their foot, removing the customized insoles, and observing the fit between the insoles and the foot's contour, focusing on whether the arch support area and heel support area match the user's foot characteristics. The user then wears their everyday shoes and walks with the customized insoles for 10-15 minutes, providing feedback on their wearing experience (e.g., arch support strength, presence of pressure points). Simultaneously, dynamic data is collected a second time using a gait analyzer to verify the improvement in foot pressure distribution. Once it is confirmed to meet expectations, the customization process is complete.

[0039] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A portable memory material physiotherapy insole customization system, characterized in that, The device includes a box-type portable device, a replaceable module group, a memory material insole (5), a foot scanning module (12), and an intelligent terminal control system (9). The box-type portable device includes a box body (1) and a box cover (101). The top of the box body (1) is provided with a base (6). A heating module (11) is installed on the base (6). A fixing seat (3) is provided on the upper side of the base (6). The replaceable module group includes multiple support modules (2) with adjustable parameters. The support modules (2) are fixed on the base (6). The intelligent terminal control system (9) includes an operating terminal and an AI diagnostic module. The AI ​​diagnostic module is based on data filtering and adaptation components.

2. The portable memory material physiotherapy insole customization system according to claim 1, characterized in that, The fixed base (3) has a side groove (301) inside. A locking block (4) is fixed in the side groove (301) by a spring (10). A sliding groove (302) is provided on both sides of the side groove (301). A slider (401) is fixed on both sides of the locking block (4) and an inclined surface (402) is provided at the upper end. The slider (401) is locked in the sliding groove (302) and can move. The support module (2) is embedded between the fixed base (3) for positioning.

3. The portable memory material physiotherapy insole customization system according to claim 2, characterized in that, The adjustable parameters of the support module (2) include arch height, tilt angle, size and hardness. The tilt angle includes the calcaneal inversion / exversion angle and the forefoot angle. The module is designed with corresponding support shapes for foot types such as flat feet and high arches.

4. The portable memory material physiotherapy insole customization system according to claim 1, characterized in that, The memory material insole (5) has a pre-set curvature before customization, with a radius of curvature of 50-150mm and a thickness of 3-10mm. The differential parameters include applicable size, insole thickness, support structure and the difference in height between the left and right heels.

5. The portable memory material physiotherapy insole customization system according to claim 1, characterized in that, The heating module (11) has a heating temperature range of 60 to 85°C and is electrically connected to the intelligent terminal control system (9). The operating terminal can set the heating temperature and heating time.

6. A portable memory material physiotherapy insole customization system according to claim 5, characterized in that, The foot scanning module (12) includes a three-dimensional foot scanner, a pressure sensor plate, and a gait analyzer, which respectively collect foot morphology, plantar pressure distribution, and gait data.

7. A portable memory material physiotherapy insole customization system according to claim 6, characterized in that, The support module (2) is made of high-strength elastic material with a hardness range of Shore A 30 to 70 degrees and a thickness of 8 to 20 mm. The support module (2) has groove 1 (202) and groove 2 (203) at its upper and lower ends, respectively, and several ventilation holes in the center. The heating module (11) is installed in groove 2 (203), and the memory material insole (5) is installed in groove 1 (202).

8. A portable memory material physiotherapy insole customization system according to claim 7, characterized in that, The intelligent terminal control system (9) has a visual interactive interface on its operating terminal. The AI ​​diagnostic module has a built-in biomechanical model that can adjust the matching algorithm weights according to foot characteristics such as arch type.

9. A portable memory material physiotherapy insole customization system according to claim 1, characterized in that, The box (1) is lined with a lining material that provides both cushioning and support. The box (1) has a handle (7) on its side and a locking structure (8) between the box (1) and the lid (101).

10. A portable memory material physiotherapy insole customization system according to claim 1, characterized in that, The foot scanning module (12) is located on the top of the housing (1) and on one side of the base (6). The intelligent terminal control system (9) is electrically connected to the housing (1). The intelligent terminal control system (9) is used to input user information. The foot scanning module (12) can acquire foot-related data.

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