An assembled insole and a manufacturing method thereof

Abstract

The application belongs to the technical field of insoles, and discloses an assembled insole and a manufacturing method, wherein the assembled insole comprises an insole main body, a heel supporting block, an arch supporting block and a hallux valgus separating block which can be detachably installed; the method comprises the following steps: collecting foot information of a user to construct a three-dimensional digital model of the foot, extracting foot characteristic parameters, obtaining core biomechanics indexes, i.e., a medial arch index, a hallux valgus angle and a heel force line offset angle, completing parameterized modeling according to the indexes, and producing the insole through additive manufacturing; and each component needs to be compared with the original three-dimensional digital model through three-dimensional point cloud data to avoid defective products from flowing into subsequent links. The application is a precise insole design driven by objective biomechanics data, and can flexibly adjust and quickly replace components according to physiological state changes of the user's foot or use scene requirements, so as to ensure the connection reliability and the spatial positioning consistency after repeated disassembly and assembly.

Description

Technical Field

[0001] This invention belongs to the field of shoe insole technology, specifically relating to an assembled shoe insole and its manufacturing method. Background Technology

[0002] In recent years, additive manufacturing technology has been widely used in the field of customized foot orthotic devices. Compared with traditional insole manufacturing processes, 3D printed insoles can be personalized and rapidly prototyped based on individual foot 3D models, with significant advantages such as high molding precision, short manufacturing cycle, and strong personalization adaptability. It has shown good application prospects in medical orthotics, sports protection, and everyday comfortable wear.

[0003] However, existing customized 3D printed insoles still have the following technical shortcomings: First, the arch support structure is a fixed, one-piece construction, lacking adjustability and replaceability. In existing customized 3D-printed insoles, the arch support component and the insole body are constructed as a single unit during the modeling stage. Once printed, its support profile, arch height, and stiffness characteristics are completely fixed. When a user's foot physiological state changes dynamically, or different usage scenarios place varying demands on arch support strength, existing solutions require the entire insole to be redesigned and printed, leading to high costs and extended waiting periods. This severely restricts the adaptability and flexibility of customized insoles in dynamic rehabilitation scenarios.

[0004] Second, the customized design of insoles lacks quantitative consideration of core biomechanical indicators of the foot.

[0005] Third, there is a lack of an automated three-dimensional closed-loop comparison mechanism between the printed finished product and the design model. In the current production process, there is a lack of a systematic three-dimensional dimensional deviation comparison scheme between the printed insole and the original design model. Deformation defects caused by factors such as material shrinkage, interlayer stacking errors, and improper removal of support structures during the printing process are difficult to detect in a timely manner. Defective products are at risk of flowing into subsequent stages, increasing quality control costs. Summary of the Invention

[0006] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a prefabricated insole and manufacturing method to solve the following problems: (1) the existing 3D printed insole arch support structure is integrally formed with the insole body and cannot be flexibly adjusted and quickly replaced according to the changes in the user's foot physiological state or the needs of the usage scenario; (2) the existing insole customization design process lacks the technical problem of systematically quantifying and analyzing the three core biomechanical indicators of the instep index, hallux valgus angle and heel force line offset angle; (3) the connection reliability between the detachable arch support component and the insole body and the spatial positioning consistency after repeated disassembly and assembly; (4) the technical problem of lacking an automated three-dimensional closed-loop comparison mechanism between the printed product and the design model.

[0007] To achieve the above-mentioned technical objectives, the technical solution adopted by the present invention is as follows: In a first aspect, the present invention provides a prefabricated insole, comprising an insole body, wherein the insole body is detachably fitted with a heel support block, an arch support block, and a hallux valgus separation block; The heel support block is located in the mounting slot at the rear of the insole body, corresponding to the human heel bearing area, and is used to provide targeted heel support and calcaneal stability. The arch support block is located in the mounting slot on the inner side of the middle part of the insole body, corresponding to the human arch bearing area, and is used to provide targeted arch support. The hallux valgus separation block is located in the mounting slot on the inner front side of the insole body, corresponding to the area of ​​the big toe, and is used to provide a corrective separation force for the big toe to correct lateral deviation. The bottom contours of the heel support block, arch support block, and hallux valgus separation block complement the corresponding mounting slots in space.

[0008] The present invention constructs the heel support block, arch support block and hallux valgus separation block as detachable modular components independent of the insole body. The heel support block, arch support block and hallux valgus separation block are all detachably installed on the insole body. For arch support blocks, reversible replacement of arch support blocks with different support strength levels can be achieved, thereby enabling on-demand switching of support characteristics without replacing the main insole, significantly reducing user costs and time costs. Of course, when needed, the heel support block and hallux valgus separation block can also be flexibly adjusted through reversible replacement; During the design phase, the heel support block, arch support block, and hallux valgus separation block need to take into account the core biomechanical indicators of the foot, namely the internal arch index, hallux valgus angle, and heel force line offset angle. Based on the core biomechanical indicators of the foot, the parametric modeling of the heel support block, arch support block, and hallux valgus separation block is completed to achieve precise insole design driven by objective biomechanical data.

[0009] As a preferred technical solution of the present invention, each of the mounting slots is provided with a positioning boss and a magnetic adsorption layer; The bottom of the heel support block, arch support block and hallux valgus separation block is provided with a positioning groove that engages with the positioning boss in the corresponding mounting slot, and is fitted with a magnetic metal sheet or permanent magnet. The positioning groove and positioning boss cooperate to determine the position of the heel support block, arch support block and hallux valgus separation block on the insole body and to provide circumferential constraint. The magnetic adsorption layer is magnetically attracted to the magnetically conductive metal sheet or permanent magnet.

[0010] In this invention, the positioning groove and the positioning boss cooperate to achieve rapid spatial positioning and circumferential constraint, and a detachable fixed connection is achieved through a magnetic adsorption layer embedded in the bottom of the installation slot. According to the foot biomechanical test results or the support requirements of different usage scenarios, the user selects the arch support block with the corresponding support strength level, and installs it in the installation slot of the insole body through the positioning structure and magnetic adsorption connection, so as to achieve rapid on-demand switching of arch support characteristics, and can complete the quick disassembly and assembly operation without the need for special tools. It can achieve quick assembly and disassembly while ensuring reliable connection and consistent spatial positioning after repeated assembly and disassembly.

[0011] Secondly, the present invention provides a manufacturing method for producing the assembled insole described in the first aspect, comprising the following: (I) Collect user foot information; Static and dynamic physiological data of the user's feet are collected using plantar pressure distribution measurement equipment and foot 3D scanning equipment; (II) Construct a three-dimensional digital model of the foot; A three-dimensional digital model of the foot is constructed based on the user foot information collected in content (I); (III) Foot feature parameter extraction; By analyzing the three-dimensional digital model of the foot, the heel force line offset angle, the internal arch index, and the hallux valgus angle are calculated. The heel force line offset angle determines the contour and hardness of the heel support block; The internal arch index determines the arch height and stiffness of the foot arch support block; The hallux valgus angle determines the outline and deflection angle of the hallux valgus separation block; (IV) Parametric modeling; Construct three-dimensional digital models of the heel support block, arch support block, hallux valgus separation block, and insole body; (V) Additive manufacturing; Additive manufacturing is performed using 3D printing. (VI) Detection; The printed heel support block, arch support block, bunion separation block and insole body were scanned by a 3D scanning device to obtain surface 3D point cloud data. By comparing the 3D point cloud data with the original 3D digital model, the spatial dimensional deviation of each area on the surface of the finished product is calculated. Deformation areas, shrinkage areas, and interlayer stacking defect areas that exceed the preset tolerance threshold are identified and marked. This enables a 3D closed-loop comparison between the printed product and the 3D digital model, timely detection of deformation defects caused by factors such as material shrinkage, interlayer stacking error, and improper removal of support structures during the printing process, preventing defective products from flowing into subsequent stages and reducing quality control costs. (VII) Assembly.

[0012] The beneficial effects of this invention are: 1. This invention enables quick replacement of the heel support block, arch support block, and hallux valgus separation block. The invention constructs these three components as detachable modular parts independent of the insole body. Through the locking and engagement of the positioning boss and positioning groove, as well as the adsorption effect of the magnetic adsorption layer, it achieves quick positioning, limiting, fixing, and separation. Users can complete the quick disassembly and assembly without the need for special tools. At the same time, it ensures the reproducibility of the support function under repeated disassembly and assembly conditions. It ensures that the heel support block, arch support block, and hallux valgus separation block can maintain a high degree of consistent positioning accuracy and connection rigidity after multiple disassembly and assembly cycles, effectively avoiding positioning offset or connection loosening caused by repeated disassembly and assembly. When a user's foot physiological condition changes dynamically or they face different usage scenarios, only the arch support block needs to be replaced instead of discarding the entire insole, which significantly reduces long-term usage costs and eliminates remanufacturing and time costs.

[0013] 2. Using objective biomechanical quantitative data to drive precise insole design; By calculating the heel force line offset angle, the internal arch index, and the hallux valgus angle, standardized values ​​are used to replace traditional empirical judgments, providing clear data for strength selection and structural design, effectively improving the orthopedic effect and biomechanical fit accuracy of customized insoles.

[0014] 3. After manufacturing is completed, the 3D point cloud data of the finished product is compared with the original 3D digital model. The spatial dimensional deviation of each area on the surface of the finished product is calculated. Deformation areas, shrinkage areas and interlayer accumulation defect areas that exceed the preset tolerance threshold are identified and marked. This achieves a 3D closed-loop comparison between the printed finished product and the 3D digital model, preventing defective products from flowing into subsequent stages and reducing quality control costs. Attached Figure Description

[0015] The present invention can be further illustrated by the non-limiting embodiments given in the accompanying drawings; Figure 1 This is a schematic diagram of the assembled insole according to an embodiment of the present invention; Figure 2 This is a diagram illustrating the manufacturing method of the assembled insole according to an embodiment of the present invention; The symbols for the main components are explained below: 1. Heel support block; 2. Arch support block; 3. Hallux valgus separation block; 4. Insole body. Detailed Implementation

[0016] The technical solutions of the present invention will be described in detail below with reference to specific embodiments and accompanying drawings. The embodiments described herein are specific implementations of the present invention, used to illustrate the concept of the present invention; these descriptions are explanatory and exemplary, and should not be construed as limiting the implementation methods or the scope of protection of the present invention. In addition to the embodiments described herein, those skilled in the art can employ other obvious technical solutions based on the content disclosed in the claims and specification of this application. These technical solutions include those that make any obvious substitutions and modifications to the embodiments described herein.

[0017] In a certain medical institution, a patient with bilateral flat feet (collapsed internal arch) needed custom intervention with orthotic insoles.

[0018] (1) Collect user foot information The user's foot pressure distribution data and foot surface three-dimensional point cloud data are collected by the plantar pressure distribution measurement device and the foot three-dimensional scanning device. (2) Constructing a three-dimensional digital model of the foot Based on the user foot information collected in content (1), a three-dimensional digital model of the foot is constructed; (3) Extraction of foot feature parameters By analyzing the three-dimensional digital model of the foot, the heel force line offset angle, the internal arch index, and the hallux valgus angle were calculated. The internal arch index was 0.31 (referring to the normal reference range of 0.21 to 0.26, which is judged as moderate flat feet); the hallux valgus angle was 18° (referring to the normal reference value of <15°, which is judged as mild hallux valgus); and the heel force line offset angle was 4° of inversion. The heel force line offset angle determines the contour and hardness of the heel support block 1; The internal arch index determines the arch height and stiffness of the arch support block 2. The user needs an arch support block 2 with a medium support strength level. The hallux valgus angle determines the contour and deflection angle of the hallux valgus separation block 3; (4) Parametric modeling Three-dimensional digital models of heel support block 1, arch support block 2, hallux valgus separation block 3 and insole body 4 are constructed. Among them, three-dimensional digital models of three support intensity levels of light support, medium support and strong support of arch support block 2 are all modeled to meet the needs of users' foot physiological changes or usage scenarios. (5) Additive manufacturing The digital models of the insole body 4, the heel support block 1, the hallux valgus separation block 3, and the three sizes of arch support blocks 2 are imported into the 3D printing equipment and printed separately using thermoplastic polyurethane elastomer (TPU) material. (6) Detection After printing, the printed heel support block 1, arch support block 2, hallux valgus separation block 3 and insole body 4 are scanned by a 3D scanning device to obtain surface 3D point cloud data. Global registration of 3D point cloud data with the original 3D digital model is performed to calculate the spatial dimensional deviation of each area on the surface of the finished product. Deformation areas, shrinkage areas and interlayer accumulation defect areas that exceed the preset tolerance threshold (±0.3mm) are identified and marked to achieve 3D closed-loop comparison between the printed finished product and the 3D digital model, and deformation defects are detected in a timely manner. (7) Assembly The assembled product includes a heel support block 1, an arch support block 2, a hallux valgus separation block 3, and an insole body 4. The heel support block 1, the arch support block 2, and the hallux valgus separation block 3 are quickly assembled and disassembled on the insole body 4 through the locking and cooperation of the positioning boss and the positioning groove, as well as the adsorption effect of the magnetic adsorption layer and the magnetic conductive metal sheet. The heel support block 1 is located in the mounting slot at the rear of the insole body 4, corresponding to the human heel bearing area, and is used to provide targeted heel support and calcaneal stability. The arch support block 2 is located in the mounting slot on the inner side of the middle part of the insole body 4, corresponding to the human arch bearing area, and is used to provide targeted arch support. The hallux valgus separation block 3 is located in the mounting slot on the inner front side of the insole body 4, corresponding to the area of ​​the big toe, and is used to provide a corrective separation force for the big toe to correct lateral deviation.

[0019] After three months of rehabilitation training, the user's arch shape improved. During rehabilitation training, a progressive training method can be adopted. The user should first adapt to the arch support block 2 with mild support intensity, and then use the arch support block 2 with moderate support intensity for rehabilitation training. Users do not need to re-customize the entire insole. They only need to remove the light-support arch support block 2 from the installation slot and install the medium-support arch support block 2 into the installation slot themselves. The remaining heel support block 1 and hallux valgus separation block 3 do not need to be replaced, which realizes low-cost and quick adaptation and adjustment of arch support characteristics.

[0020] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A prefabricated insole, characterized in that: The insole body (4) includes a heel support block (1), an arch support block (2), and a hallux valgus separation block (3) which are detachably mounted. The heel support block (1) is located in the mounting slot at the rear of the insole body (4) corresponding to the human heel bearing area, and is used to provide targeted heel support and calcaneal stability; The arch support block (2) is located in the mounting slot corresponding to the human arch bearing area on the inner side of the middle part of the insole body (4), and is used to provide targeted arch support. The hallux valgus separation block (3) is located in the mounting slot corresponding to the big toe area of ​​the human body on the inner front side of the insole body (4), and is used to provide a corrective separation force for the big toe to correct lateral deviation. The bottom contours of the heel support block (1), arch support block (2) and hallux valgus separation block (3) complement the corresponding mounting slots in space.

2. The assembled insole according to claim 1, characterized in that: Each of the aforementioned mounting slots is equipped with a positioning boss and a magnetic adsorption layer; The bottom of the heel support block (1), the arch support block (2) and the hallux valgus separation block (3) are respectively provided with positioning grooves that lock with the positioning bosses in the corresponding mounting slots, and are fitted with magnetic metal sheets or permanent magnets. The positioning groove and the positioning boss cooperate to determine the position of the heel support block (1), the arch support block (2), and the hallux valgus separation block (3) on the insole body (4) and to perform circumferential constraint; The magnetic adsorption layer is magnetically attracted to the magnetically conductive metal sheet or permanent magnet.

3. A manufacturing method for producing an assembled insole as described in claim 1 or 2, characterized in that: Includes the following: (I) Collect user foot information; (II) Construct a three-dimensional digital model of the foot; (III) Foot feature parameter extraction; By analyzing the three-dimensional digital model of the foot, the heel force line offset angle, the internal arch index, and the hallux valgus angle are calculated. The offset angle of the heel force line determines the contour and hardness of the heel support block (1); The internal arch index determines the arch height and stiffness of the arch support block (2); The hallux valgus angle determines the contour and deflection angle of the hallux valgus separation block (3); (IV) Parametric modeling; (V) Additive manufacturing; (VI) Detection; (VII) Assembly.

4. The manufacturing method according to claim 3, characterized in that: In Content (I), static and dynamic physiological data of the user's feet are collected using a plantar pressure distribution measurement device and a three-dimensional foot scanning device.

5. The manufacturing method according to claim 3, characterized in that: In content (II), a three-dimensional digital model of the foot is constructed based on the collected user foot information.

6. The manufacturing method according to claim 3, characterized in that: In content (IV), parametric modeling requires the construction of three-dimensional digital models of the heel support block (1), arch support block (2), hallux valgus separation block (3), and insole body (4).

7. The manufacturing method according to claim 3, characterized in that: In content (V), additive manufacturing is carried out using 3D printing.

8. A manufacturing method according to claim 3, characterized in that: In content (VI), the printed heel support block (1), arch support block (2), hallux valgus separation block (3) and insole body (4) are scanned by a 3D scanning device to obtain surface 3D point cloud data; The three-dimensional point cloud data is compared with the original three-dimensional digital model to calculate the spatial dimensional deviation of each area on the surface of the finished product, and to identify and mark the deformation area, shrinkage area and interlayer accumulation defect area that exceed the preset tolerance threshold.

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