Modular sports insole system with integrated biomechanical return elements, sensory pressure analysis and anatomically stimulating massage points for movement optimization and injury prevention.

Abstract

Insole system characterized in that it comprises an anatomically shaped support layer into which several biomechanically calibrated restoring elements are integrated, which react to the load on the foot and generate a controlled restoring force.

Description

1. Technical field

[0001] The invention relates to a modular insole system for sports and everyday shoes that integrates biomechanical restoring elements (e.g., springs or elastic amortization modules), sensory pressure analysis, and anatomically positioned massage points. The aim is to actively stabilize the foot, improve movement dynamics, and prevent injuries. 2. State of the art

[0002] Conventional insoles consist of passive cushioning materials such as EVA or gel, which deform under load and do not generate any active rebound force. No modular systems with integrated mechanical rebound elements exist that dynamically respond to biomechanical loads while simultaneously providing sensory and neurophysiological functions. 3. Object of the invention

[0003] The invention is intended to: • generate biomechanically calibrated restoring forces • to distribute the load on the foot dynamically and anatomically correctly • promote blood circulation through massage points • Capture and analyze movement patterns • be modular, interchangeable and durable 4. Solution to the task

[0004] The insertion system includes: • An anatomically shaped carrier layer made of TPU or EVA • Six integrated rebound elements (e.g., coil springs, nitinol modules) positioned along the main stress zones (heel, midfoot, forefoot) • Mechanical connection between each return element and an underlying Krampon (stud) • Elastic encapsulation of the springs for controlled compression • Multiple massage points on the surface of the insole that stimulate the sole of the foot with every step. • Optional: Sensor integration for pressure measurement and motion analysis 5. Technological Process • CAD modeling of anatomical geometry • Micro-precise placement of the springs using laser cutting or injection molding technology • Integration into TPU or EVA matrix • Lamination with antibacterial textile layer • Optional: Integration of sensors and microcontroller modules 6. Simulation and Validation

[0005] The biomechanical effect is validated by finite element simulation (FEM). Target parameters: • Reset time < 0.2 seconds • Pressure distribution across the entire sole • Reduction of ankle joint stress by >30% • Improved microcirculation through massage points 7. Purpose and Application

[0006] The invention is suitable for: • Football, basketball, handball, tennis • Everyday shoes for people with unstable ankles • Rehabilitation shoes after injuries • Orthopedic applications and prevention 8. Economic assessment

[0007] Manufacturing costs per unit: • Stainless steel springs: approx. €4-6 • Graphene composites: approx. 12-18 € • Final product price in retail: €29-49

[0008] The technology is scalable and can be integrated into existing shoe lines or marketed as a standalone product. 9. Anatomical fit and comfort

[0009] The geometry takes the following into account: • Longitudinal vault • Transverse vault • Heel cups

[0010] The insole is covered with a skin-friendly, antibacterial textile layer. The spring positions relieve pressure points and promote dynamic movement. 10. Safety and injury prevention

[0011] The restoring force is biomechanically calibrated. The design prevents: • Supination / pronation outside the physiological range • Microtraumas • Instability during changes of direction • Overload due to localized pressure peaks 11. Modularity and compatibility

[0012] Usable in: • Football boots • Running shoes • Everyday shoes • Orthopedic shoes

[0013] Available in several sizes and hardness levels. Individual modules can be replaced. 12. Durability and elasticity • Usage period: 12-18 months • Load cycles: >500,000 • Loss of elasticity • Interchangeability of individual springs and textile layers 13. Variants of the design • Standard version • Sports professional version • Rehab version • Children's version • Sensor-integrated version • Massage version with active or passive stimulation points 14. Sensor-integrated design

[0014] In this version, pressure-sensitive sensors (capacitive or piezoelectric) are embedded directly above the spring modules. They detect: • Vertical pressure load • Dynamic load changes • Asymmetries in foot pressure

[0015] The data is transmitted to a mobile device via Bluetooth or NFC. An app visualizes pressure distribution and movement patterns. Power is supplied by a flat button cell battery or inductive charging. The sensors are protected against moisture and abrasion by a textile protective layer. 15. Technical comparison with the state of the art

[0016] Compared to conventional foam inserts, which passively deform under load and do not generate any resilience, the innovative insert system offers a biomechanically active response. The following comparison illustrates the differences: Characteristic: Response to stress Conventional foam: Deforms passively Innovative insertion system: Actively reacts with restoring force. Note: Dynamic. Characteristic: Restoring behavior Conventional foam: No recovery Innovative insertion system: Return to starting position Note: Stabilizing Feature: Pressure distribution Conventional foam: Spot-based Innovative insert system: Anatomically shaped and flat Note: Gentle Feature: Long-term deformation Conventional foam: Remains deformed Innovative insert system: Dimensionally stable due to elastic structure Note: Permanent Feature: Adapts to movement Conventional foam: Limited Innovative insertion system: Adaptive depending on the movement phase Note: Sports optimized Feature: Protection against microtrauma Conventional foam: Low Innovative insertion system: High performance through biomechanical damping Note: Preventive Feature: Integration of additional functions Conventional foam: Not intended Innovative insertion system: Possible: Sensors, massage points Note: Modular

[0017] The Fig. This shows a technical side view of a sports shoe, specifically a football boot, featuring an innovative sole design. The outsole contains seven vertically arranged studs, each designed as an integrated coil spring. Each stud consists of a cylindrical housing with an internal spring structure that generates an active rebound force.

[0018] The spring-loaded studs are evenly distributed along the length of the sole and functionally connected to the insole, which contains biomechanical rebound elements. This design enables targeted shock absorption, movement stabilization, and energy return during athletic activity.

[0019] The shoe's contour is clean and minimalist, with the spring mechanisms clearly highlighted. The drawing serves to illustrate the mechanical integration of rebound elements into the outsole of a sports shoe. Description of the drawing Fig. 2 - Side view of a sports shoe with semi-curved, activated spring studs

[0020] Fig. The image shows a side view of a sports shoe with a biomechanically optimized outsole. The sole contains several semi-curved, elastically pre-tensioned spring mechanisms, each connected to an underlying stud (krampon). The spring modules are designed to be activated by vertical load from the foot, generating a controlled rebound force.

[0021] The springs shown are partially compressed and inclined at different angles, indicating adaptive force distribution and a dynamic response to movement impulses. This design enables targeted shock absorption, energy return, and stabilization during athletic activity, especially changes of direction and jumping movements.

[0022] The spring studs are functionally connected to the insole according to description point 4 and claims 1-3 and 13-15. The drawing illustrates the mechanical coupling between foot pressure, spring activation and stud behavior. Description of the drawing Fig. 3 - Top view of an insole with integrated spiral springs and massage function

[0023] Fig. The image shows a top view of a modular insole with ten evenly distributed coil springs embedded along the longitudinal axis of the sole. Each spring is integrated into a cylindrical capsule and mechanically designed to generate vertical compression and a biomechanically calibrated rebound force when loaded by the foot.

[0024] The positioning of the springs corresponds to the main pressure zones of the foot (heel, midfoot, forefoot) and enables even pressure distribution as well as active support of movement during sporting activities. In addition, the elastic movement of the spring capsules creates a stimulating effect on the sole of the foot, resulting in a massage function with a blood circulation-promoting effect.

[0025] The insole is compatible with various shoe types and is functionally connected to the spring studs according to Fig. and Fig. The structure shown supports claims 1-3, 6-8 and 17. Description of the drawing Fig. 4 - Side and bottom view of a sports shoe with integrated spring zones for force distribution

[0026] Fig. shows two views of a sports shoe with biomechanically optimized sole technology: • Top view (bottom view of the sole): The outsole features several elongated recesses and spring-activated zones positioned along the foot's main pressure lines. These zones are equipped with integrated coil springs that activate when weight is applied. This arrangement ensures an even distribution of force across the entire sole surface and supports stability during movement. • Bottom view (side view): The side view shows the vertical integration of the spring mechanisms into the sole structure. The springs are depicted at different heights and compression levels, indicating a zone-specific cushioning function. Particularly noticeable under the heel and forefoot are reinforced spring modules that generate a targeted rebound force.

[0027] The illustrated design enables biomechanically controlled force transmission from the foot to the shoe and promotes a balanced distribution of load during athletic activity. The spring zones are functionally connected to the insole according to... Fig. and support claims 1-4, 6, 13-15 and 17.

Claims

[1] Insert system, characterized by , that it includes an anatomically shaped support layer into which several biomechanically calibrated restoring elements are integrated, which react to the load on the foot and generate a controlled restoring force. [2] Insert system according to claim 1, wherein the return elements are positioned above the pressure zones of the foot (heel, midfoot, forefoot) and are connected to the underlying studs via mechanical connections. [3] Insert system according to one of the preceding claims, wherein the restoring elements are designed as spiral springs, nitinol modules or elastic capsules and are embedded in a flexible TPU structure. [4] Insertion system according to one of the preceding claims, wherein the return elements are activated via a kinematic pole construction which transfers the vertical load into a horizontal return movement. [5] Insert system according to one of the preceding claims, wherein the carrier layer consists of thermoplastic polyurethane (TPU) or ethylene vinyl acetate (EVA) and is covered with an antibacterial textile surface. [6] Insertion system according to one of the preceding claims, wherein the return elements are interchangeable and can be replaced by a modular plug-in system. [7] Insert system according to one of the preceding claims, wherein several anatomically positioned massage points are integrated on the surface of the carrier layer, which stimulate the sole of the foot during movement and promote microcirculation. [8] Insert system according to claim 7, wherein the massage points are designed as raised silicone or TPU elements and are arranged along the medial arch of the foot. [9] Insert system according to one of the preceding claims, wherein one or more sensors are integrated for real-time measurement of the pressure distribution and movement dynamics of the foot. [10] Insertion system according to claim 9, wherein the sensors operate capacitively or piezoelectrically and transmit the data wirelessly via Bluetooth or NFC to a mobile device. [11] Insertion system according to claim 9 or 10, wherein the sensors are positioned above the return elements and are protected against moisture and abrasion by a textile protective layer. [12] Insertion system according to one of the preceding claims, wherein the energy supply of the sensors is provided by a flat button cell or an inductive charging system. [13] Insert system according to any of the preceding claims, which can be used in football boots, running shoes, everyday shoes or orthopedic shoes. [14] Sports shoe, characterized bythat it includes an insert system according to one of claims 1 to 13 and additionally has several replaceable screw studs on the outsole. [15] Sports shoe according to claim 14, wherein an integrated spring mechanism is arranged above each screw-in stud which generates a restoring force during abrupt movements. [16] Sports shoe according to claim 14 or 15, wherein the spring mechanisms are functionally connected to the inner sole and biomechanically support the movement dynamics of the player. [17] Insert system according to one of the preceding claims, characterized by, that it differs functionally and structurally from the state of the art in that, instead of a passively deformable damping material (e.g. foam), it uses a dimensionally stable, resilient restoring element that generates an active biomechanical response to load, ensuring permanent pressure distribution, return to the neutral position and protection against microtrauma.

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