Shoe insole having fiber as base material and manufacturing method thereof

Abstract

To provide a shoe insole that is formed of a recyclable fiber and / or a biodegradable fiber and can be detached.SOLUTION: A shoe insole includes an insole pad having a lower surface and an upper surface. The insole pad is formed of nonwoven fibers orientated perpendicularly. The nonwoven fibers forming the insole pad are orientated substantially perpendicularly with respect to the lower surface and the upper surface of the insole pad.SELECTED DRAWING: Figure 1A

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 034,151, filed June 3, 2020, entitled “Machine Washable and Dryable Shoe Insoles and a Method of Manufacturing the Same,” which is incorporated by reference in its entirety.

[0002]

[0003] The present invention relates generally to shoe insoles and methods of making same, and more particularly to removable shoe insoles made from recyclable and / or biodegradable fibers. [Background technology]

[0003]

[0004] Conventional insoles, also known as sock liners, when breathability, also known as air permeability, is concerned, are usually made from chemically derived foams such as open-cell polyurethane foam. The manufacture of open-cell polyurethane foam often requires the use of isocyanates, which can be harmful to the environment. Furthermore, the open-cell polyurethane foam used in the manufacture of insoles requires the different chemistries of adhesives and fabrics to be oriented in a layered configuration to form the insoles. The layered configuration of adhesives and fabrics creates an end product that cannot be easily recycled or biodegraded. Furthermore, the use of conventional insoles made from open-cell polyurethane foams requires the use of socks worn by the shoe wearer to prevent foot odor. Furthermore, the use of adhesives and chemically derived foams in the manufacture of conventional insoles can cause the insoles to warp, fall apart, and / or tear when machine washed and / or machine dried. Open cell foam based insoles can also retain water when machine washed, which can require additional drying to remove the water and thus cause the insoles to warp further. Summary of the Invention [Means for solving the problem]

[0004]

[0005] The insole of the present disclosure is a fiber-based insole that is an alternative to conventional foam-based insoles. In one embodiment, the insole includes an insole padding having a lower surface and an upper surface and made of nonwoven fibers, the nonwoven fibers being generally oriented perpendicular to the lower and upper surfaces of the insole padding. In some embodiments, the insole further includes a knitted cover that at least partially encases the insole padding. In some embodiments, the knitted cover is made of the same type of fiber as the insole padding. In some embodiments, the knitted cover completely encases the insole padding. In some embodiments, the nonwoven fibers are made of recycled materials. In some embodiments, the insole is held together solely by mechanical forces and thermal bonding. In some embodiments, the insole does not include any chemically derived foam or adhesive. In some embodiments, the entire insole is biodegradable. In some embodiments, the entire insole is made of a single type of material. In some embodiments, the nonwoven fibers are made of one or more of cotton, polyester, and nylon.

[0005]

[0006] In some embodiments, the nonwoven fibers are made of elastomeric polyester fibers. In some embodiments, the insole padding has a mass of about 0.13 g / cm 3 to about 0.16 g / cm 3 In some embodiments, the insole padding has an air permeability in the range of about 92 μL / Pa·s to about 98 μL / Pa·s. In some embodiments, the insole padding has a thickness in the range of about 4 millimeters to about 6 millimeters. In some embodiments, the insole padding has a thickness of at least 4 millimeters. In some embodiments, the insole padding includes a heel portion having a generally concave shape, a toe portion that is generally flat, and an arch portion that is generally convex in shape and extends from the heel portion to the toe portion.

[0006]

[0007] In one embodiment, there is an insole that includes an insole padding made of nonwoven fibers made of elastomeric polymer fibers, and a cover at least partially encasing the insole padding, the cover being made of woven elastomeric polymer fibers, and the elastomeric polymer fibers of the cover being of the same material as the elastomeric polymer fibers of the insole padding. The insole does not include any foam material or adhesive, and the insole padding has an air permeability in the range of about 92 μL / Pa·s to about 98 μL / Pa·s and a thickness in the range of about 4 millimeters to about 6 millimeters. In some embodiments, the nonwoven fibers are oriented generally perpendicular to the lower surface of the insole padding.

[0007]

[0008] In one embodiment, there is a method for forming a fiber-based insole, comprising the steps of: preparing a plurality of discontinuous fibers; arranging, separating, and orienting the discontinuous fibers to form a plurality of parallel-oriented fibers; batting the plurality of parallel-oriented fibers into a padding sheet having an upper surface and a lower surface, the parallel-oriented fibers being generally perpendicular to the lower surface and the upper surface of the padding sheet; and cutting the padding sheet into a desired insole shape. In some embodiments, the method further comprises placing the padding sheet formed into the desired insole shape into a knitted cover. In some embodiments, the batting of the parallel-oriented fibers comprises partially intertwining the parallel-oriented fibers. In some embodiments, no chemical foaming agent is used to form the padding sheet. In some embodiments, the desired insole shape generally matches the shape of the sole of a user's foot. In some embodiments, the arranging, separating, and orienting steps are performed by a carding machine.

[0008]

[0009] In some embodiments, forming the padding sheet into an insole comprises mechanically punching the padding sheet. In some embodiments, the plurality of discontinuous fibers is comprised of recycled fibers. In some embodiments, the entire insole is biodegradable. In some embodiments, the entire insole is free of any chemically derived soft foam or adhesives. In some embodiments, the entire insole is comprised of a single type of material. In some embodiments, the padding sheet is molded into a desired insole shape. In some embodiments, punching the plurality of parallel oriented fibers into a padding sheet comprises thermally bonding the plurality of parallel oriented fibers.

[0009]

[0010] The foregoing summary and the following detailed description of embodiments of a textile-based insole and method of manufacture thereof will be better understood when read in conjunction with the accompanying drawings of illustrative embodiments, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.

[0010]

[0011] The drawing is as follows: [Brief description of the drawings]

[0011] [Figure 1A]

[0012] FIG. 1A is a perspective view of a textile-based shoe insole according to an exemplary embodiment of the present disclosure. [Figure 1B]

[0013] FIG. 1B is a cross-sectional schematic diagram of vertically oriented parallel fibers that make up a portion of the fiber-based insole of FIG. 1A. [Figure 2A]

[0014] FIG. 2A is a perspective view of the textile-based insole of FIG. 1A encased in an optional sock-like cover. [Figure 2B]

[0015] FIG. 2B is a cross-sectional schematic diagram of the textile-based insole shown in FIG. 2A. [Diagram 3]

[0016] 2C illustrates a system for forming shoe insole filler and placing it into the sock-like structure of FIG. 2B, according to an exemplary embodiment of the present disclosure. [Figure 4]

[0017] 1B is a method flow chart illustrating a method of making the fiber-based insole of FIG. 1A according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012]

[0018] Referring specifically to the drawings, in which like reference numerals refer to like elements throughout, FIGS. 1A-2B show a textile-based shoe insole, generally designated 100, in accordance with an exemplary embodiment of the present invention.

[0013]

[0019] The insole 100 is a fiber-based insole that is an alternative to conventional foam-based insoles. The insole 100 can be made of nonwoven fibers. In contrast to conventional insoles, the insole 100 can be free of chemicals and / or chemically derived soft foams and adhesives to reduce the environmental impact of manufacturing and disposing of the insole 100. The fibers used to form the insole padding can be made of recycled fibers and / or biodegradable fibers. As described in more detail below, the configuration, orientation, and / or materials used for the nonwoven fibers can allow the insole to have compression, rebound, and / or air permeability properties equal to or greater than conventional soft foam-based insoles. The fibers used to form the insole padding can allow the insole to be easily machine washed and / or dried. Additionally, the lack of chemicals, chemically derived soft foams and / or adhesives may allow the insole to be machine washed and / or machine dried without warping or tearing the insole. The insole may optionally include a sock-like cover that encases the insole stuffing, thereby replacing the need for the wearer to wear socks and / or improving the wearer's comfort while reducing the wearer's environmental impact.

[0014]

[0020] 1A-1B, a shoe insole 100 is shown that may include a footbed padding 102 in one embodiment. In some embodiments, the footbed padding 100 may be configured to be a padded layer for use in a shoe (not shown) under a user's foot and removable from the shoe. In some embodiments, the footbed padding 102 may be configured to be machine washable and / or machine dryable such that the footbed padding 100 may be machine washed and / or machine dried prior to reinsertion into the shoe. In some embodiments, the machine washable and / or machine dryable aspect of the footbed padding 102 may be achieved by not including any foam materials and / or chemically derived soft foams used in conventional footbed padding. In some embodiments, by not including the use of chemically derived soft foams, the footbed padding 102 may not include any chemical blowing agents used in the manufacture of conventional soft foams.

[0015]

[0021] The insole padding 102 may be made of non-woven fibers. Although the insole padding 102 is made of fibers, it may have a foam-like structure. For example, the fibers may be oriented (e.g., intertwined and / or thermally bonded with adjacent fibers) in a manner that forms a foam-like fiber structure. In other words, the insole padding 102 may enable the insole padding 102 to have resilience and compression properties while maintaining breathability, also known as air permeability. The fiber structure may be such that the insole padding 102 can withstand repeated loading from a user standing on the insole padding 102 and their foot exerting downward pressure on the fibers that make up the insole padding 102. The nonwoven structure may be a voluminous, lofty, three-dimensional structure having generally vertically oriented fibers.

[0016]

[0022] In some embodiments, the nonwoven fibers are generally vertically oriented (as shown diagrammatically in FIG. 1B). As discussed herein, vertically oriented fibers can refer to fibers that are generally oriented in a vertical direction that is generally perpendicular to the upper surface 104 and the lower surface 106 of the insole padding 102. In some embodiments, substantially all of the fibers that make up the insole padding 102 are vertically oriented. In some embodiments, at least 99% of the fibers that make up the insole padding 102 are vertically oriented. In some embodiments, at least 98% of the fibers that make up the insole padding 102 are vertically oriented. In some embodiments, at least 97% of the fibers that make up the insole padding 102 are vertically oriented. In some embodiments, at least 95% of the fibers that make up the insole padding 102 are vertically oriented. In some embodiments, at least 94% of the fibers that make up the insole padding 102 are vertically oriented. In some embodiments, at least 93% of the fibers that make up the insole padding 102 are vertically oriented. In some embodiments, at least 92% of the fibers that make up the insole padding 102 are oriented vertically. In some embodiments, at least 91% of the fibers that make up the insole padding 102 are oriented vertically. In some embodiments, at least 90% of the fibers that make up the insole padding 102 are oriented vertically. In some embodiments, the vertically oriented fibers may be oriented in a vertical direction that is at an angle of about 88° relative to the upper surface 104 and / or lower surface 106 of the insole padding. In some embodiments, the vertically oriented fibers may be oriented in a vertical direction that is at an angle of about 86° relative to the upper surface 104 and / or lower surface 106 of the insole padding. In some embodiments, the vertically oriented fibers may be oriented in a vertical direction that is at an angle of about 84° relative to the upper surface 104 and / or lower surface 106 of the insole padding. In some embodiments, the vertically oriented fibers may be oriented in a vertical direction that is at an angle of about 82° relative to the upper surface 104 and / or lower surface 106 of the insole padding. In some embodiments, the vertically oriented fibers may be oriented in a vertical direction that is at an angle between about 82° and about 75° relative to the upper surface 104 and / or lower surface 106 of the insole padding.In some embodiments, the fibers making up the insole padding 102 may be oriented at various angles, such as horizontally or in a random orientation.

[0017]

[0023] In some embodiments, the insole padding 102 may not include any chemical binders or chemical bonding layers (e.g., plates) to bond together the fibers that make up the insole padding 102. In some embodiments, the fibers that make up the insole padding 102 are bonded together by mechanical and / or thermal bonds. In some embodiments, the insole padding 102 does not include any chemicals, such as chemical blowing agents, used in traditional soft foam manufacturing.

[0018]

[0024] In one embodiment, the fibers that make up the insole padding 102 are elastomeric polyester fibers. In some embodiments, the insole padding 102 can be made from recycled materials (e.g., recycled fibers). In some embodiments, the insole padding 102 is made entirely from recycled fibers. In some embodiments, the insole padding 102 is made from about 95% recycled fibers. In some embodiments, the insole padding 102 is made from 90% recycled fibers. In other embodiments, the insole padding 102 is made from recyclable fibers. In some embodiments, the insole padding 102 is made entirely from recyclable fibers. In some embodiments, the insole padding 102 is made from 95% recyclable fibers. In some embodiments, the insole padding 102 is made from 90% recyclable fibers.

[0019]

[0025] In some embodiments, the insole padding 102 may be made of cotton, polyester, nylon, or a combination thereof. may be made of a biodegradable material. For example, the fibers that make up insole padding 102 may be made from a biodegradable material (e.g., cotton). In some embodiments, insole padding 102 may be made entirely of a single type of fiber and / or material. For example, in some embodiments, insole padding 102 may be made entirely of cotton fibers.

[0020]

[0026] In some embodiments, the insole padding 102 can be colored to suit any desired aesthetic. For example, the fibers forming the foam-like fiber structure may be dyed or colored (e.g., a combination of fibers having the same or different colors may be used) to suit any desired aesthetic. In some embodiments, the insole padding 102 can include an antimicrobial agent configured to prevent foot odor associated with continued wearing of the insole 100. In some embodiments, the antimicrobial agent may be a naturally occurring antimicrobial agent, such as peppermint oil or a derivative thereof. In some embodiments, the antimicrobial agent may be dispersed within the insole padding 102. In some embodiments, the insole padding 102 can be made of a hypoallergenic material. In some embodiments, the insole padding 102 can be made of a flame-retardant material. In some embodiments, the insole padding 102 can be made of a material that is resistant to discoloration, such as elusive yellowing.

[0021]

[0027] The thickness of the insole 100, measured in a direction perpendicular to the upper surface 104 and the lower surface 106, may be similar to existing foam insoles. In some embodiments, the insole padding 102 has a thickness ranging from about 1 millimeter to about 7 millimeters. In some embodiments, the insole padding 102 has a thickness ranging from about 2 millimeters to about 6 millimeters. In some embodiments, the insole padding 102 has a thickness ranging from about 3 millimeters to about 5 millimeters. In some embodiments, the insole padding 102 has a thickness of at least 3 millimeters. In some embodiments, the insole padding 102 has a thickness of at least 4 millimeters. In some embodiments, the insole padding 102 has a thickness of at least 5 millimeters. In some embodiments, the thickness of the insole padding 102 is about 5 millimeters.

[0022]

[0028] In some embodiments, the density of the insole padding 102 ranges from about 100 grams per square meter (GSM) to about 600 GSM. In some embodiments, the density of the insole padding 102 ranges from about 150 GSM to about 550 GSM. In some embodiments, the density of the insole padding 102 ranges from about 200 GSM to about 400 GSM. In some embodiments, the density of the insole padding 102 ranges from about 250 GSM to about 350 GSM. In some embodiments, the density of the insole padding 102 is at least 100 GSM. In some embodiments, the density of the insole padding 102 is at least 150 GSM. In some embodiments, the density of the insole padding 102 is at least 200 GSM. In some embodiments, the density of the insole padding 102 is at least 250 GSM. In some embodiments, the density of the insole padding 102 is at least 300 GSM. In some embodiments, the density of the insole padding 102 is at least 350 GSM. In some embodiments, the density of the insole padding 102 is at least 400 GSM. In one embodiment, the density of the insole padding 102 is about 350 GSM.

[0023]

[0029] In some embodiments, the insole padding 102 is approximately 35 kg / cm 2 from about 55kg / cm 2 In some embodiments, the insole padding 102 has a tensile strength in the range of about 40 kg / cm 2 from about 50kg / cm 2 In some embodiments, the insole padding 102 has a tensile strength in the range of about 46 kg / cm 2 In some embodiments, the insole padding 102 has an elongation in the range of about 20% to about 40%. In some embodiments, the insole padding 102 has an elongation in the range of about 22% to about 38%. In some embodiments, the insole padding 102 has an elongation in the range of about 24% to about 36%. In some embodiments, the insole padding 102 has an elongation in the range of about 26% to about 34%. In some embodiments, the insole padding 102 has an elongation in the range of about 28% to about 32%. In some embodiments, the insole padding 102 has an elongation in the range of about 25% to about 30%. In some embodiments, the fibers that make up the insole padding 102 have an elongation of about 27%. In some embodiments, the insole padding 102 has a compression set of less than 40%. In some embodiments, the insole padding 102 has a compression set of less than 38%. In some embodiments, the insole padding 102 has a compression set of less than 36%. In some embodiments, the insole padding 102 has a compression set of less than 34%. In some embodiments, the insole padding 102 has a compression set of less than 32%. In some embodiments, the insole padding 102 has a compression set of less than 30%. In some embodiments, the insole padding 102 has a compression set of less than 28%. In some embodiments, the insole padding 102 has a compression set of less than 24%. In some embodiments, the insole padding 102 has a compression set of less than 22%. In some embodiments, the insole padding 102 has a compression set of less than 20%.

[0024]

[0030] In some embodiments, the insole padding 102 has a compression set of less than 28%, a thickness ranging between about 2 millimeters and about 6 millimeters, and a density ranging between about 250 GSM and about 450 GSM. In some embodiments, the insole padding 102 has a compression set of less than 24%, a thickness ranging between about 3 millimeters and about 5 millimeters, and a density ranging between about 300 GSM and about 400 GSM. In one embodiment, the insole padding 102 has a compression set of less than 20%, a thickness of at least 4 millimeters, and a density of about 350 GSM.

[0025]

[0031] The insole padding 102 may be configured to be generally more breathable and lighter in weight than conventional soft polyurethane foam insole padding. In some embodiments, the insole padding 102 may be configured to have performance characteristics comparable to or superior to conventional soft polyurethane foam insoles. In some embodiments, the insole padding 102 has an air permeability in the range of about 90 μL / Pa·s to about 100 μL / Pa·s. In some embodiments, the insole padding 102 has an air permeability in the range of about 92 μL / Pa·s to about 98 μL / Pa·s. In some embodiments, the insole padding 102 has an air permeability in the range of about 94 μL / Pa·s to about 96 μL / Pa·s. In one embodiment, the insole padding 102 has an air permeability of about 95 μL / Pa·s. In some embodiments, the insole padding 102 has an air permeability of about 0.13 g / cm 3 to about 0.16 g / cm 3 In some embodiments, the insole padding 102 has a specific gravity in the range of about 0.14 g / cm 3 to about 0.15 g / cm 3 It has a specific gravity in the range of

[0026]

[0032] In some embodiments, the insole padding 102 may have a pattern and / or shape resulting from a molding and / or heating process that the insole padding 102 undergoes during manufacture. For example, the top surface 104 of the insole padding 102 may have a generally quilted pattern as shown in FIG. 1A resulting from a heating process that the insole padding 102 undergoes during manufacture. In some embodiments, the insole padding 102 is molded and / or cut to have a shape that generally corresponds to the shape of the sole of the wearer's foot. For example, the insole padding 102 is molded and / or cut to have a heel portion 108 that has a generally concave shape that corresponds to the shape of the sole of the heel of the wearer's foot. The insole padding 102 may be molded and / or cut to have a toe portion 112 that is generally flat and shaped generally similar to the contour of the front of the wearer's foot (e.g., the toes and ball of the foot). The insole padding may be molded and / or cut to have a heel portion 112 that is generally convex in shape and has a concave shape that corresponds to the shape of the sole of the heel of the wearer's foot. 108 to a toe portion 112. Arch portion 110 may be shaped and / or dimensioned to correspond to the shape and / or size of the arch of the wearer's foot.

[0027]

[0033] 2A-2B, the insole 100 may include an optional sock-like cover 108 coupled to the insole padding 102. The sock-like cover 108 may provide additional comfort to a user of the insole 100, absorb sweat from the user's feet, and / or reduce odor from the user's feet. As discussed herein, sock-like may refer to a knitted and / or woven fabric structure configured to at least partially encase or fully encase a core material (e.g., the insole padding 102). In some embodiments, the sock-like cover 108 is coupled to the insole padding 102 such that the sock-like cover 108 at least partially encases the insole padding 102. In some embodiments, the sock-like cover 108 completely encases the insole padding 102. In some embodiments, the sock-like cover 108 is configured to cover the entire upper surface 104 of the insole padding 102. In some embodiments, the sock cover 108 is configured to be selectively removable from the insole padding. For example, the sock cover 108 may include an opening (e.g., a hole or slot under the insole padding near the heel) so that the insole padding 102 can be inserted or removed from the sock cover 108. In other embodiments, the sock cover 108 is mechanically coupled to the insole padding 102 (e.g., sewn or stitched to the insole padding 102). In some embodiments, the insole padding 102 and the sock cover 108 are coupled to each other so that a user can simultaneously remove both from the shoe. In some embodiments, the sock cover 108 may be omitted entirely or provided as a separate accessory.

[0028]

[0034] In some embodiments, the thickness of the sock cover 108 ranges from about 0.5 millimeters to about 4.0 millimeters. In some embodiments, the thickness of the sock cover 108 ranges from about 1.0 millimeters to about 3.5 millimeters. In some embodiments, the thickness of the sock cover 108 ranges from about 1.5 millimeters to about 3.0 millimeters. In some embodiments, the thickness of the sock cover 108 may range from about 2.0 millimeters to about 2.5 millimeters. In some embodiments, the thickness of the sock cover 108 is at least 0.5 millimeters. In some embodiments, the thickness of the sock cover 108 is at least 1.0 millimeters. In some embodiments, the thickness of the sock cover 108 is at least 1.3 millimeters. In one embodiment, the thickness of the sock cover 108 is about 0.7 millimeters.

[0029]

[0035] In some embodiments, the thickness of the insole 100 including the insole padding 102 enclosed by the sock-like cover 108 ranges from about 4 millimeters to about 8 millimeters. In some embodiments, the thickness of the insole 100 including the insole padding 102 enclosed by the sock-like cover 108 ranges from about 5 millimeters to about 7 millimeters. In some embodiments, the thickness of the insole 100 including the insole padding 102 enclosed by the sock-like cover 108 is about 6 millimeters. In some embodiments, the thickness of the insole 100 including the insole padding 102 enclosed by the sock-like cover 108 is at least 3 millimeters. In some embodiments, the thickness of the insole 100 including the insole padding 102 enclosed by the sock-like cover 108 is at least 4 millimeters. In some embodiments, the thickness of the insole 100 including the insole padding 102 enclosed by the sock-like cover 108 is at least 5 millimeters. In some embodiments, the thickness of the insole 100, including the insole padding 102 encased by the sock-like cover 108, is at least 6 millimeters.

[0030]

[0036] The sock cover 108 can be made from recycled and / or recyclable materials (e.g., recycled fibers). In some embodiments, the sock cover 108 is made entirely from recycled fibers. In some embodiments, the sock cover 108 is made from about 95% recycled fibers. In some embodiments, the sock cover 108 is made from 90% recycled fibers. In other embodiments, the sock cover 108 is made from recyclable fibers. In some embodiments, the sock cover 108 is made entirely from recyclable fibers. In some embodiments, the sock cover 108 is made from 95% recyclable fibers. In some embodiments, the sock cover 108 is made from 90% recyclable fibers.

[0031]

[0037] The insole padding 102 and the sock cover 108 can be made of the same type of material as each other. In one embodiment, the insole padding 102 and the sock cover 108 can be made of the same type of fiber. In one embodiment, the insole padding 102 and the sock cover are made of the same recycled materials and / or recycled fibers to ensure that the insole 100 is entirely recyclable or biodegradable. In some embodiments, the sock cover 108 is made of fibers such as, but not limited to, polyester, nylon, wool, etc. In some embodiments, a combination of two or more fiber combinations is included in the sock cover 108. In some embodiments, the sock cover can be made of the same type of fiber (e.g., polyester) with different levels of elasticity. For example, the same type of fiber (e.g., polyester) may have different levels of elasticity due to different processing and / or manufacturing methods. A single type of fiber may have different elasticity values ​​by knitting / weaving tighter, by introducing another fiber into the knitting / weaving, or by introducing a reinforcing product such as starch.

[0032]

[0038] In some embodiments, the sock cover 108 is made of a material configured to improve one or more properties of the insole padding 102. For example, the sock cover 108 can be made of an absorbent material configured to absorb moisture (e.g., sweat) from the bottom of the user's foot. The sock cover 108 can be made of a material configured to prevent the insole padding 102 from tearing, discoloring, and / or warping. The sock cover 108 can be made of a material configured to improve the decorative appearance of the insole padding 102. For example, the sock cover 108 can be a material that can be dyed, printed, or woven with an aesthetically beneficial pattern. The sock cover 108 can include a non-slip material that resists movement of the user's foot against the sock cover 108 when worn. The sock cover 108 can be made of a softer and / or stiffer material than the insole padding 102 to provide two compression stages in combination with the insole padding 102 when worn by a user. In some embodiments, the sock 108 is configured to be interchangeable with another sock.

[0033]

[0039] In some embodiments, the insole 100 can reduce the environmental impact of the components of the shoe and the environmental impact of the shoe wearer. In some embodiments, the insole 100 is made of a single material type (e.g., fiber) that can adhere to the sustainable practices of a closed-loop manufacturing system. Furthermore, by providing the insole stuffing 102 encased in a sock-like cover 108, the number of socks that the shoe wearer must own and / or use can be reduced, thereby reducing consumer consumption. In other words, the insole 100 can reduce and / or eliminate the need for the wearer to own or wear traditional socks, and thus the insole 100 can enable the shoe wearer to own fewer products and rotate them.

[0034]

[0040] Referring to FIG. 3, the shoe insole padding 102 is formed and then covered with a sock-like cover 108. 3 shows a diagram of a system, generally designated 300, for feeding a plurality of discontinuous fibers 302 into a carding machine 304. In some embodiments, the plurality of discontinuous fibers 302 can be comprised of recycled material. In some embodiments, the carding machine 304 can be configured to position, separate, and orient the plurality of discontinuous fibers 302 in parallel such that the fibers are generally parallel to one another. In some embodiments, the plurality of discontinuous fibers 302 are oriented in parallel in a vertically upright position by the carding machine 304. In some embodiments, the parallel oriented fibers can be punched into a batting sheet 306. In some embodiments, the batting sheet 306 can be formed to any desired thickness. In some embodiments, the batting sheet 306 can have a thickness ranging from about 3 mm to about 6 mm. In some embodiments, the batting sheet 306 can have a thickness of about 5 mm.

[0035]

[0041] In some embodiments, the carding machine 304 can operate by mechanical machining, pneumatic machining, and / or "air-type" machining, where a suction device and / or blower is used to vertically orient the fibers and configure the overall thickness of the fibers into a continuous sheet. In some embodiments, the carding machine 304 operating by mechanical machining and / or pneumatic machining can consist of a first rotating lickering component and a second rotating drum component (not shown). The first rotating lickering component and the second rotating drum component can be configured to move the discontinuous fibers 302 in a coordinated manner by passing the discontinuous fibers 302 along a working path. In some embodiments, the carding machine 304 operating by "air-type" machining can include air treatment, which is performed by conveying the discontinuous fibers 302 near a suction device or conveying the discontinuous fibers 302 near a suction device with the aid of a blower.

[0036]

[0042] The padding sheet 306 can be multiple sheets of varying thickness and density to meet a given technical specification. In some embodiments, the padding sheet 306 can be formed into insole padding (e.g., insole padding 102). As discussed above, the carding machine 304 can be configured to place the discontinuous fibers 302 in a vertically upright position, separate, and orient them in parallel to form the padding sheet 306. In some embodiments, the fiber sheet 306 can be intertwined in such a way that the fibers form a foam-like fiber structure that functions as a foam-like structure. The foam-like fiber structure can have similar rebound and compression properties as known foam insoles while maintaining breathability, also known as air permeability. The foam-like fiber structure may not require the use of chemicals in its assembly. To meet any desired technical specification, the foam-like fiber structure may be made denser or less dense. In some embodiments, to meet any desired technical specification, the foam-like fiber structure may utilize fibers with varying fiber diameters and varying fiber lengths.

[0037]

[0043] In some embodiments, the padding sheet 306 may be provided to some type of former 308 configured to form the padding sheet 306 into a desired shape (e.g., the shape of the insole padding 102). In some embodiments, the padding sheet 306 may be formed into the insole padding 102 by machine punching, slicing, and / or molding by methods known to those skilled in the art. In some embodiments, the insole padding 102 may be formed to fit a given shoe size, shape, and / or type. In some embodiments, the insole padding 102 may be steamed at a temperature ranging from about 160° C. to about 180° C., and in one embodiment at about 170° C., for between 50 and 100 seconds to soften the insole padding 102. In some embodiments, the softened insole padding 102 may be compression molded by methods known to those skilled in the art into a contoured insole shape. In some embodiments, the contoured insole shape may be die cut into the shape of the individual insole padding 102. In some embodiments, the shape of the insole padding 102 can generally correspond to the shape of the sole of the wearer's foot. In some embodiments, the insole padding 102 can have a heel portion having a generally concave shape, a toe portion that is generally flat, and an arch portion that is generally convex in shape and extends from the heel portion to the toe portion.

[0038]

[0044] In some embodiments, the insole padding 102 may be formed to generally conform to the bottom of a user's foot. In one embodiment, the former 308 may be a device configured to perform mechanical punching. The mechanical punching device may be configured to mechanically press the padding sheet 306 into the shape of the insole padding 102 for a given size (e.g., a given shoe size). In some embodiments, the insole padding 102 may be provided (e.g., manually fed) to the knitting machine 310. In some embodiments, the knitting machine 310 may be configured to construct a knitted sock cover (e.g., sock cover 108) around the insole padding 102 such that the insole padding 102 is at least partially enclosed by the sock cover. In some embodiments, the knitting machine 310 is configured to completely encase the insole padding 102 within the sock cover 108. In some embodiments, the insole padding 102 and sock cover 108 produced by the system 300 may be machine washable and machine dryable. In some embodiments, the insole padding 102 and the sock cover 108 can be made of the same material or materials.

[0039]

[0045] In some embodiments, the fibers that make up the insole padding 102 and / or the sock cover 108 may be elastomeric fibers. In some embodiments, the fibers that make up the insole padding 102 and / or the sock cover 108 may be a blend of one or more types of elastomeric fibers. In some embodiments, the fibers that make up the insole padding 102 are a blend of about 75% 1.5 denier polyester fibers and about 25% 2 denier bicomponent fibers. In some embodiments, the fibers that make up the insole padding 102 are a blend of about 80% 6 denier polyester fibers and about 20% 4 denier bicomponent fibers. In some embodiments, the fibers that make up the insole padding 102 are a blend of about 80% 15 denier polyester fibers and about 20% 4 denier bicomponent fibers. In some embodiments, the fibers making up the insole padding 102 are a blend of approximately 80% 25 denier polyester fibers and approximately 20% 4 denier bicomponent fibers.

[0040]

[0046] In some embodiments, the fibers making up the insole padding 102 and / or the sock cover 108 may be blended with other types of fibers to suit a given demand. For example, in some conditions, the use of natural fibers such as jute, flax hemp, or cotton may be desirable. In some conditions, other materials such as high-tech fibers (e.g., Kevlar and Dyneema) may be desirable. In some embodiments, any fiber type suitable for a given market demand, whether blended or used by itself, may be utilized to form the insole padding 102 and / or the sock cover 108. In some embodiments, the insole padding 102 and the sock cover 108 may be made of structural fibers that are fully biodegradable or fully recyclable, and thus the insole 100 is fully biodegradable or fully recyclable. In some embodiments, a top sheet of fabric (not shown) may be bonded to the upper surface 104 of the insole padding 102. In some embodiments, the top sheet of fabric may be bonded to the top surface 104 of the insole padding 102 by hot melt bonding (melting like materials together until they fuse together).

[0041]

[0047] 4, in some embodiments, there is a method, generally designated 400, for forming a machine washable insole (e.g., insole 100) according to an exemplary embodiment of the present disclosure. In some embodiments, prior to method 400, one or more suitable types of fibers may be selected. In some embodiments, suitable fibers may be selected. The fibers may be selected based on fiber type, fiber diameter, fiber color, and / or fiber length. In some embodiments, the suitable fibers may be elastomeric fibers. In some embodiments, a plurality of suitable fibers (e.g., elastomeric fibers) may be used in the method 400. In some embodiments, the method 400 includes a step 402 of providing a plurality of discontinuous fibers, the plurality of discontinuous fibers comprising recycled material. For example, as described above with reference to FIG. 3, the discontinuous fibers 302 may be provided to a carding machine 304. In some embodiments, the plurality of discontinuous fibers comprises the selected suitable fibers.

[0042]

[0048] In some embodiments, the method 400 can include a step 404 of placing, separating, and orienting the discontinuous fibers into a generally vertical, generally upright, and generally parallel oriented orientation to form a plurality of parallel oriented fibers. For example, the carding machine 304 can be configured to place, separate, and orient the discontinuous fibers 302 into a generally vertical, generally upright, and generally parallel oriented orientation. In some embodiments, the method 400 can include a step 406 of beating the parallel oriented fibers into a stuffing sheet having a foam-like fibrous structure. For example, the parallel oriented fibers produced by the carding machine 304 can be beaten into a stuffing sheet 306. The fibers forming the stuffing sheet 306 can be intertwined to form a foam-like fibrous structure. In some embodiments, the method 400 can include a step 408 of forming the stuffing sheet into a desired insole shape. For example, the stuffing sheet 306 can be fed to a former 308 configured to form the stuffing sheet 306 into the shape of the insole padding 102. In some embodiments, the method 400 can include placing the stuffing sheet formed into the desired insole shape into a sock cover. For example, the insole padding 102 can be fed to a knitting machine 310, which can be configured to place the insole padding 102 into the sock cover 108.

[0043]

[0049] Those skilled in the art will appreciate that changes may be made to the exemplary embodiments shown and described above without departing from the broad inventive concept thereof. It is therefore understood that the present invention is not limited to the exemplary embodiments shown and described, but is intended to encompass modifications that are within the spirit and scope of the present invention as defined by the claims. For example, specific features of the exemplary embodiments may or may not be part of the claimed invention, and various features of the disclosed embodiments may be combined. Unless specifically stated herein, the terms "a," "an," and "the" should not be read as being limited to one element, but rather as meaning "at least one."

[0044]

[0050] It should be understood that in order to focus on elements relevant to a clear understanding of the invention, at least some of the figures and descriptions of the invention have been simplified and, for clarity of description, other elements that a person skilled in the art would understand may also form part of the invention have been excluded, however, because such elements are well known in the art and because they do not necessarily facilitate a better understanding of the invention, descriptions of such elements are not provided herein.

[0045]

[0051] Moreover, to the extent that the method of the present invention does not depend on the particular order of steps set forth herein, the particular order of steps should not be construed as a limitation on the claims. Any claim directed to the method of the present invention should not be limited to performing those steps in the order they are written, and one of ordinary skill in the art can readily appreciate that the steps may be varied and still remain within the spirit and scope of the present invention.

Claims

1. a padding material having a lower surface and an upper surface and made of nonwoven fibers; the nonwoven fibers are oriented generally perpendicular to the lower and upper surfaces of the insole padding; Shoe insoles.

2. and further comprising a knitted cover at least partially enclosing the insole padding.

2. The shoe insole according to claim 1.

3. the knitted cover is made of the same type of fiber as the insole filling; 3. The shoe insole according to claim 2.

4. The knitted cover completely encases the insole padding.

3. The shoe insole according to claim 2.

5. The nonwoven fabric is made of recycled materials.

2. The shoe insole according to claim 1.

6. The insoles are held together solely by mechanical forces and thermal bonding.

2. The shoe insole according to claim 1.

7. The insole does not contain any chemically derived foams or adhesives; 2. The shoe insole according to claim 1.

8. The entire insole is biodegradable; 2. The shoe insole according to claim 1.

9. The entire insole is made of a single type of material; 2. The shoe insole according to claim 1.

10. the nonwoven fibers being comprised of one or more of cotton, polyester, and nylon; 2. The shoe insole according to claim 1.

11. The nonwoven fibers are made of elastomeric polyester fibers.

2. The shoe insole according to claim 1.

12. The insole filling is about 0.13 g / cm ３ to about 0.16 g / cm ３ having a specific gravity in the range of 2. The shoe insole according to claim 1.

13. The insole filling has an air permeability in the range of about 92 μL / Pa·s to about 98 μL / Pa·s; 2. The shoe insole according to claim 1.

14. The insole padding has a thickness ranging from about 4 millimeters to about 6 millimeters.

2. The shoe insole according to claim 1.

15. the insole padding has a thickness of at least 4 millimeters; 2. The shoe insole according to claim 1.

16. The insole filling is a heel portion having a generally concave shape; a generally flat toe area; an arch portion that is generally convex in shape and extends from said heel portion to said toe portion; Including, 2. The shoe insole according to claim 1.

17. A shoe insole, An insole filling material made of nonwoven fibers made of elastomeric polymer fibers; a cover at least partially enclosing the insole padding, the cover being made of woven elastomeric polymer fibers, the elastomeric polymer fibers of the cover being of the same material as the elastomeric polymer fibers of the insole padding; Equipped with the insole does not include any foam material or adhesive; The insole padding has an air permeability in the range of about 92 μL / Pa·s to about 98 μL / Pa·s and a thickness in the range of at least 4 millimeters; Shoe insoles.

18. the nonwoven fibers of the insole padding are oriented generally perpendicular to a lower surface of the insole padding; 18. The shoe insole of claim 17.

19. Providing a plurality of discontinuous fibers; locating, separating and orienting the discontinuous fibers to form a plurality of parallel oriented fibers; beating the plurality of parallel oriented fibers into a batting sheet having an upper surface and a lower surface, the parallel oriented fibers being oriented generally perpendicular to the lower surface and the upper surface of the batting sheet; cutting the padding sheet into a desired insole shape; Including, A method for forming a fiber-based shoe insole.

20. further comprising placing the padding sheet formed into the desired insole shape into a knitted cover.

20. The method of claim 19.

21. beating the parallel oriented fibers includes partially intertwining the parallel oriented fibers.

20. The method of claim 19.

22. No chemical foaming agents are used to form the padding sheet; 20. The method of claim 19.

23. The desired insole shape generally conforms to the shape of the sole of the user's foot; 20. The method of claim 19.

24. The placing, separating and orienting are performed by a carding machine.

20. The method of claim 19.

25. forming the padding sheet into the insole includes machine punching the padding sheet.

20. The method of claim 19.

26. The plurality of discontinuous fibers are made of recycled fibers.

20. The method of claim 19.

27. The entire insole is biodegradable; 20. The method of claim 19.

28. The entire insole is free of any chemically derived soft foam or adhesives; 20. The method of claim 19.

29. The entire insole is made of a single type of material; 20. The method of claim 19.

30. The padding sheet is molded into the desired insole shape.

20. The method of claim 19.

31. beating the plurality of parallel oriented fibers into a batting sheet includes thermally bonding the plurality of parallel oriented fibers.

20. The method of claim 17.

Images