Method and device for covering 3d-printed orthopedic shoe inserts

Abstract

The invention relates to a device (1) for connecting a 3D-printed orthopedic shoe insert (2) to a multi-layer hybrid cover made of at least an adhesive layer and a covering material. According to the invention, the device (1) has a heating device (3), a pressing device (4), and a control device, and the device (1) is designed to heat a multi-layer hybrid cover made of at least an adhesive layer and a cover material by means of the heating device (3) in a connection process and to press the hybrid cover onto a 3D-printed orthopedic shoe insert (2) by means of the pressing device (4), the control device being designed to control the heating device (3) and the pressing device (4) individually for each connection process and to automatically connect the orthopedic shoe insert (2) and the hybrid cover in response to a trigger signal SF. The invention additionally relates to a method for connecting a 3D-printed orthopedic shoe insert (2) to a multi-layer hybrid cover consisting at least of an adhesive layer and a cover material by means of the device (1) and to an assembly consisting of the device (1) and a communication terminal, in particular a smartphone.

Description

[0001] BÖWO-2025-09010, WODE-Text

[0002] Description

[0003] title

[0004] The invention relates to a method and a device for covering individual 3D-printed orthopedic shoe insoles with a multi-layered hybrid cover consisting of at least an adhesive layer and a covering material.

[0005] State of the art

[0006] Industrial systems are known in the prior art for covering shoe soles with a covering material. These systems are characterized by the fact that a mostly flat covering material is pressed onto a more or less flat shoe insole under relatively high pressure. The shoe insole typically has a low profile, negligible compared to orthopaedic insoles. These systems are generally unsuitable for covering orthopaedic insoles, as an individually tailored, custom-made height profile is at risk of being permanently deformed in such systems.

[0007] For this reason, the production of orthopaedic shoe insoles still involves a relatively high proportion of manual labor, which is mostly carried out in workshops of orthopaedic shoe technicians, also called orthopaedic mechanics or orthopaedic technicians, and which also includes covering, specifically bonding, an individual 3D-printed orthopaedic shoe insole with a multi-layered hybrid cover made of BÖWO-2025-09010, WODE-Text

[0008] - 2 - at least the adhesive layer and covering material are included. Accordingly, this step is usually carried out manually.

[0009] EP 3603 587 A1 describes a method for manufacturing an orthopaedic insole based on a 3D model, in which, in a final process step, the orthopaedic shoe insole is covered. However, the document leaves open how this process step is carried out in practice.

[0010] Disclosure of the invention

[0011] The object of the present invention is to provide an improved solution for connecting an individual, 3D-printed orthopedic shoe insole with a multilayer hybrid cover consisting of at least an adhesive layer and a covering material.

[0012] The problem is solved according to the invention by the features of the independent claim. Advantageous embodiments of the invention are specified in the dependent claims.

[0013] The invention provides a device for joining a 3D-printed orthopedic shoe insole to a multilayer hybrid cover consisting of at least an adhesive layer and a covering material. The device comprises a heating device, a pressing device, and a control device. In a joining process, the device is configured to heat a multilayer hybrid cover consisting of at least an adhesive layer and a covering material using the heating device, particularly without contact, and to press it onto a 3D-printed orthopedic shoe insole using the pressing device. The control device is configured to individually control the heating device and / or the pressing device for each joining process and to automatically join the orthopedic shoe insole and the hybrid cover upon receiving a trigger signal SF. BÖWO-2025-09010, WODE-Text

[0014] - 3 -

[0015] The 3D-printed orthopedic shoe insert and the multi-layered hybrid blanket will both be referred to individually as semi-finished products in the following.

[0016] In addition to the adhesive layer and the cover material, the multi-layered hybrid cover can also have further layers, such as a cushioning layer. The multi-layered hybrid cover is sealed on one side, with a downward-facing adhesive layer in relation to the orientation of the shoe insole during use. This adhesive layer is designed to create a bond with the orthotic shoe insole. The multi-layered hybrid cover can also consist of several components that are initially placed in the device without being bonded to each other. These components are then bonded together by the device along with the 3D-printed orthotic shoe insole.

[0017] The device has the advantage that, similar to a manual connection, it can individually accommodate the pronounced surface contours typically found in orthopaedic shoe insoles. The contact pressure of the pressing device can be individually adjusted for each connection process. The device is not designed for mass production; rather, the control system is configured to individually control the heating device and the pressing device—that is, at least one of these devices—for each connection process.

[0018] The device only connects the multi-layered hybrid ceiling upon a trigger signal SF, so that after each connection process it is possible to define individual, i.e., possibly different from the previous connection process, connection process-specific manufacturing parameters for the next connection process.

[0019] Furthermore, the connection process is carried out automatically by the device, i.e., without any user intervention. This eliminates the need for the user to perform demanding and time-consuming tasks, as manually applying a single-sided adhesive, sometimes only moderately flexible, hybrid ceiling to a highly curved, often or usually BÖWG-2025-09010, WODE-Text

[0020] - 4 - A concave surface, which may also exhibit convex curves in certain sections, presents a technically demanding challenge. This is often further complicated by the fact that the adhesive layer of the hybrid ceiling is usually only activated by heating, and the hybrid ceiling must be applied while hot.

[0021] By individually configuring the joining process-specific manufacturing parameters, particularly the contact pressure of the press, these parameters can be selected depending on the inserted 3D-printed orthopedic shoe insole. This allows the height profile or bulges of the orthopedic shoe insole to be partially reduced, but not completely flattened. The contact pressure can be adjusted to prevent permanent plastic deformation of the orthopedic shoe insole. The term "height profile" or "profile" of a shoe insole or other surface refers to its height relative to a specific point on a base.

[0022] A reduction in the height profile, even if only partial, preferably achieved by compressing the insole within an elastic area that does not plastically deform the 3D-printed orthopedic insole, significantly facilitates the bonding of the orthopedic insole to the hybrid cover. The pressing device can include a die, particularly a contoured die, by means of which the hybrid cover can be pressed onto the orthopedic insole over a larger area compared to manual methods. The compression and / or contact pressure can be set, for example, depending on the height profile and / or a die profile, such that no plastic deformation of the 3D-printed orthopedic insole occurs.The compression and / or contact pressure is advantageously determined individually based on the properties of the individual shoe insole, possibly in conjunction with the properties of the stamp. The properties of the stamp may depend, for example, on its contour, its height profile, particularly across a contact surface, or the elasticity of the stamp material. BÖWO-2025-09010, WODE-Text.

[0023] - 5 -

[0024] The stamp can be advantageously unheated. An unheated stamp offers the benefit of virtually eliminating the risk of plastic deformation of the 3D-printed orthopedic shoe insole due to heat exposure.

[0025] In an advantageous embodiment of the device, operator interaction is required between two connection processes. Only through operator interaction is a new connection process initiated, which starts an individual process for each application of an orthopaedic shoe insole to a hybrid cover. This mandatory interaction by a human user constitutes an interruption that allows for the input of parameters or at least the manual or manually initiated insertion of the orthopaedic shoe insole and hybrid cover, while simultaneously preventing automatic continuation with a subsequent connection process.

[0026] Advantageously, the device can be configured to heat the multi-layered hybrid blanket, consisting of at least an adhesive layer and a covering material, without contact, particularly by means of radiant heat. Unlike, for example, heating an adhesive layer on an orthopedic shoe insole using a heated stamp, contactless heating offers the advantage that the entire surface of the hybrid blanket can be heated uniformly, regardless of pressure peaks caused by the profile of the orthopedic shoe insole.

[0027] Furthermore, the hybrid blanket can be heated independently of the orthotic insole. Within the device's capabilities, the location for heating the hybrid blanket is freely selectable; contact between the hybrid blanket and the orthotic insole is not required for contactless heating.

[0028] Advantageously, the device can be designed as a tabletop unit, with a base area having a length of less than three, in particular two and a half, English feet, and a width, also referred to as depth, of BÖWQ-2025-09010, WODE-Text

[0029] - 6 - less than one and a half, in particular less than one English foot. As a tabletop device, it will preferably be oriented with its longer side parallel to the front edge of a table or workbench, so that the dimension given as width corresponds to a depth.

[0030] Furthermore, the device can advantageously be designed to be less than three feet high. Such a device has the advantage of being space-saving and suitable for placement on an orthopaedic shoemaker's workbench.

[0031] In an advantageous embodiment of the device, the pressing device is configured to exert a vertical, and in particular exclusively vertical, contact pressure on a hybrid cover resting on the orthopaedic shoe insole, especially free from lateral or transverse movements. A pressing process free from forces transverse to a vertical axis has the advantage, for example, that a non-planar height profile of a 3D-printed orthopaedic shoe insole is not subjected to transverse forces that would otherwise occur, particularly on inclines in the height profile.

[0032] In an advantageous embodiment of the device, the pressing device includes a punch for transmitting or for transmitting and distributing a pressing pressure onto a hybrid cover resting on the orthopedic shoe insole. Advantageously, a pressing pressure from an output of a pressing device, for example a piston or a spindle, can be distributed from a pressure surface of the output, i.e., for example, the piston or the spindle rod, onto a larger surface of a punch.

[0033] In an advantageous embodiment, the device includes means for documentation, in particular of individually defined manufacturing parameters. The device may, for example, include a documentation device and / or a communication interface for transferring data to an external device, in particular a computer device such as a server or a smartphone, or an external storage medium such as an external hard drive, for the purpose of external documentation. BÖWO-2025-09010, WODE-Text

[0034] - 7 -

[0035] In a further advantageous configuration, the device features an input / output device for the input – particularly manual – and / or display of individual, connection-process-specific manufacturing parameters. The input / output device can be implemented, for example, as a display, possibly in combination with a push button or rotary switch, or, in particular, as a touchscreen. A manual input / output device allows for individual settings to be made and enables the device to operate independently, without additional equipment.

[0036] The device's control unit is configured to individually control the heating device and the pressing device for each joining process. Furthermore, an individual joining process can include individual, joining-process-specific manufacturing parameters. In an advantageous embodiment, the joining process is based on one or more individual, joining-process-specific manufacturing parameters, wherein the individual, joining-process-specific manufacturing parameters include one or more parameters from the groups

[0037] • Material parameters, where the group includes parameters such as raw material, material manufacturer, date of manufacture, and production batch.

[0038] • Pressing parameters, where the group includes parameters such as contact pressure, pressing duration,

[0039] • Heating parameters, where the group includes parameters such as heating power, heating duration, target temperature, and cut-off temperature;

[0040] • Relief parameters, wherein the group includes parameters that describe the structure and / or characteristics of a height profile of an orthopaedic shoe insole,

[0041] • Stem pel para meter, wherein the group includes parameters that describe the structure and / or characteristics of the ram of the press device, such as elasticity or height profile,

[0042] • Workshop parameters, where the group includes parameters such as orthopedic workshop, contact details, employee, device identification number, transaction number, date, and time. BÖWG-2025-09010, WODE text

[0043] - 8 -

[0044] Parameters from the material group can be used to derive heating and / or pressing parameters, or to verify existing ones. Furthermore, they can serve to document manufacturing parameters for an orthopedic shoe insole.

[0045] Parameters from the group "Press parameters" can be used for the control device or for individual control of the press device by the control device.

[0046] Parameters from the group "Heating parameters" can be used for the control unit or for individual control of the heating device by the control unit.

[0047] Parameters from the Relief Parameters group can describe features of the structure and / or the height relief of a 3D-printed orthopedic shoe insole. The latter can be described, for example, by specific, identifying markers. Alternatively, it can be the printing data of the 3D-printed orthopedic shoe insole, thus providing the device with detailed information about the structure of the shoe insole, in particular the height profile across the surface and / or layer thicknesses.

[0048] Parameters from the group of stamp parameters can be used to calculate an expected pressure distribution, especially if the stamp is elastic and / or has inhomogeneities and / or contours.

[0049] Parameters from the workshop parameters group can be used to document manufacturing parameters for an orthopedic shoe insole.

[0050] Advantageously, the device is designed such that the heating device and / or the pressing device can be controlled based on at least one individual, joining-process-specific manufacturing parameter from the groups of pressing parameters or heating parameters. BÖWG-2025-09010, WODE-Text

[0051] - 9 -

[0052] Furthermore, the device can be set up in such a way that a heating parameter for controlling the heating device is determined based on parameters from the group material and / or a pressing parameter for controlling the pressing device is determined based on parameters from the groups punch parameters and / or relief parameters.

[0053] By individually defining one or more joining process-specific manufacturing parameters from these two groups, an automatic joining of an orthopedic shoe insole with a hybrid cover can be achieved despite the diversity of the semi-finished products.

[0054] In particular, the device can be configured so that, when controlling the press, the pressure applied is determined based on the height profile of the 3D-printed shoe insole in conjunction with the height profile of a press die. For example, the expected point-to-point deformations across a surface when a die with a height profile that differs from that of the shoe insole is pressed against the insole can be calculated in advance, and the maximum permissible pressure for non-plastic deformation can be determined.

[0055] Furthermore, the device can advantageously include a communication module through which the device can be controlled and / or individual manufacturing parameters specific to the connection process can be entered and / or output. This can be used, for example, to receive external trigger signals during remote control, or to send or receive individual manufacturing parameters specific to the connection process.

[0056] In an advantageous embodiment, the control device is configured, particularly internally, to determine an individual, joining-process-specific manufacturing parameter, in particular a pressing parameter, in particular a contact pressure, and / or a heating parameter individually for each joining process, BÖWO-2025-09010, WODE-Text

[0057] - 10 - in particular to calculate, and / or it has an interface for communication with a computer device configured to communicate with the device, and is configured to receive manufacturing parameters determined externally in this way, in particular those calculated externally. Advantageously, the control device may have a microprocessor and be configured to execute computer program code.

[0058] In an advantageous configuration, the communication module is designed to communicate with a smartphone. Such a configuration offers a communication option with a widely used communication device featuring standardized communication interfaces and only a few variations of operating systems. This, in turn, simplifies the development of corresponding control programs, also known as apps.

[0059] In an advantageous embodiment, the device has a first receptacle for receiving the multilayer hybrid cover and a second receptacle for receiving the 3D-printed orthopedic shoe insole. These receptacles allow for a defined and targeted feeding of the hybrid cover and the orthopedic shoe insole into the device. The hybrid cover and the orthopedic shoe insole are thus located at a defined position known to the device, from which they can be processed and / or manipulated by the device to automatically create the connection between the hybrid cover and the orthopedic shoe insole. The processing and / or manipulation of the hybrid cover and / or the orthopedic shoe insole can advantageously take place within the respective receptacle.

[0060] Advantageously, the device can have a first recess for receiving the multi-layered hybrid ceiling, within which the multi-layered hybrid ceiling is automatically centered, particularly for further processing and / or finishing of the hybrid ceiling.

[0061] Furthermore, the device can advantageously be configured such that the first and / or second receptacle is essentially movable either exclusively translationally along an axis or exclusively about an axis. BÖWO-2025-09010, WODE-Text

[0062] - 11 - are. Such a restriction of the degree of freedom leads to a comparatively low mechanical complexity and thus allows a comparatively simple mechanical design, which permits both a comparatively small and a comparatively cost-effective implementation.

[0063] The first and / or second intake advantageously each have a drive by which they can be moved into different positions, for example to open, in particular controlled by the control device.

[0064] For example, in order to achieve a small volume, in particular a small depth of the device, the device can be designed in such a way that the first receptacle is rotatably or, in particular, even exclusively rotatably movable.

[0065] Advantageously, the rotation radius of the rotatable mount can be less than one, in particular less than 0.75 English feet.

[0066] To securely fix a hybrid ceiling in the first holder against falling out or slipping, particularly during rotation, the device can be designed such that the first holder has an adhesive device for one-sided contact fixing of the hybrid ceiling. Such an adhesive device allows for safe handling of the hybrid ceiling even if it has a full-surface adhesive layer on one side.

[0067] In an advantageous embodiment, the adhesion device can be designed as a suction device. This offers the advantage of being easy to implement for handling a relatively lightweight and flat hybrid ceiling. In a simple embodiment, this can be achieved, for example, by providing the first receptacle with through-holes and configuring it so that a negative pressure, particularly one that can be switched on and off, can act between the hybrid ceiling and the receptacle.

[0068] The adhesive device can advantageously be designed to be so strong that the hybrid blanket can be fixed in the holder even directly against its own weight force. BÖWÖ-2025-09010, WODE-Text

[0069] - 12 - is. In other words, the adhesive device can advantageously be designed to be so strong that the hybrid blanket is held in the first position by the adhesive device even when it is turned upside down.

[0070] For example, for the purpose of targeted, relative positioning of the hybrid cover on the orthopaedic shoe insole, for instance so that an inscription on the hybrid cover is placed at a predetermined location on the orthopaedic shoe insole, the first mount can have a centering device such as a stop for aligning the hybrid cover on the first mount, and / or the second mount can have a centering device for aligning the orthopaedic shoe insole on the second mount.

[0071] For the manual insertion of the semi-finished products, the device can be configured to position the first holder in a loading position, in which the first holder can be loaded with the multi-layer hybrid cover, and / or to position the second holder in an open position, in which the second holder can be loaded with the 3D-printed orthopedic shoe insole. These positions are advantageously designed so that the holders are easily accessible for inserting the semi-finished products, for example, from above, to make inserting and, if necessary, positioning the semi-finished products in the holders as simple as possible.

[0072] The loading position and opening position can be assumed simultaneously or one after the other.

[0073] In an advantageous embodiment of the device, the first receptacle has a receiving surface rotatably mounted about a longitudinal axis. The longitudinal axis can be arranged off-center. In particular, the longitudinal axis can be arranged in an edge region of the receiving surface.

[0074] This design offers the advantage that, when rotated around its longitudinal axis, the receptacle describes a relatively small cylinder of rotation, the radius of which corresponds at most to the width of the receptacle. Since the receptacle is designed to hold a hybrid ceiling for connection with an orthopedic shoe insole, the receptacle can have a surface area of ​​[BÖWG-2025-09010, WODE-Text].

[0075] - 13 - whose length does not exceed 1.5 times the length of an English foot, and whose width is less than 0.75 English feet. If the longitudinal axis is arranged in an area near a surface of a housing of the device, a portion of a theoretically describable rotating cylinder of the receptacle lies outside the housing of the device, so that it is easily accessible from the outside, especially from above. Thus, a position of the receptacle in this area can advantageously be used as a loading position. Furthermore, the portion of the theoretically describable rotating cylinder extending into the housing, with a longitudinal axis arranged near the surface, is also not much more than the width of the receptacle, and in particular, also not much more than 0.75 English feet, comparatively speaking, in relation to the width of the first receptacle.Thus, this design offers the advantage that only a comparatively small installation space, and in particular no comparatively large depth, is required for movement of the first recording.

[0076] Furthermore, a receptacle rotatable about a longitudinal axis offers the advantage that, depending on an angle of rotation, the receptacle can be accessed from different directions for different tasks. In an advantageous embodiment, the device is designed and configured such that a first receptacle rotatable about an axis, in particular a longitudinal axis, assumes different working positions depending on an angle of rotation.

[0077] Depending on the angle of rotation, the first recording can assume various working positions such as a loading position, a heating position, a storage position and / or a release position.

[0078] The second recording can assume different positions, such as a manufacturing position and / or opening position, depending, for example, on the position of a sliding mechanism.

[0079] In advantageous embodiments, the device can be configured

[0080] • to rotate the first inlet into a loading position, in particular into a rotation angle between -90° and the vertical or 0°, preferably in BÖWO-2025-09010, WODE-Text

[0081] - 14 - a rotation angle between -20° and -45° in which the first receptacle for loading with a hybrid blanket is rotated out of a housing surface of the device,

[0082] • to rotate the first recording into a heating position, in particular into the vertical position, i.e. into a rotation angle of 0°, in particular in which the recording is arranged parallel to a heating device or the heating surface of a heating device,

[0083] • to rotate the first recording into a storage position, in particular into the horizontal, i.e. into a rotation angle of 90°, in which the hybrid blanket, in particular held by an adhesive device, can be positioned over an orthopaedic shoe insole, in particular vertically above it,

[0084] » to rotate the first inset into a release position, in particular into a rotation angle between -90° and 0°, into which it can be rotated back from the storage position for a pressing operation.

[0085] In the heating position, the first recess assumes a position in which a hybrid ceiling arranged on the first recess can be heated by a heating device. Advantageously, the multi-layered hybrid ceiling is arranged in the first recess such that the adhesive layer does not come into contact with the device. Advantageously, the hybrid ceiling is inserted into the first recess with the adhesive layer facing upwards in a single loading step.

[0086] A device with a first receptacle in which, particularly in a horizontal orientation, a hybrid ceiling is arranged with the adhesive layer facing upwards, has the advantage that the side of the adhesive layer effective for the intended bond is arranged without contact. Furthermore, this side is freely accessible. In particular, it can be heated without contact by means of radiant heat.

[0087] In an advantageous embodiment of the device, the first receptacle assumes a position in the heating position in which a hybrid ceiling arranged on the first receptacle, and in particular its adhesive layer side, can be heated by a heating device using a radiant heater. BÖWO-2025-09010, WODE-Text

[0088] - 15 -

[0089] This can be, for example, the vertical position in which the support has a rotation angle of 0°, and in which, for example, the receiver can be arranged parallel to a heating device or the heating surface of a heating device.

[0090] Advantageously, the device is configured such that the hybrid ceiling, in the heating position, can be heated by means of thermal radiation at a distance from the heating device. Furthermore, it is advantageous that the hybrid ceiling, in the heating position, can be arranged essentially or preferably parallel to a heating device or the heating surface of a heating device, so that the thermal radiation strikes the adhesive layer of the hybrid ceiling as perpendicularly as possible.

[0091] One advantage of non-contact heating is that the adhesive layer can be heated directly, without passing through other layers of the hybrid ceiling. Furthermore, it avoids the formation of unintended adhesive bonds that could lead to contamination.

[0092] Aligning the first inlet vertically is not strictly necessary, but it offers the advantage that the direction of heat radiation is essentially parallel to other components of the device, such as the stamp, thus preventing unnecessary heating of the latter. Furthermore, such an orientation allows for a simple, right-angled, and therefore cost-effective device design.

[0093] In the release position, the first mounting assumes a position or angle of rotation in which a working area is cleared for pressure, for example by lowering the punch onto the hybrid surface. Advantageously, the angle of rotation of the first mounting for a release position and the angle of rotation of the first mounting for a heating position can be identical.

[0094] Furthermore, the device can be configured to position the hybrid blanket in the deposit position, particularly close to and / or directly over the orthopaedic shoe insole, and to deposit it by deactivating an adhesion device on the orthopaedic shoe insole. BÖWO-2025-09010, WODE-Text

[0095] - 16 -

[0096] Advantageously, the adhesion device can be designed to be deactivated by an electrical switching operation. This can be achieved, for example, by switching off a vacuum, by electrically actuating a shut-off valve, or by switching off a device for generating a vacuum.

[0097] In an advantageous embodiment of the device, the pressing device can be arranged outside, and in particular above, a rotational area of ​​the first receptacle. An actuating element of the pressing device, for example a piston or a spindle rod, can include a punch which can be brought towards, and in particular lowered towards, the multi-layered hybrid cover, and wherein the multi-layered hybrid cover can be pressed by the punch onto the orthopaedic shoe insole in the second receptacle.

[0098] The pressing device can be set up to press the multi-layered hybrid cover onto the 3D-printed orthopedic shoe insole with an individual pressure or with an individual pressure and for an individual duration.

[0099] In an advantageous embodiment of the device, the second receptacle features a horizontal extension. The device can be configured to position the second receptacle in an open position for loading and a manufacturing position for joining the 3D-printed orthopedic shoe insole to the hybrid ceiling. A horizontal extension offers the advantage of being easily designed to handle relatively heavy loads, for example, as a heavy-duty extension or as a rail-mounted carriage. Such a design is advantageous for safely dissipating forces from the pressing device acting on the second receptacle in a manufacturing position.

[0100] Furthermore, the device can include a starting device, in particular one or at least one electrical push button, for generating the trigger signal SF. In a special embodiment of the starting device, it can also include several, in particular two, push buttons, which are spaced apart from each other on the device and which generate the BÖWO-2025-09010, WODE-Text

[0101] - 17 -

[0102] Both buttons must be activated simultaneously. Spacing the buttons apart, for example by more than a hand's width, reduces the risk of injury, as both hands are required by the operator to generate the trigger signal SF.

[0103] In an advantageous embodiment, the device has one or more loading sensors for detecting the presence of a hybrid blanket and / or an orthopedic shoe insole in the device. These offer the possibility of checking the loading of the fixtures with the corresponding semi-finished products, in order to prevent, for example, a blank start of the device.

[0104] Furthermore, the device can include pressure sensors to detect the height of a contact pressure from the hybrid ceiling onto the 3D-printed orthopedic shoe insole.

[0105] A stamp can have multiple pressure sensors distributed across its surface. These sensors can detect the pressure exerted by the stamp on the hybrid cover, particularly at specific points or in localized areas, and thus the pressure exerted by the hybrid cover on the 3D-printed shoe insole, particularly at specific points or in localized areas.

[0106] Alternatively or additionally, the device can have a force sensor that allows the force exerted by the pressing device to be determined. A measured pressure or force can be transmitted to the control unit. The control unit can be configured to convert a transmitted force value, i.e., a force measurement, into a contact pressure. The control unit can use a predefined or user-defined die area to calculate the contact pressure.

[0107] Alternatively and / or additionally, the control device can use individual parameters of the 3D-printed orthopedic shoe insole to calculate the contact pressure. These individual parameters can be entered, transferred via an interface, or retrieved from a server and / or database, for example, using an identifier. BÖWO-2025-09010, WODE-Text

[0108] - 18 -

[0109] Furthermore, the control device can be configured to determine, for example, the expected pressure distribution across the surface of the 3D-printed orthotic insole. A height profile of the 3D-printed orthotic insole across its surface can be taken into account. Alternatively and / or additionally, a height profile of the die can be used. Furthermore, an inhomogeneous structure of the 3D-printed orthotic insole and / or the die can be considered. In particular, it can be taken into account that the materials of the insole and / or the die may exhibit different elastic properties across the surface. For example, the insole and / or die may be multi-layered, with the layers exhibiting different elastic properties and / or varying layer thicknesses across the surface.

[0110] The control device can be configured to determine, for example, an expected pressure distribution over the surface of the 3D-printed orthopedic shoe insole based on the parameters described above.

[0111] Furthermore, the control device can be configured, particularly before the pressing process, to calculate an individually adjustable contact pressure distribution depending on a pressing force. It can also be configured to determine a maximum value from the contact pressure distribution. Additionally, it can be configured to determine a maximum pressing force for the pressing device at which no point on the surface of the 3D-printed orthopedic shoe insole exceeds a threshold value for a contact pressure calculable from the contact pressure distribution. This threshold value can be below a contact pressure at which plastic deformation of the 3D-printed insole occurs. In particular, the threshold value can correlate with a pressure at which plastic deformation of the 3D-printed orthopedic shoe insole just barely does not occur.

[0112] The control device may be configured to determine and / or calculate, for example, an expected contact pressure distribution or an individually permissible contact pressure, either by itself or externally, by BÖWO-2025-09010, WODE-Text

[0113] - 19 - is carried out on a computer device connected to it via a communication interface, for example a smartphone.

[0114] Furthermore, the device may have one or more pressure and / or force sensors for detecting and / or determining the magnitude of a force exerted by the pressing device and / or acting on the second receiving device.

[0115] Furthermore, in an advantageous embodiment, the device can include a temperature sensor, in particular a non-contact temperature sensor, for measuring a surface temperature on the hybrid ceiling.

[0116] In an advantageous embodiment of the device, the device has smart features to support individual, connection process-specific manufacturing with changing manufacturing parameters.

[0117] Advantageously, the device can be configured to determine one or more individual, joining-process-specific manufacturing parameters using an identifier. This can be done, for example, by retrieving individual, joining-process-specific manufacturing parameters from a database using the identifier.

[0118] The device may include a detection unit for capturing the identifier. This unit may be configured to capture an identifier assigned to the orthopedic shoe insert and / or an identifier assigned to the hybrid blanket and, for example, transmit this identifier to the control unit.

[0119] Alternatively and / or additionally, a corresponding identifier can also be entered manually, in particular by means of the input / output device.

[0120] Furthermore, the identifier can be implemented, for example, as a character string, color code, barcode, 2D code, QR code, or in the form of an RFID tag. The associated information, in particular the individual, connection-process-specific manufacturing parameters, can be determined from the identifier in various ways. BÖWO-2025-09010, WODE-Text

[0121] - 20 -

[0122] In a first embodiment, the device is configured to determine joining-process-specific manufacturing parameters from a database using the identifier. In a second embodiment, if, for example, the joining-process-specific manufacturing parameters contain the parameters in the identifier, the device is configured to extract the joining-process-specific manufacturing parameters from the identifier. In a third embodiment, if, for example, the joining-process-specific manufacturing parameters are indirectly contained in the identifier, the device is configured to determine the joining-process-specific manufacturing parameters indirectly from the identifier, for example, using code tables or conversion tables.

[0123] Furthermore, the device can be configured to assign a process number to a connection process, possibly automatically, and to document the connection process and / or manufacturing process, in particular with individual connection-process-specific manufacturing parameters. An automatic manufacturing number can be a sequential number or a manufacturing number generated from manufacturing parameters.

[0124] In an advantageous embodiment of the device, the detection unit is arranged such that it automatically detects the identifier of an orthopedic shoe insole and / or the identifier of a hybrid blanket when it is inserted into the device and / or before the hybrid blanket and orthopedic shoe insole are connected. For this purpose, the identifiers can be, for example, in the form of an RFID tag, and the detection unit can be, for example, an RFID reader. In an advantageous embodiment of the device, such a detection unit can, for example, be arranged between the receptacles, so that the same detection unit can detect the identifiers of both the hybrid blanket and the orthopedic shoe insole.

[0125] In an advantageous embodiment of the device, the control unit is configured to automatically initiate the first recording upon a trigger signal OA1 in BÖWÖ-2025-09010, WODE-Text

[0126] - 21 - to move to a loading position. The device can, for example, be configured to generate the trigger signal OA1 upon the first actuation of a corresponding button during one-button operation.

[0127] Furthermore, the control device can be configured to automatically move the second shutter into the open position upon receiving a trigger signal OA2. The trigger signal OA2 can be generated, for example, by pressing a corresponding button again, or, for instance, together with the trigger signal OA1 for simultaneous opening of both shutters.

[0128] In an advantageous embodiment of the device, the control unit, in particular based on a computer program code or in interaction with an external computer device, in particular a communication terminal device, and upon receipt of corresponding data, is configured to start the connection process and execute the steps upon a trigger signal SF.

[0129] - to move the first recording into the heating position;

[0130] - to move the second take-up into the manufacturing position;

[0131] - to heat the heating device for a predetermined, predeterminable, received, calculated or derivable from an identifier duration with a predetermined, predeterminable, received, calculated or derivable from the identifier heating power, or until a predetermined, predeterminable, received, calculated or derivable from the identifier, in particular on the hybrid ceiling, in particular without contact, is reached;

[0132] - to move the first recording to the storage position;

[0133] - to disable an adhesion device for the first recording;

[0134] - to move the first recording into the release position;

[0135] - to press a stamp of the pressing device onto the second printing plate with a predetermined, predeterminable, received, calculated or determined by the identifier pressure for a predetermined, predeterminable, received, calculated or derivable by the identifier duration;

[0136] - to signal the completion of the connection process and / or to move the second receiver into the open position. BÖWO-2025-09010, WODE-Text

[0137] - 22 -

[0138] Furthermore, the control device can be set up to document individual, connection process-specific manufacturing parameters in a further step.

[0139] In an advantageous embodiment of the device, the die, and in particular its effective die surface, has a non-planar height profile. Typically, the hybrid cover has no height profile; it is usually provided as a flat, multi-layered intermediate product, comprising, for example, an adhesive layer, a cushioning layer, and a cover layer. A flat die thus has the fundamental advantage that the hybrid cover lies flat against the die surface. Unlike an orthopedic shoe insert, an elastic insole of a conventional shoe, which has no or only a relatively shallow height profile, can be temporarily flattened by the die during a bonding process without permanently altering its height profile.

[0140] A stamp with a non-planar height profile has the advantage that leveling of the profile is prevented. However, a device with a stamp with a non-planar height profile has the problem that the height profile of the stamp is fixed, while the height profile of an orthopaedic shoe insert is individual.

[0141] In an advantageous embodiment of the device, the die is interchangeable. The device can be configured to access a set of dies, from which a die can be selected, particularly automatically, depending on the individual height profile of the orthopaedic shoe insole. The device can comprise a set of dies. A set of dies can be arranged within the device itself or externally.

[0142] The device can further be designed in such a way that it is configured to replace the stamp automatically. BÖWO-2025-09010, WODE-Text

[0143] - 23 - and / or to submit or indicate a proposal for the use of a stamp for the purpose of, in particular, manual, exchange.

[0144] Furthermore, the device can be configured so that an exchange occurs manually or automatically depending on the detection of an identifier, in particular a manually or automatically detected identifier. For example, a device that automatically detects an identifier of the orthopedic shoe insole and / or identifiers of the orthopedic shoe insole and hybrid cover can be configured to inform a user, based on the identifier(s), which punch from a set of punches should be selected. Simultaneously, an individual contact pressure for the joining process can also be made dependent on the punch, in particular on its suitability for the pressing process, for example, due to any remaining deviations of the height profile compared to that of the orthopedic shoe insole.

[0145] In an advantageous embodiment of the device, the die is made up of multiple parts; in particular, the die can have an upper and a lower shell. A lower shell with a contoured profile offers the advantage of providing static support from below to the arch of an orthopedic shoe insole during a pressing process. This allows the forces acting on the orthopedic shoe insole to be distributed over a larger surface area. Furthermore, deformation of the orthopedic shoe insole can be reduced, or the pressure exerted by an upper shell of the die can be increased to achieve a comparatively uniform deformation.

[0146] Furthermore, it is advantageous for the stamp to have a multi-layered structure and / or several layers with different hardness or elasticity. Additionally or alternatively, in a multi-part design, an upper or lower part of the stamp can have a multi-layered structure and / or several layers with different hardness or elasticity.

[0147] The stamp is advantageously designed such that it forms a first layer with high elasticity towards the semi-finished product compared to a second layer. BÖWO-2025-09010, WODE-Text

[0148] - 24 - or low hardness, and towards the device has a second layer with comparatively low elasticity or high hardness.

[0149] A multi-layered, especially a two-layered, construction offers the advantage that pressure on particularly raised areas in the height profile of the orthopedic shoe insole can be reduced, or distributed over a larger area, especially less raised areas of the orthopedic shoe insole. From the perspective of the stamp, this means that point loads acting on the first layer will be distributed evenly within the first layer towards the adjacent layer, resulting in lower pressure peaks on the adjacent layer compared to the first layer.

[0150] Conversely, from the perspective of the orthopaedic shoe insole, pressure peaks can be reduced to particularly raised areas in the height profile of the orthopaedic shoe insole.

[0151] This, in turn, makes it possible, within certain limits, to use the same die to connect different orthopaedic shoe insoles, each with an individually tailored height profile, to a hybrid cover. Since, for example, the left and right feet of a person are generally structurally similar, the device can have a die that is shaped symmetrically to the longitudinal axis.

[0152] In a multi-layered, particularly two-layered, design of the punch, especially in a multi-layered, particularly two-layered design of its upper and / or lower shell, a first layer, particularly the layer with high elasticity or low hardness, can have a Shore value of 15 to 25. The layer with low elasticity or high hardness can preferably have a Shore value of 26 to 45.

[0153] In a preferred embodiment, the device has a punch made of foamed polyurethane. Such an embodiment is characterized by relatively high heat resistance and relatively good resilience, making the punch relatively resistant to permanent deformation. BÖWO-2025-09010, WODE-Text

[0154] - 25 -

[0155] The properties, in particular the elasticity, of the stamp, a height profile of the orthopedic shoe insert and a contact pressure of the pressing device are interrelated, so that the device, in particular the control device, is advantageously designed to derive individual, joining process-specific manufacturing parameters from these parameters.

[0156] The characteristics of the stamp can also be captured manually via the input / output device or automatically via the same or another capture device.

[0157] This document also describes a stamp for joining a 3D-printed orthopedic shoe insole with a multi-layered hybrid cover made of at least an adhesive layer and a covering material, wherein, to create the connection, a multi-layered hybrid cover made of at least an adhesive layer and a covering material is pressed onto the 3D-printed orthopedic shoe insole by means of the stamp, and wherein the stamp has one or more of the features of the stamp of the device described above.

[0158] Furthermore, the invention relates to a method for connecting a 3D-printed orthopedic shoe insole with a multilayer hybrid cover consisting of at least an adhesive layer and a covering material, wherein the method comprises one or more of the method steps for which the aforementioned device is set up, and / or wherein the method is carried out with the aforementioned device for connecting a 3D-printed orthopedic shoe insole with a multilayer hybrid cover.

[0159] Furthermore, the invention relates to an arrangement comprising the aforementioned device for connecting a 3D-printed orthopedic shoe insole with a multilayer hybrid cover and a computer device, in particular a communication terminal, especially a smartphone. BÖWO-2025-09010, WODE-Text

[0160] - 26 -

[0161] The communication terminal can be, for example, an input / output terminal, a tablet PC, or, in particular, a smartphone. Furthermore, the device can have a communication module and be configured to communicate with the computer device, in particular a communication terminal, wherein the computer device, in particular the communication terminal, can have a control program, also referred to as an app, which is configured to control the device and / or to determine, ascertain, or calculate individual, connection-process-specific manufacturing parameters, and / or to transmit or send and / or receive, and / or document them.

[0162] Drawings

[0163] The invention is explained in more detail below with reference to the attached schematic drawings and a preferred embodiment.

[0164] They show

[0165] Fig. 1 shows a schematic sketch of an embodiment of a device for connecting a 3D-printed orthopedic shoe insole to a multi-layered hybrid cover in perspective view;

[0166] Fig. 2 is a schematic sketch of the embodiment, wherein the rotatable first receptacle of the device is in a heating position;

[0167] Fig. 3 is a schematic sketch of the embodiment, wherein the rotatable first receptacle of the device is in a storage position; BÖWO-2025-09010, WODE-Text

[0168] - 27 -

[0169] Fig. 4 is a schematic sketch of the embodiment during a pressing process.

[0170] Fig. 1 shows a sketch of an embodiment of the device 1 in perspective view.

[0171] Fig. 1 shows a device 1 for joining a 3D-printed orthopedic shoe insole 2 with a multi-layered hybrid cover made of at least an adhesive layer and a covering material, wherein the device 1 has a heating device 3, a pressing device 4 and a control device.

[0172] The device 1 is set up to heat a multi-layered hybrid blanket made of at least an adhesive layer and a covering material in a contactless joining process using the heating device 3 and to press it onto a 3D-printed orthopedic shoe insole 2 using the pressing device 4.

[0173] Furthermore, the control device is set up to individually control the heating device 3 and the pressing device 4 for each connection process and to automatically connect the orthopedic shoe insert 2 and the hybrid blanket upon a trigger signal SF.

[0174] The device 1 has a first receptacle 7 for receiving the multi-layered hybrid cover and a second receptacle 8 for receiving the 3D-printed orthopedic shoe insole 2. For aligning the hybrid cover on the first receptacle 7, the latter has a centering device in the form of a stop 10.

[0175] The first mounting 7 is rotatably movable exclusively about an axis 12, specifically a longitudinal axis 10 located in an edge region of the first mounting 7, wherein the radius of rotation of the rotatably movable first mounting 7 is less than one English foot. To fix the hybrid ceiling to a mounting surface of the first mounting 7, the first mounting 7 has an adhesive device (not shown here), which is configured BÖWÖ-2025-09010, WODE-Text

[0176] - 28 - is to create a negative pressure under the hybrid ceiling. The first intake 7 is shown in Fig. 1 in a loading position in which the receiving surface of the first intake 7 has a rotation angle of approximately -30° relative to the vertical and is rotated out of a housing surface of the device 1 for loading with a hybrid ceiling.

[0177] The first mounting 7, which is rotatable about a longitudinal axis 10, is designed to assume different working positions by rotating about the longitudinal axis 10 depending on a rotation angle.

[0178] The second receptacle 8 is designed as a movable carriage. This carriage, which moves on rails and resembles a drawer or horizontal extension, can be manually extended from the device 1 into an open position for loading the receptacle 8 by means of a handle. The second receptacle 8 is shown in its open position in Fig. 1 with an orthopaedic shoe insert 2 positioned on it.

[0179] In a position of the second receptacle 8 shown in Fig. 2, it is inserted into or closed in the device 1, in which position it assumes the manufacturing position.

[0180] Fig. 2 shows a sketch of an embodiment of the device 1 with the first 7 and second receptacle 8 closed, the first receptacle 7 being in the heating position. The receiving surface of the first receptacle 7 is rotated into the heating position, here the vertical, in which it is aligned parallel to a heating device 3 arranged on the rear inner surface of the housing of the device 1.

[0181] Fig. 3 shows a sketch of an embodiment of the device 1, the first receptacle 7 of which is in the storage position. The receiving surface of the rotatable first receptacle 7 is rotated horizontally by an angle of +90°, in which the hybrid blanket, in particular held by the adhesion device (not shown here), can be positioned above the orthopaedic shoe insole 2, in particular vertically above it, so that the hybrid blanket can be positioned when the adhesion device is deactivated by moving it back a BÖWO-2025-09010, WODE-Text

[0182] - 29 - comparatively short fall distance on the orthopaedic shoe insole 2 is placed.

[0183] Fig. 4 shows a sketch of the embodiment of the device 1 during a pressing process, in which the rotatable first receptacle 7 - not shown here for the sake of clarity - is turned back into the vertical position.

[0184] The embodiment of the device 1 has a punch 5 above a rotation area of ​​the first receptacle 7, which is lowered onto the multilayer hybrid cover in Fig. 4 and presses the multilayer hybrid cover onto the orthopaedic shoe insert 2 on the second receptacle 8.

[0185] As further shown in Figures 1-4, the exemplary embodiment has an input / output device 6 for entering and displaying individual, connection-process-specific manufacturing parameters. Furthermore, two electrical pushbuttons 11 are shown, the simultaneous pressing of which can start the pressing process, or, with a suitably configured control device and driven first receptacle 7, the complete connection process.

[0186] The starting device is designed in the form of two pushbuttons 11, which are arranged on the device 1 more than a hand span apart, and which must be actuated simultaneously to generate the trigger signal, so that both hands of an operator are required to generate the trigger signal SF.

Claims

BÖWG-2025-09010, WODE-Text - 30 - Claims 1. Device (1) for joining a 3D-printed orthopedic shoe insole (2) with a multi-layered hybrid cover made of at least an adhesive layer and a covering material, characterized in that the device (1) has a heating device (3), a pressing device (4) and a control device, and the device (1) is configured to heat a multi-layered hybrid cover made of at least an adhesive layer and a covering material by means of the heating device (3) and to press it onto a 3D-printed orthopedic shoe insole (2) by means of the pressing device (4) in a joining process, wherein the control device is configured to control the heating device (3) and the pressing device (4) individually for each joining process and to automatically join the orthopedic shoe insole (2) and the hybrid cover upon a trigger signal SF.

2. Device (1) according to claim 1, characterized in that an individual joining process is carried out on the basis of one or more individual, joining process-specific manufacturing parameters, and the joining process-specific manufacturing parameters are one or more parameters from the groups - Material parameters, where the group includes parameters such as raw material, material manufacturer, date of manufacture, and production batch. - Pressing parameters, where the group includes parameters such as contact pressure, pressing duration, - Heating parameters, where the group includes parameters such as heating power, heating duration, target temperature, and cut-off temperature, BÖWG-2025-09010, WODE-Text - 31 - - Relief parameters, wherein the group includes parameters that describe the structure and / or features of the height profile of an orthopaedic shoe insole (2), - Stem pel para meter, wherein the group includes parameters that describe the structure and / or characteristics of a punch (5) of the press device (4) such as elasticity or height profile, - Workshop parameters, where the group includes parameters such as orthopedic workshop, contact details, employees, transaction number, date, time.

3. Device (1) according to claim 2, characterized in that the device (1) is configured such that a heating parameter for controlling the heating device (3) is determined based on parameters from the group material and / or a pressing parameter for controlling the pressing device (4) is determined based on parameters from the groups punch parameters and / or relief parameters 4. Device (1) according to one of the preceding claims, characterized in that the device (1) is configured such that when the press device (4) is controlled, the height of a contact pressure is determined on the basis of a height profile of the 3D-printed shoe insole (2) in conjunction with a height profile of a punch (5) of the press device (4).

5. Device (1) according to one of the preceding claims, characterized in that the control device is configured to determine, in particular calculate, an individual, joining-process-specific manufacturing parameter, in particular a pressing parameter, in particular a contact pressure, and / or a heating parameter individually for each joining process, and / or that it has an interface for communication with a computer device configured for communication with the device (1), and is configured to determine, in particular calculate, such externally determined parameters, in particular parameters calculated externally. BÖWO-2025-09010, WODE-Text - 32 - To receive manufacturing parameters.

6. Device (1) according to one of the preceding claims, characterized in that the device (1) has a first receptacle (7) for receiving the multilayer hybrid cover, and a second receptacle (8) for receiving the 3D-printed orthopaedic shoe insole (2).

7. Device (1) according to claim 6, characterized in that the first receptacle (7) has an adhesion device for fixing the hybrid ceiling by contacting it on one side.

8. Device (1) according to claim 6 or 7, characterized in that the first receptacle (7) is rotatably movable and a radius of rotation of the rotatably movable receptacle (7) is less than one, in particular less than 0.75 English feet.

9. Device (1) according to one of claims 6 to 8, characterized in that the device (1) is arranged such that a first receptacle (7) rotatable about a longitudinal axis (10) is designed to assume different working positions by rotating about the longitudinal axis (10) depending on an angle of rotation.

10. Device (1) according to one of claims 7 to 9, characterized in that the pressing device (4) has a punch (5) arranged outside, in particular above, a rotation area of ​​the first receptacle (7), which can be lowered onto the multilayer hybrid cover and wherein the multilayer hybrid cover can be pressed onto the orthopaedic shoe insert (2) in the second receptacle (8) by the punch (5), in particular by means of an electric spindle or pneumatically.

11. Device (1) according to one of the preceding claims, characterized in that the device (1) has a detection device for detecting an identifier. BÖWO-2025-09010, WODE-Text - 33 - 12. Device (1) according to claim 11 , characterized in that the identifier is designed as a string of characters, color code, barcode or barcode, 2D code, as a QR code or in the form of an RFID tag.

13. Device (1) according to one of the preceding claims 7 to 12, characterized in that the control device is configured, in particular on the basis of a computer program code or in interaction with an external computer device, in particular a communication terminal device, and upon receipt of corresponding data, to start the connection process and execute the steps upon a trigger signal SF - to move the first recording (7) into a heating position; - to move the second intake (8) into a manufacturing position; - to heat the heating device (3) for a predetermined, predeterminable, received, calculated or derivable from an identifier according to claim 11 duration with a predetermined, predeterminable, received, calculated or derivable from the identifier heating power, or until a predetermined, predeterminable, received, calculated or derivable from the identifier, in particular measured on the hybrid ceiling, temperature is reached, in particular without contact; - to move the first recording (7) to a storage position; - to deactivate the adhesion device of the first recording (7); - to move the first recording (7) into a release position; - to press a punch (5) of the pressing device (4) onto the second printing plate with a predetermined, predeterminable, received, calculated or determined by the identifier pressure for a predetermined, predeterminable, received, calculated or derivable by the identifier duration; - to signal the completion of the connection process and / or to move the second receptacle (8) into an open position.

14. Method for connecting a 3D-printed orthopaedic shoe insole (2) with a hybrid blanket, characterized in that the method is carried out with a device (1) according to one of the preceding claims. BÖWO-2025-09010, WODE-Text - 34 - 15. Arrangement comprising a device (1) according to one of the preceding device claims and a computer device, in particular a communication terminal, in particular a smartphone or a tablet PC, wherein the device (1) has a communication module and is configured to communicate with the computer device, in particular a communication terminal, and wherein the computer device, in particular the communication terminal, has a control program configured to control the device (1) and / or to transmit and / or document individual connection process-specific manufacturing parameters.

Images