Dual-Layer Orthopedic Foot Appliance with Re-attachable Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current footwear and insoles fail to provide customizable optimal cushioning and support, leading to discomfort and biomechanical issues due to mass production methods that do not account for individual foot variations, especially with aging and changing foot conditions, resulting in inadequate shock absorption and support.
Innovation Solution
A dual-layer orthopedic foot appliance using slow recovery memory foam with varying densities and a re-attachable support component made from materials like polyethylene and polypropylene, allowing for customizable arch, heel, and motion control, adaptable to different foot shapes and needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mass production methods are used for insoles, then manufacturing cost is reduced and productivity is improved, but customization capability deteriorates and comfort deteriorates due to inability to account for individual foot variations
Solution Approach 1:
The insole is divided into multiple layers with distinct functions: a cushioning layer for shock absorption and a support layer for structural integrity. This segmentation allows each layer to be optimized independently for mass production while the combination provides customized comfort and support characteristics.
Solution Approach 2:
The insole uses composite construction combining different materials with complementary properties - a soft cushioning material layer paired with a firmer support layer. This composite structure enables mass-produced insoles to deliver customized-like comfort and support without requiring individual customization of each component.
2Ease of operation
If custom orthotics are made for each individual, then comfort is improved and support is optimized, but manufacturing cost increases and productivity decreases
Solution Approach 1:
By separating the insole into independent cushioning and support layers that can be mass-produced separately, the system achieves custom orthotic-like comfort through standardized components, eliminating the need for time-consuming individual customization while maintaining high comfort levels.
Solution Approach 2:
The invention varies material parameters (density, firmness, thickness) within the mass-produced layers to create different comfort and support characteristics, allowing a single production line to generate multiple comfort levels without individual customization, thus maintaining productivity while improving ease of operation.
3Ease of manufacture
If single-density foam is used in insoles, then manufacturing is simplified and cost is reduced, but shock absorption deteriorates and comfort deteriorates due to inability to provide varying support levels
Solution Approach 1:
The foam structure is segmented into multiple layers with different density characteristics. This segmentation enables each layer to perform specific functions (cushioning vs. support) that collectively provide superior shock absorption, while the modular design keeps manufacturing relatively simple compared to creating fully customized density distributions.
Solution Approach 2:
The insole combines foam materials with different density values in a layered composite structure. This composite approach allows the product to exhibit both soft cushioning properties and firm support properties simultaneously, achieving effective shock absorption while maintaining manufacturing feasibility through standardized material selection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The appliance provides self-customizable comfort, cushioning, and shock absorption, dynamically adapting to each step, offering additional support and motion control as needed, addressing the limitations of mass-produced insoles and custom orthotics in terms of cost and adaptability.
Implementation Method 1
an upper layer constructed from slow recovery memory foam comprising billions of high density visco-elastic memory cells
Implementation Method 2
providing dynamic impact compression that rebounds with each step of the walking cycle
Implementation Method 3
slow recovery memory foam comprising billions of high density visco-elastic memory cells having a first thickness and first high density
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An orthopedic foot appliance (10) providing optimal and adaptable comfort and shock absorption while at the same time varying degrees of heel support, arch support and motion control depending on the foot type and footwear. The orthopedic foot appliance consists of a cushioning insole (12, 14) and a re-attachable support piece (16) for attaching and re-attaching to the insole. The insole includes a trim line (52) allowing the insole to be adapted to a three quarters length of a full insole. The three quarters length may extend form from the back of the heel to the metatarsal heads. The support component may be constructed from any of a group of materials including polyethylene, polypropylene and polypropylene incorporating glass or silica.