Footwear Midsole with Integrated Orthotic Support Structure

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Solution Overview

Problem

Footwear often lacks proper support, especially for individuals with foot ailments, and removable orthotic inserts can be misplaced, dislodged, or misaligned, limiting their effectiveness.

Innovation Solution

Incorporating an orthotic support within the sole assembly of footwear, using a soft and flexible material to secure the orthotic in place, which can be tailored to fit specific foot shapes or ailments, and optionally including a shank for added rigidity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If removable orthotic inserts are used, then wearers can switch inserts between footwear, but the inserts can be easily misplaced, lost, or dislodged during use

Engineering Contradiction:

Improveswitchability of orthotic insertsVSAvoidretention of orthotic inserts

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The orthotic insert is integrated into the footwear structure by being received within a recess in the insole and secured with adhesive. This merging of the removable insert with the footwear structure resolves the contradiction by providing both the adaptability of having an orthotic component and the reliability of it being securely retained, eliminating the risk of loss or dislodgement while maintaining the ability to replace the entire insole assembly.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If orthotic inserts are designed to fit generic footwear, then they can be universally applied, but they cannot provide customized support for specific foot ailments or shapes

Engineering Contradiction:

Improveuniversal fit of orthotic insertsVSAvoidcustomization of orthotic support

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The orthotic insert is designed with differentiated regions including a heel cup with specific curvature, an arch support portion with tailored curvature, and a forefoot portion. Each region has locally optimized geometry and material properties to provide customized support for specific foot areas, resolving the contradiction by enabling both universal application through the standardized insole interface and customization through region-specific design features.

Inventive Principle:

Principle #3Local quality

3Reliability

If orthotic inserts are made with sufficient height to provide proper support, then foot support is improved, but they cannot fit into the foot compartment of standard footwear

Engineering Contradiction:

Improvesupport effectiveness of orthoticVSAvoidheight of orthotic insert

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The orthotic insert is nested within the insole structure, which itself is received within the footwear. The insert fits into a recess in the insole, allowing it to provide full support height without increasing the overall footwear volume. This nested arrangement resolves the contradiction by enabling sufficient orthotic height for proper support while maintaining compatibility with standard footwear dimensions.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Reliability

If footwear is made with rigid support structures, then foot support is improved, but the footwear loses flexibility and comfort

Engineering Contradiction:

Improvesupport of footwearVSAvoidflexibility of footwear

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The orthotic insert provides localized rigid support in specific areas (heel cup, arch support) while the surrounding insole material maintains flexibility. The insert is bonded to the insole rather than spanning the entire footwear, allowing the material between and around the insert to remain flexible. This resolves the contradiction by providing rigid support exactly where needed while preserving overall footwear flexibility and comfort.

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP3503756B1Midsole with incorporated orthotic support

Publication Date: 2026.03.11 SUPERFEET WORLDWIDE LLC

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AI summary

A midsole of footwear (22) with an incorporated orthotic (1) support. The midsole includes a soft and flexible member and a more rigid orthotic (1) support. The orthotic (1) support includes a heel cup (10) and an arch support portion (11) that extends forwardly from the heel cup (10). Embodiments produce the midsole by positioning the orthotic insert (1) between an upper portion (22) of the footwear (22) and an outsole (21). Then, soft and flexible material (2) is injected into the space surrounding the orthotic (1). The soft and flexible material (2) subsequently cures forming the multi-part unitary midsole. A midsole of footwear (22) with an incorporated orthotic (1) support. The midsole includes a soft and flexible member and a more rigid orthotic (1) support. The orthotic (1) support includes a heel cup (10) and an arch support portion (11) that extends forwardly from the heel cup (10). Embodiments produce the midsole by positioning the orthotic insert (1) between an upper portion (22) of the footwear (22) and an outsole (21). Then, soft and flexible material (2) is injected into the space surrounding the orthotic (1). The soft and flexible material (2) subsequently cures forming the multi-part unitary midsole.