Multilayer Insole with Activated Carbon and Cork Thermal Bridge
Solution Overview
Problem
Existing insoles fail to provide individualized foot shaping, comfort, and effective odor and moisture management, often retaining moisture and having short durability due to exposed activated carbon layers.
Innovation Solution
A multilayer insole with a supporting cork layer, an intermediate cork layer forming a thermal bridge, an active layer with activated carbon, and a permeable upper layer that prevents moisture retention, ensuring shape stability, antimicrobial properties, and long-term effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a surface layer of cotton is used, then the insole provides soft contact with the foot, but the cotton retains moisture and prevents it from reaching the activated carbon layer, reducing odor absorption effectiveness
Solution Approach 1:
The patent uses a porous upper layer material that allows moisture to pass through while maintaining soft contact. This porous structure enables liquid moisture to reach the activated carbon layer below, solving the contradiction between comfort and odor absorption effectiveness.
Solution Approach 2:
The insole combines multiple materials with different properties: a soft porous upper layer for comfort, an intermediate layer for structural support, and activated carbon for odor absorption. This composite structure resolves the contradiction by allowing each layer to perform its specific function without interfering with others.
2Reliability
If a layer of activated carbon is applied to the surface layer, then the insole gains odor-absorbing properties, but the exposed activated carbon layer is subject to abrasion and has little durability
Solution Approach 1:
The patent divides the insole into multiple functional layers: an upper layer for comfort and moisture transport, an intermediate layer for structural support, and an activated carbon layer for odor absorption. This segmentation protects the activated carbon from direct abrasion while maintaining its odor absorption capability.
Solution Approach 2:
The intermediate layer acts as a protective mediator between the upper layer and the activated carbon layer. It provides mechanical support and protection to the activated carbon, preventing direct exposure to abrasion while still allowing the activated carbon to perform its odor absorption function.
3Ease of manufacture
If a unified foot shape is used for the insole, then the insole can be manufactured simply, but it does not adapt to individual foot shapes, particularly toe shape and inclination, decreasing walking comfort
Solution Approach 1:
The insole incorporates a flexible damping layer that can adapt its shape to the user's foot contours during use. This dynamic adaptation allows the insole to conform to individual foot shapes, particularly toe variations, while maintaining a simple manufactured form for production.
Solution Approach 2:
The insole uses materials with specific physical properties that allow shape adaptation. The damping layer's material parameters enable it to deform and conform to the user's foot shape, providing customization without requiring complex manufacturing processes for each individual foot.
4Ease of operation
If the insole provides flexible support that adapts to the foot shape, then walking comfort is improved, but the insole shapes itself to foot defects, worsening improper foot conditions
Solution Approach 1:
The insole features localized relief structures with protrusions and recesses in specific areas to provide targeted support for proper foot alignment, while the damping layer provides general flexible adaptation. This local quality approach ensures comfort through adaptation while maintaining foot health through structured support in critical areas.
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 insole provides customized foot support, reduces moisture condensation, enhances comfort, and maintains antimicrobial properties while effectively absorbing odors and moisture, addressing the limitations of previous insole designs.
Implementation Method 1
an intermediate cork layer to form a thermal bridge between the foot sole of the user and the bottom layers of the insole
Implementation Method 2
the cork ensures that the other layers of the insole are thermally insulated from the shoe sole, thereby reducing condensation of liquid moisture from vapour
Implementation Method 3
an upper layer, which is permeable to both liquid and vapour moisture
Implementation Method 4
an active layer, which is on its upper side covered by an upper layer... containing activated carbon... effectively absorbing odors and moisture
Implementation Method 5
the insole... effectively absorbing odors and moisture
Data Source
Figure 1a~1c
Figure 2~4
Figure 5~6b
AI summary
The invention relates to a multilayer insole with activated carbon, which comprises a supporting layer (1), an active layer (4) with activated carbon and an upper layer (5). Above the supporting layer (1) formed by pressing a mixture of crushed cork and a binder together is arranged at least one damping layer (2), on whose upper side is arranged a intermediate cork layer (3) to form a thermal bridge between the user's foot and the bottom layers of the insole, above the intermediate cork layer (3) is arranged an active layer (4), which is on its upper side covered by an upper layer (5), which is permeable to vapour and liquid moisture, whereby all the layers of the insole are joined together and the insole has spatial shaping, which on its upper side corresponds to the shape of the impression of the lower part of the human foot with planar toe section, with a recess for the big toe joint and a recess for the heel, arid which on the bottom part of the insole corresponds to the shape of the lower part of the human foot with planar toe section The invention also relates to a method of producing this insole and footwear provided with the insole according to the invention.