Orthotic with Integrally Molded Heel Cushion and Hard Shell
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Solution Overview
Problem
Conventional footwear inserts, or orthotics, often face challenges in providing both adequate cushioning and arch support while being cost-effective and versatile enough to fit a wide range of users, as they tend to be either too expensive, bulky, or limited in size options, and custom-made options are impractical for mass production.
Innovation Solution
The development of a pre-manufactured orthotic shoe insert with an integrally molded protruding heel cushion as part of the overall cushioning layer, combined with a hard shell layer that provides lateral stability and compressibility, allowing for use in various shoe sizes, and using arch support elements made from different materials to reduce manufacturing costs and increase versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom-made orthotics are produced to meet individual user needs, then cushioning and support quality are improved, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The orthotic is divided into separate functional components: a cushioning layer with protruding heel cushion and a hard shell layer with arch support. This segmentation allows each component to be manufactured independently using optimized processes, then assembled together, achieving both customized performance and cost-effectiveness
Solution Approach 2:
The invention provides multiple variations of the orthotic by changing parameters such as material composition, cushioning thickness, and shell hardness rather than creating entirely custom designs. This allows adjustment of performance characteristics while maintaining standardized manufacturing processes
2Ease of manufacture
If pre-manufactured orthotics are produced to reduce cost, then manufacturing cost is reduced, but cushioning and support quality deteriorate
Solution Approach 1:
The orthotic combines different materials with complementary properties: soft cushioning materials (foam, rubber, or gel) in the cushioning layer and rigid shell materials (thermoplastic or polymer) in the hard shell layer. This composite construction achieves both adequate support and cushioning at pre-manufactured cost levels
Solution Approach 2:
By separating the cushioning function from the support function into distinct layers, each layer can be optimized for its specific purpose while being manufactured efficiently as a separate component, then assembled together
3Reliability
If orthotics are designed with separate heel cushioning elements, then cushioning quality is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The protruding heel cushion is integrally formed as part of the cushioning layer rather than being a separate element. This merging reduces the number of components, simplifies manufacturing, and eliminates assembly steps while maintaining effective heel cushioning through the protruding geometry
4Stability of the object's composition
If hard shell layers are used throughout the orthotic, then lateral stability is improved, but heel cushioning is compromised
Solution Approach 1:
The orthotic is segmented into a hard shell layer providing lateral stability and a separate cushioning layer with protruding heel cushion providing heel comfort. The hard shell layer has openings or cutouts in the heel region to allow the cushioning layer to protrude, enabling both stability and cushioning functions to coexist
Solution Approach 2:
The hard shell layer transitions from a solid, stable structure in the midfoot area to an open or reduced structure in the heel area, allowing local variation in properties: rigid where needed for stability, flexible/cushioning where needed for comfort
5Adaptability or versatility
If multiple size variations are produced to fit different users, then adaptability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The orthotic incorporates compressible cushioning materials that can dynamically adapt to different foot sizes and shapes. The soft cushioning layer compresses to fit various foot contours, allowing a single standardized size to accommodate multiple users effectively
Solution Approach 2:
The orthotic design is intended to be universally applicable across different foot sizes through the combination of standardized dimensions and compressible materials, allowing one product model to serve multiple users rather than requiring extensive size variations
Data Source
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AI summary
An orthotic is disclosed. The orthotic may include a cushioning layer configured to extend from at least the metatarsal region to the proximal heel region, the cushioning layer having a heel region with a protruding heel piece integrally molded as part of the cushioning layer. The orthotic may also include an outer shell layer fixedly coupled to the cushioning layer, the outer shell layer extending longitudinally from at least the medial cuneiform-first metatarsal joint region to the calcaneus bone region of the user, the outer shell layer configured to receive the protruding heel piece.