Orthotic Shell Footwear with Recessed Insole Support
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Solution Overview
Problem
Conventional footwear lacks adequate support for foot abnormalities or deformities, and removable orthotic inserts can be misplaced, dislodged, or misaligned, diminishing their effectiveness.
Innovation Solution
A composite sole structure with an orthotic shell enclosed between a midsole platform and insole, supported by semi-rigid material and multiple support plugs for stability, and a shank for enhanced rigidity, allowing for customizable support and natural foot flexion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If removable orthotic inserts are used to provide support for foot abnormalities, then foot support and comfort are improved, but the inserts can be easily misplaced, lost, or dislodged during use
Solution Approach 1:
The orthotic insert is integrated with the footwear by providing recesses in the insole that receive and retain the orthotic inserts. This merging of the insert retention function into the footwear structure itself eliminates the problem of misplaced or lost inserts while maintaining the orthotic support benefits.
Solution Approach 2:
The recesses in the insole serve as an intermediary structure that mediates between the orthotic insert and the footwear. These recesses provide a dedicated positioning mechanism that prevents dislodgement and misalignment while allowing the insert to be removed and reinserted as needed.
2Adaptability or versatility
If orthotic inserts are made removable for convenience, then ease of swapping between shoes is improved, but the inserts become prone to dislodgement and misalignment
Solution Approach 1:
The footwear is segmented into distinct components including the insole with recesses and the removable orthotic inserts. This segmentation allows the inserts to be easily removed and swapped between footwear while the recesses ensure stable positioning when installed.
Solution Approach 2:
The insole is designed with localized recesses at specific positions to receive the orthotic inserts. This local quality modification provides targeted retention and positioning stability exactly where the inserts need to be held securely, while maintaining overall footwear flexibility.
3Ease of manufacture
If conventional footwear is designed without specialized support structures, then manufacturing simplicity and cost are improved, but adequate support for foot abnormalities or deformities is not provided
Solution Approach 1:
The insole is designed with universal recesses that can accommodate different types of orthotic inserts for various foot conditions. This multi-functional design allows a single footwear model to provide specialized support for different foot abnormalities without requiring complex manufacturing variations.
Solution Approach 2:
The orthotic inserts can be manufactured as separate, potentially disposable components that are inexpensive to produce and replace. This allows the footwear itself to remain simple and cost-effective while providing access to customized orthotic support through affordable, replaceable inserts.
Data Source
AI summary
Footwear is provided having a midsole platform, a full length insole and a orthotic midsole in the form of an orthotic shell received between the midsole platform and the insole. The orthotic shell has a heel portion to support a heel of a foot of a wearer and a forefoot portion to support a forefoot of the wearer at least in a region behind and near metatarsal heads of the foot. The orthotic shell is shaped to partially cup the heel and support the forefoot in one of a plurality of determined orientations. The footwear may further include a plurality of support plugs to support the orthotic shell in one of the determined orientations and a shank coupled to the midsole platform to increase torsional rigidity of the footwear with respect to a longitudinal length thereof. Methods of making footwear are also provided.