Pressure-Relief Insole Manufacturing with Cavity Air Cushion Support
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Solution Overview
Problem
Conventional insoles lack sufficient support and durability, particularly in the hindfoot and arch regions, and often deform under pressure, leading to discomfort and loss of shape over time.
Innovation Solution
A method for manufacturing insoles with a base having cavities on the lower surface, filled with air cushions and lightweight foam pieces, and a mesh on the upper surface, providing support and cushioning while maintaining stability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If foam material is used to provide cushioning, then comfort is improved, but support strength and durability deteriorate
Solution Approach 1:
The insole combines foam material with a thermoplastic polyurethane (TPU) reinforcement layer to create a composite structure. The foam provides cushioning comfort while the TPU layer adds structural strength and support, particularly in the hindfoot and arch regions, resolving the contradiction between softness and strength.
Solution Approach 2:
The reinforcement layer is strategically positioned in specific areas (hindfoot and arch regions) where support is most needed, rather than uniformly across the entire insole. This localized reinforcement provides maximum support strength where required while maintaining cushioning comfort in other areas.
2Strength
If significant contour is imparted to the foam material to support the foot, then support capability is improved, but deformation and collapse under pressure worsen
Solution Approach 1:
The contoured foam structure is reinforced with a rigid TPU layer that maintains the intended shape and prevents collapse under pressure. The composite structure allows the foam to provide contour support while the TPU reinforcement prevents deformation and maintains shape stability over time.
Solution Approach 2:
The TPU reinforcement layer acts as a flexible shell that conforms to the foot's anatomy while providing structural integrity. This thin film reinforcement prevents the foam from collapsing outward under pressure while maintaining the contoured shape for proper biomechanical support.
3Ease of operation
If the upper is made of flexible material to provide comfort, then ease of operation is improved, but inwardly-buttressing support deteriorates
Solution Approach 1:
The insole uses a composite of foam and TPU materials that work together to provide both comfort and support. The foam provides comfortable contouring while the TPU reinforcement layer provides the necessary inwardly-buttressing support that flexible upper materials alone cannot provide.
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 method enhances foot comfort and support by using air cushions with foam pieces to absorb shock and provide energy return, while maintaining a firm upper surface for stability and reducing deformation, thus improving endurance and reducing foot fatigue.
Implementation Method 1
air cushions with foam pieces to absorb shock and provide energy return
Implementation Method 2
air cushions with foam pieces to absorb shock and provide energy return
Data Source
AI summary
Method for manufacturing an insole includes providing a base having a shape for insertion onto a sole of or in a shoe. The base includes a lower surface, an opposite upper surface, and at least one cavity extending inward from the lower surface over only a part of the lower surface. Over a remaining part of the lower surface, the lower surface is a lowermost surface of the insole. Each cavity is defined in part by a downward-facing surface recessed inward of the base's lower surface. A mesh is attached to the base's upper surface and forms the insole's uppermost surface. A respective air cushion is arranged at least partly in each cavity to be peripherally surrounded by the base. Each respective air cushion includes a sealing structure and foam pieces held in the cavity by the sealing structure, is part of a lowermost surface of the insole.