Sensor Insole Layer for Real-Time Foot Force Monitoring

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Solution Overview

Problem

Existing systems fail to provide continuous, real-time monitoring of athlete performance and injury risk during training and open play, relying solely on GPS devices that lack anatomical specificity and fail to capture ground reaction forces.

Innovation Solution

An insole layer with integrated sensors, including force-sensitive resistors, accelerometers, gyroscopes, and electromyography sensors, that capture motion data and transmit it to an external computing device for analysis, providing predictive feedback and interactive visualizations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If GPS devices are used to monitor athlete performance, then overall intensity and location data can be obtained, but anatomical specificity and ground reaction force data are lost

Engineering Contradiction:

Improveanatomical specificity and ground reaction force dataVSAvoidmonitoring system complexity

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

The patent embeds multiple sensors (accelerometers, gyroscopes, force-sensitive resistors, electromyography sensors) within the insole layer structure. The sensors are nested between the top and bottom cover layers of the insole, with the flexible printed circuit board carrying the sensors conforming to the contours of the foot. This nesting approach captures detailed anatomical and biomechanical data without requiring external bulky equipment.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent replaces traditional mechanical monitoring systems (GPS devices worn on the body) with an insole-based system that uses piezoelectric and capacitive sensing. Force-sensitive resistors and piezoelectric elements detect ground reaction forces through mechanical deformation, while capacitive sensors measure pressure distribution, substituting mechanical measurement with electrical signal detection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If multiple sensors are integrated into the insole layer, then real-time motion data and injury risk assessment are improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvecontinuous monitoring capability and injury risk assessmentVSAvoidinsole layer manufacturing

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insole layer serves multiple functions simultaneously: it provides structural support as a footwear component, acts as a substrate for sensor integration, and functions as a data collection platform. The flexible printed circuit board carries multiple sensor types (accelerometers, gyroscopes, force-sensitive resistors, electromyography sensors) that all work together to provide comprehensive motion analysis and injury risk assessment from a single device.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent uses a flexible printed circuit board that conforms to the contours of the foot, allowing the sensor array to adapt to different foot shapes and sizes. The insole layer itself is constructed as a thin, flexible structure with top and bottom cover layers that protect the embedded sensors while maintaining comfort and adaptability. This flexibility simplifies manufacturing by allowing the insole to be produced as a customizable insert rather than a rigid structured device.

Inventive Principle:

Principle #30Flexible shells and thin films

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

Enables continuous, real-time monitoring of lower limb and foot performance, offering predictive insights into injury risk and performance metrics, bridging the gap between controlled environments and open play.

Implementation Method 1

The motion-tracking device includes a plurality of sensors, each sensor configured to detect motion of one of a plurality of sensing areas

Methodology Applied

Scientific EffectPiezoresistive effect: Piezoresistive Effect

Implementation Method 2

The motion-tracking device includes a plurality of sensors, wherein each sensor is configured to detect motion

Methodology Applied

Scientific EffectAccelerometer: Accelerometer

Implementation Method 3

The motion-tracking device includes a plurality of sensors configured to detect motion

Methodology Applied

Scientific EffectGyroscope: Gyroscope

Implementation Method 4

electromyography sensors, that capture motion data

Methodology Applied

Scientific EffectElectromyography:

Data Source

PatentUS12414738B2Insole layer for monitoring human lower limb and foot performance

Publication Date: 2025.09.16 SPORTSCIENTIA PTE LTD

AI summary

An insole layer includes a top cover layer, a bottom cover layer, and a flexible printed circuit board disposed between the top cover layer and the bottom cover layer. The flexible printed circuit board includes a motion-tracking device, a processor, and a power supply. The motion-tracking device includes a plurality of sensors, wherein each sensor is configured to detect motion of one of a plurality of sensing areas disposed adjacent to a lower surface of the flexible printed circuit board. The processor is configured to receive motion data generated by the motion-tracking device. The power supply device is coupled to the motion-tracking device and the processor.