Thermoplastic Insole Customization via Phase Transition
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Solution Overview
Problem
Traditional custom-made shoes and insoles are time-consuming and costly to produce, often resulting in inaccurate fit and delayed delivery, failing to effectively correct foot position issues such as pronation and supination, which can lead to pain and injuries in the feet and other joints.
Innovation Solution
The use of thermoplastic preforms for insoles and shoes that can be heated above their glass transition temperature, molded to the individual's foot shape, and then cooled to provide customized arch support, allowing for quick and accurate correction of foot position and distribution of ground force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional custom-made shoes and insoles are manufactured by professionals, then manufacturing precision and reliability are improved, but production time and cost increase significantly
Solution Approach 1:
The patent applies parameter changes by utilizing temperature as a control parameter to transform the thermoplastic material between solid and molten states. This enables rapid shaping of the insole to match the customer's foot contours, achieving custom fit without requiring lengthy manual manufacturing processes. The material transitions from a rigid preform to a moldable state through heating, then solidifies into the customized shape, dramatically reducing production time while maintaining precision.
Solution Approach 2:
The patent employs phase transitions of thermoplastic material, specifically the melting and solidification processes. The insole preform is heated above the glass transition temperature to become pliable, allowing it to conform to the foot shape. Upon cooling, the material solidifies into the customized form. This phase change mechanism enables quick, accurate customization without requiring complex manual crafting procedures.
2Manufacturing precision
If traditional custom-made shoes and insoles are manufactured by professionals, then manufacturing precision and reliability are improved, but cost increases significantly
Solution Approach 1:
The patent reduces manufacturing cost by using temperature-controlled material transformation instead of expensive manual crafting processes. The thermoplastic preform requires only heating and cooling, which can be achieved with simple equipment, eliminating the need for costly professional shoemakers and physiotherapists. This parameter-based approach maintains precision while dramatically lowering production costs.
Solution Approach 2:
The patent employs a disposable thermoplastic preform that is heated, shaped, and then discarded after single use. This eliminates the need for expensive, complex manufacturing processes and professional expertise, significantly reducing cost while maintaining adequate fit accuracy for the intended application.
3Ease of manufacture
If ready-made supports are used in insoles, then manufacturing cost is reduced, but manufacturing precision deteriorates due to lack of individual customization
Solution Approach 1:
The patent resolves this contradiction by using phase transitions of thermoplastic material to transform a generic preform into a customized fit. The preform is heated above the glass transition temperature to become moldable, then shaped to match the individual's foot contours. Upon cooling, the material solidifies into a perfectly fitted custom insole. This process maintains low manufacturing cost while achieving high precision fit, eliminating the need for expensive professional customization.
4Reliability
If wedges are glued to insoles to correct foot position, then foot position correction is improved, but device complexity and time consumption increase
Solution Approach 1:
The patent eliminates the complex wedge-gluing process by using phase transitions of thermoplastic material. The preform is heated to become pliable, then directly shaped to correct foot position through manual molding. Upon cooling, the corrected shape is locked in place without requiring additional wedges or adhesives. This dramatically simplifies the device while maintaining effective foot position correction.
Solution Approach 2:
The patent extracts and eliminates the complex wedge-gluing sub-process from the foot correction system. Instead of adding separate corrective elements, the thermoplastic preform itself is heated and shaped to directly provide the necessary correction. This removal of unnecessary components simplifies the overall device and process while maintaining or improving correction effectiveness.
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
This method provides natural arch support, reduces pronation and supination, alleviates fatigue and pain, and stabilizes the foot, while being cost-effective and efficient enough to be implemented in retail settings, offering customizable footwear solutions with a high profit margin.
Implementation Method 1
heating the chosen preform above the glass transition temperature (Tg) temperature of the thermoplastic layer
Implementation Method 2
waiting for the temperature of the heated insole preform to drop under the glass transition temperature of the thermoplastic
Data Source
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AI summary
Individually formed footwear such as shoes and insoles for correcting the feet position and alleviate related problems. The shoe or insole comprises at least one layer made of thermoplastic material, which material is advantageously chosen from a group of ABS, PVC, A-PET and PETG. A method for providing such footwear to a client at a retail store is likewise presented.