Washable Breathable Insole With Self-Adhering Silicone Base
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Solution Overview
Problem
Footwear insoles made from synthetic materials lack breathability, leading to discomfort and odor issues, and existing solutions with adhesives fail to address washability and shrinkage concerns.
Innovation Solution
A footwear insole design featuring a self-adhering liquid silicone rubber base layer that bonds directly to the fabric, providing tackiness for secure placement without adhesives and resisting shrinkage through multiple wash cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesives are used to bond fabric insole to footbed, then the insole is secured in place, but the adhesive fails to retain chemistry through wash cycles causing delamination and shrinkage
Solution Approach 1:
The patent removes the adhesive layer entirely and replaces it with a self-adhering base layer made of curable silicone rubber or thermoplastic polyurethane. This base layer is directly bonded to the fabric layer through thermal or chemical bonding, eliminating the intermediate adhesive that causes delamination and shrinkage issues during washing.
Solution Approach 2:
The insole is constructed as a composite structure with a fabric layer bonded to a self-adhering base layer made of curable silicone rubber or thermoplastic polyurethane. This composite design provides both the breathability of fabric and the adhesive properties needed for secure attachment, while being washable and resistant to shrinkage.
2Strength
If smooth vinyl foam is used for insole, then it provides cushioning, but it lacks breathability causing foot sweat and odor
Solution Approach 1:
The patent combines a breathable fabric layer with a self-adhering base layer made of curable silicone rubber or thermoplastic polyurethane. This composite structure provides both breathability from the fabric and cushioning from the base layer, eliminating the sweat and odor problems associated with smooth vinyl foam.
Solution Approach 2:
The fabric layer used in the insole is selected to be porous and breathable, allowing air circulation beneath the foot. This prevents moisture buildup and odor while maintaining comfort during wear.
3Ease of manufacture
If textiles are made washable, then they can be repeatedly washed, but polymeric materials used for adherence are not washable
Solution Approach 1:
The patent removes the non-washable adhesive material and replaces it with a self-adhering base layer made of curable silicone rubber or thermoplastic polyurethane that is specifically selected to be washable. This material maintains its adhesive properties through repeated washing while allowing the entire insole to be machine washed.
4Reliability
If adhesives are used to secure insole, then placement is secure, but adhesives may stick too well and remove footbed portions when insole is removed
Solution Approach 1:
The patent eliminates the adhesive layer that causes footbed damage and replaces it with a self-adhering base layer made of curable silicone rubber or thermoplastic polyurethane. This base layer provides secure placement through its inherent tackiness but allows for clean removal without damaging the footbed, as it bonds directly to the fabric rather than the footwear substrate.
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 insole maintains breathability and comfort while being washable and durable, preventing shrinkage and delamination, thus offering a solution for both aesthetic and functional issues.
Implementation Method 1
a self-adhering material that is directly bonded to the bottom surface of the fabric layer
Data Source
AI summary
The present disclosures concerns embodiments of a footwear insole that can be used with various types of footwear, including, without limitation, shoes (including open and closed toe shoes), boots, sandals, etc. The insole includes an upper fabric layer that comes in contact with the foot and a cushioning base layer that contacts the footbed of the footwear. The base layer desirably is formed from a self-adhering material that can be applied to in liquid form to the fabric and bonds directly to the fibers of the fabric when cured, so as to eliminate the need for a separate intermediate adhesive layer for securing the fabric to the base layer. The base layer is also configured to substantially prevent shrinkage of the insole when subjected to multiple wash and dry cycles.