High performance footbed and method of manufacturing same

• US 10,653,204 B2
• Filed: 10/12/2018
• Issued: 05/19/2020
• Est. Priority Date: 05/29/2018
• Status: Active Grant

• Current Assignee: Insite Performance LLC, JRCM Holdings LLC
• Original Assignee: Matmarket, LLC
• Inventors: Homer, Von Maurice, Mutschler, Charles Aaron, Reinhartz, Heath Jarett, Diharce, Gregory, Swain, Kehlin
• Primary Examiner(s): Lin, Jason
• Application Number:
  US16/158,395
• Publication Number:
  US 20190365024A1
• Time in Patent Office: 585 Days
• Field of Search: None
• CPC Class Codes: A43B 17/006 multilayered
• CPC Class Codes: A43B 17/14 made of sponge, rubber, or plastic materials
• CPC Class Codes: A43B 3/0036 characterised by a special shape or design
• CPC Class Codes: A43B 7/14 with foot-supporting parts
• CPC Class Codes: A43B 7/141 having an anatomical or curved form
• CPC Class Codes: A43B 7/18 Joint supports, e.g. instep supports
• CPC Class Codes: A43D 1/025 comprising optical means, e.g. mirrors, photo-electric cells, for measuring or inspecting feet
• CPC Class Codes: A43D 1/027 Shoe fit indicating devices
• CPC Class Codes: A43D 2200/60 Computer aided manufacture of footwear, e.g. CAD or CAM
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G06F 17/18 for evaluating statistical data , e.g. average values, frequency distributions, probability functions, regression analysis forecasting specially adapted for a specific administrative, business or logistic context G06Q10/04
• CPC Class Codes: G06F 2111/16 Customisation or personalisation
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: G06F 30/20 Design optimisation, verification or simulation optimisation, verification or simulation of circuit designs G06F30/30

Abstract

A footbed for use in footwear is provided. The footbed assembly includes a resilient, flexible material (e.g. EVA or PU foam) that extends the entire length of the footbed. a heel plate made from a material that is more rigid (plastic, carbon fiber) than the resilient foam attaches to the flexible material. The shape of the resilient footbed defines a geometry that provides support and comfort to the user by reducing peak pressures, improving cushioning, and enhancing foot support. The resilient foam and heel plate defines the shape of the midfoot R2 and rearfoot R1 of the footbed while the resilient flexible foam continues forward to define the shape of the forefoot R3 region of the footbed.

Claims

1. A method of manufacturing a foot insert comprising:

choosing a sample patient population;

positioning each patient'"'"'s foot in a sub-talar neutral position;

collecting three-dimensional data of at least one foot of each patient in a scan, and placing the scan in a collection of scans representing the sample patient population;

separating the collection of scans into groupings based on each patient'"'"'s preferred shoe size;

aligning the scans within each grouping by using correspondence point pairs;

obtaining contour data from the scans;

applying at least one filter to the scans;

averaging the scans;

obtaining seven representative measurements for each grouping, the seven representative measurements including forefoot width, rearfoot width, arch height, arch length, heel-to-head of first metatarsal phalangeal joint, heel-to-head of fifth metatarsal phalangeal joint, and foot length; and

modeling an insole based on the seven representative measurements;

wherein modeling an insole based on the seven representative measurements includes determining a footbed dimension from an anthropometric dimension and a differential coefficient for at least one shoe size.

2. The method of claim 1, further comprising the step of creating a multivariate linear regression model.

3. The method of claim 2, further comprising the step of training the model based on at least 500 samples of the data.

4. The method of claim 3, further comprising the step of testing the accuracy of the model.

5. A method of manufacturing a foot insert comprising:

choosing a sample patient population;

positioning each patient'"'"'s foot in a sub-talar neutral position;

collecting three-dimensional data of at least one foot of each patient in a scan, and placing the scan in a collection of scans representing the sample patient population;

separating the collection of scans into groupings based on each patient'"'"'s preferred shoe size;

aligning the scans within each grouping by using correspondence point pairs;

obtaining contour data from the scans;

applying at least one filter to the scans;

averaging the scans;

obtaining seven representative measurements for each grouping, the seven representative measurements including forefoot width, rearfoot width, arch height, arch length, heel-to-head of first metatarsal phalangeal joint, heel-to-head of fifth metatarsal phalangeal joint, and foot length;

modeling an insole based on the seven representative measurements;

and using a nonparametric multiplicative regression to estimate at least one of the seven representative measurement based on another one of the seven representative measurements.

6. The method of claim 5, wherein estimating at least one of the seven representative measurement includes estimating at least one of the forefoot width, the rearfoot width, the arch height, the arch length, the heel-to-head of first metatarsal phalangeal joint, and the heel-to-head of fifth metatarsal phalangeal joint.

7. The method of claim 6, wherein estimating at least one of the seven representative measurement includes estimating each of the forefoot width, the rearfoot width, the arch height, the arch length, the heel-to-head of first metatarsal phalangeal joint, and the heel-to-head of fifth metatarsal phalangeal joint.

8. A method of manufacturing a foot insert comprising:

choosing a sample patient population;

positioning each patient'"'"'s foot in a sub-talar neutral position;

collecting three-dimensional data of at least one foot of each patient in a scan, and placing the scan in a collection of scans representing the sample patient population;

separating the collection of scans into groupings based on each patient'"'"'s preferred shoe size;

aligning the scans within each grouping by using correspondence point pairs;

obtaining contour data from the scans;

applying at least one filter to the scans;

averaging the scans;

obtaining seven representative measurements for each grouping, the seven representative measurements including forefoot width, rearfoot width, arch height, arch length, heel-to-head of first metatarsal phalangeal joint, heel-to-head of fifth metatarsal phalangeal joint, and foot length;

modeling an insole based on the seven representative measurements;

adjusting the insole based on acquired data from footwear including adjusting the insole based on a footwear last bottom perimeter; and

converting last bottom data to vector and scalar coordinates and comparing the vector and scalar coordinated to the modeled insole.