Dynamic cushioning system for insoles
View Patent ↗Provided are dynamic cushioning systems (e.g., for use in insoles, orthoses, shoes, etc.), comprising: a fluid chamber (e.g., 100, 200 ) having at least one flexible fluid reservoir cell in each of a hindfoot and a forefoot portion, and having at least one main fluid transfer channel spanning a midfoot portion and connecting, in fluid exchange communication, the at least one hindfoot fluid reservoir cell with the at least one forefoot fluid reservoir cell to provide a reactive network of hindfoot and/or forefoot fluid reservoir cells in fluid exchange communication. The interconnected multi-reservoir networks provide optimal reactivity and dynamic positional cushioning by controlling fluid transfer rate(s) between and among the fluid reservoir cells. Also provided are methods for making the fluid chambers, along with insoles, orthoses, shoes, and other footwear, etc., comprising same.
1 . A cushioning system, comprising an insole having:
a polyurethane fluid chamber having top and bottom surfaces, hindfoot, midfoot, and forefoot portions extending between a heel end and a toe end, and having a lateral (outer) side and a medial (inner) side;
a flexible fluid reservoir cell centered between the lateral and medial sides in the hindfoot portion;
three flexible fluid reservoir cells in the forefoot portion positioned laterally between the lateral and medial sides, and laterally interconnected by secondary forefoot fluid transfer channels; and
a single main fluid transfer channel spanning the midfoot portion from the hindfoot portion to the forefoot portion and having two branches, connecting the main fluid transfer channel directly to the outer cells of the three laterally interconnected forefoot fluid reservoir cells, in the forefoot portion to connect, in fluid exchange communication, the main fluid transfer channel to each of the three laterally interconnected forefoot flexible fluid reservoir cells, such that the three laterally interconnected forefront fluid reservoir cells are each in direct fluid exchange communication with the centered hindfoot fluid reservoir cell via the main fluid transfer channel to provide a reactive fluidic network, wherein the diameter of the single main fluid transfer channel, including of the branches thereof, is a value in a range of 5 mm to 10 mm, and wherein the fluid chamber is filled with a liquid silicone gel to a level of 80% to 85% of a resting (unstretched) fluid capacity of all of the fluid reservoir cells and the fluid transfer channels, collectively.
2 . The cushioning system of claim 1 , wherein at least one of the three laterally interconnected forefoot flexible fluid reservoir cells is positioned at or within a ball of the foot portion of the forefoot position of the fluid chamber.
3 . The cushioning system of claim 1 , wherein the top surface of the fluid chamber is flat or substantially flat, and wherein the bottom surface of the fluid chamber is contoured, extending downwardly away from the top surface.
4 . The cushioning system of claim 1 , wherein the fluid chamber comprises sealed margins defining the hindfoot flexible fluid reservoir cell, and/or the three laterally interconnected forefoot flexible fluid reservoir cells, and/or the main fluid transfer channel and/or the secondary forefoot fluid transfer channels.
5 . The cushioning system of claim 4 , wherein the top surface of the fluid chamber is substantially coplanar with the sealing margins, and wherein the bottom of the fluid chamber is contoured below the sealing margins by the walls of the hindfoot and/or the three laterally interconnected forefoot reservoir cells extending downwardly from the respective sealing margins.
6 . The cushioning system of claim 1 , wherein the forefoot portion comprises at least three to ten forefoot reservoir cells interconnected directly or indirectly by a plurality of the secondary forefoot fluid transfer channels, such that the interconnected forefront fluid reservoir cells are, directly or indirectly, in fluid exchange communication with the hindfoot fluid reservoir cell via the main fluid transfer channel.
7 . The cushioning system of claim 6 , wherein the hindfoot portion comprises a single hindfoot fluid reservoir cell, and wherein the forefoot portion comprises at least four forefoot fluid reservoir cells interconnected directly or indirectly by the secondary forefoot fluid transfer channels, such that the at least four interconnected forefront fluid reservoir cells are, directly or indirectly, in fluid exchange communication with the hindfoot fluid reservoir cell via the main fluid transfer channel.
8 . The cushioning system of claim 7 , wherein three of the at least four interconnected forefoot fluid reservoir cells are positioned laterally between the lateral and medial sides of forefoot portion of the fluid chamber, and wherein one of the at least four interconnected forefoot fluid reservoir cells is positioned between the toe end of the fluid chamber and the three laterally disposed interconnected forefoot fluid reservoir cells within the forefoot portion.
9 . The cushioning system of claim 1 , wherein the branches comprise two diagonal fluid transfer channels connecting the main fluid transfer channel directly to the outer cells of the three laterally disposed interconnected forefoot fluid reservoir cells.
10 . The cushioning system of claim 1 , wherein the combined volume (resting fluid capacity) of the hindfoot fluid reservoir cell(s) is the same or smaller than the combined volume of the forefoot fluid reservoir cell(s).
11 . The cushioning system of claim 1 , comprising a plurality of forefoot fluid reservoir cells of more than one volume.
12 . The cushioning system of claim 1 , as part of an insole, orthosis, or shoe.
13 . A method of making footwear, comprising incorporating a cushioning system according to claim 1 into an insole.
14 . The method of claim 13 , wherein incorporating comprises laminating the cushioning system into the insole.
15 . The cushioning system of claim 1 , wherein the midfoot portion of the fluid chamber has no fluid reservoir cells.
16 . The cushioning system of claim 1 , wherein the diameter of the single main fluid transfer channel, including of the branches thereof, is 7 mm, and wherein the fluid chamber is filled with a liquid to a level of 80% to 85% of a resting (unstretched) fluid capacity of all of the fluid reservoir cells and the fluid transfer channels, collectively.