Cushioned orthotic
View Patent ↗An orthotic is disclosed. The orthotic may include a cushioning layer configured to extend from at least the metatarsal region to the proximal heel region, the cushioning layer having a heel region with a protruding heel piece integrally molded as part of the cushioning layer. The orthotic may also include an outer shell layer fixedly coupled to the cushioning layer, the outer shell layer extending longitudinally from at least the medial cuneiform-first metatarsal joint region to the calcaneus bone region of the user, the outer shell layer configured to receive the protruding heel piece.
1. An orthotic, comprising:
a covering layer on the top surface;
a foam cushioning layer fixedly coupled to the covering layer, the foam cushioning layer configured to extend from at least the proximal metatarsal region to the proximal heel region, the cushioning layer being at its thinnest towards the proximal metatarsal region and thickest at the proximal heel region,
the cushioning layer having a protruding heel piece integrally molded as part of the cushioning layer at the proximal heel region, and
an upturned medial flange extending towards the proximal heel portion, wrapping around to the opposite lateral side, and tapering towards the distal forefoot portion;
an outer shell layer fixedly coupled to the cushioning layer, the outer shell layer configured to extend longitudinally from at least the medial cuneiform-first metatarsal joint region to the calcaneus bone region of the user,
the outer shell layer further having an upturned flange on the medial side, parallel to the upturned medial flange of the cushioning layer,
an enclosure defining a aperture therethrough at the heel region, the enclosure configured to receive the integral protruding heel piece of the cushioning layer, and
an inner shell insert layer operably attached between the cushioning layer and the outer shell layer, the inner shell insert layer extending from at least the medial cuneiform-first metatarsal joint region to the talus-navicular joint region and not extending to the proximal heel region of the user.
2. The orthotic of claim 1 , wherein the inner shell insert layer comprises a thermoplastic material.
3. The orthotic of claim 2 , wherein the thermoplastic material is thermoplastic urethane.
4. The orthotic of claim 1 , wherein the cushioning layer comprises a foamed material.
5. The orthotic of claim 4 , wherein the foamed material is thermoset polyurethane foam.
6. The orthotic of claim 1 , wherein the cushioning layer forms a heel cup at the proximal end.
7. The orthotic of claim 1 , the outer shell layer further comprising a plurality of perforations in the mid portion of the outer shell layer.
8. The orthotic of claim 7 , wherein the perforations in the mid portion of the outer shell layer comprises a plurality of parallel slots extending from the medial side to the lateral side.
9. The orthotic of claim 1 , the foam cushioning layer further comprising a raised convex protrusion at the distal forefoot region between the second to fourth metatarsal.
10. An orthotic, comprising:
a covering layer on a top surface;
a foam cushioning layer fixedly coupled to the covering layer,
the foam cushioning layer is configured to extend from at least the proximal metatarsal region to the proximal heel region, the cushioning layer being thinnest at the distal forefoot region and thickest at the heel region, the cushioning layer having an upwardly raised convex protrusion between the second and fourth metatarsal,
the cushioning layer further having a heel region with a protruding heel piece integrally formed as part of the foam cushioning layer, the protruding heel piece supporting the entire heel region and
an upturned medial flange extending towards the proximal heel portion, wrapping around to the opposite lateral side, and tapering towards the distal forefoot portion;
an outer shell layer fixedly coupled to the foam cushioning layer, the outer shell layer is configured to extend longitudinally from at least the medial cuneiform-first metatarsal joint region to the talus-navicular bone region, extending on either side around the calcaneus bone portion, the outer shell layer at the calcaneuous bone region cut out to form an enclosure defining a aperture therethrough for receiving the protruding heel piece, the outer shell layer extending on either side of the calcaneous region a pair of projecting extensions having a first end and a second end, the projecting extensions embracing the heel piece on either side with the first end and the second end terminating just behind the heel region,
the outer shell layer further having an upturned medial flange, parallel to the upturned flange of the cushioning layer; and
an inner shell insert layer operably attached between the cushioning layer and the outer shell layer, the inner shell insert layer extending from at least the medial cuneiform-first metatarsal joint region to the talus-navicular joint region and not extending to the proximal heel region of the user.
11. An orthotic, comprising:
a covering layer on a top surface;
a foam cushioning layer fixedly coupled to the covering layer,
the foam cushioning layer is configured to extend from at least the proximal metatarsal region to the proximal heel region, the cushioning layer is thinnest at the distal forefoot region and thickest at the heel region, the cushioning layer having an upwardly raised convex protrusion between the second and fourth metatarsal,
the cushioning layer further having a heel region with a protruding heel piece integrally formed as part of the foam cushioning layer, the protruding heel piece supporting the entire heel region and
an upturned medial flange extending towards the proximal heel portion, wrapping around to the opposite lateral side, and tapering towards the distal forefoot portion;
an outer shell layer fixedly coupled to the foam cushioning layer, the outer shell layer is configured to extend longitudinally from at least the medial cuneiform-first metatarsal joint region to the talus-navicular bone region, extending on either side around the calcaneus bone portion, the outer shell layer at the calcaneuous bone region cut out to form an enclosure defining a aperture therethrough for receiving the protruding heel piece, the outer shell layer extending on either side of the calcaneuos region a pair of projecting extensions having a first end and a second end, the projecting extensions embracing the heel piece on either side with the first end and the second end joined at the heel region,
the outer shell layer further having an upturned medial flange, parallel to the upturned flange of the cushioning layer; and
an inner shell insert layer operably attached between the cushioning layer and the outer shell layer, the inner shell insert layer extending from at least the medial cuneiform-first metatarsal joint region to the talus-navicular joint region and not extending to the proximal heel region of the user.