Light-cured composite insole
AssigneeLight Composites, LLC
InventorAlan Jon Jacobsen
Life of this patent
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Abstract
The present invention describes a shaped footwear device intended to be used as a supportive insole or orthotic and a system and methods for making the same. The footwear device includes a top foam layer, a light-cured composite material layer, and a bottom textile layer. The footwear device is created by conforming a pre-cured insole assembly to the plantar surface of a foot or foot mold and then exposing the pre-cured insole assembly to light to create a shaped footwear device with a light-cured composite material support plate.
Claims15
A system for making a shaped footwear device, the said system comprising:
- a light box configured to hold a transparent stretch film substantially taut over an opening on one surface of the light box;
- wherein the transparent stretch film is secured near at least a portion of the edges of the opening on the one surface of the light box;
- a pre-cured insole assembly;
- wherein, the pre-cured insole assembly is adapted to fit within the opening on the one surface of the light box;
- wherein the light box includes at least one light source adapted to direct light on at least one surface of the pre-cured insole assembly;
- wherein the light from the light source is adapted to cure the light-curable resin in the pre-cured insole assembly;
- and
- wherein an open volume exists directly below the transparent stretch film when taut, the open volume being of a depth to accommodate the pre-cured insole assembly when pressed into the transparent stretch film and through the opening.
A system for making a shaped footwear device, the said system comprising:
- a light box configured to hold a transparent stretch film substantially taut over an opening on one surface of the light box;
- wherein the transparent stretch film is secured near at least a portion of the edges of the opening on the one surface of the light box;
- a pre-cured insole assembly;
- wherein, the pre-cured insole assembly is adapted to fit within the opening on the one surface of the light, box;
- wherein the light box includes at least one light source adapted to direct light on at least one surface of the pre-cured insole assembly;
- wherein the light from the light source is adapted to cure the light-curable resin in the pre-cured insole assembly;
- and
- wherein the light box comprises a transparent guide plate secured between the opening on the one surface of the light box and the light source, the transparent guide plate positioned below the transparent stretch film such that an open volume exists between the transparent guide plate and the transparent stretch film, with the transparent guide plate being at least 25 millimeters from the transparent stretch film that is between the edges of the opening on the one surface of the light box.
A system for making a shaped footwear device, the said system comprising:
- a light box with an opening on one surface of the light box;
- a transparent stretch film;
- wherein the transparent stretch film is covering at least a portion of the opening on the one surface of the light box;
- wherein there is no rigid material within 25 mm directly below the transparent stretch film that is between the edges of the opening on the one surface of the light box;
- a pre-cured insole assembly;
- wherein, the pre-cured insole assembly is adapted to fit within the opening on the one surface of the light box;
- wherein the light box includes at least one light source adapted to direct light on at least one surface of the pre-cured insole assembly;
- and
- wherein the light from the light source is adapted to cure the light-curable resin in the pre-cured insole assembly.
Dependencies are inferred from the claim text.