# US 10,477,917 B2 · Energy return orthotic systems

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- Number: US 10,477,917 B2
- Document ID: US10477917B2
- Status: Granted
- Kind: B2
- Application number: 15/914,596
- Filed: 2018-03-07
- Published: 2018-07-12
- Granted: 2019-11-19
- Earliest claimed: 2012-06-27
- Applicants: Barry A. Butler
- Inventors: Barry A. Butler
- Web page: https://patentgrep.com/patent/US10477917B2

## CPC

- A43B 7/28: Adapting the inner sole {or the side of the upper} of the shoe to the sole of the foot
- A43B 7/14: with foot-supporting parts
- A43B 7/141: {having an anatomical or curved form}
- A43B 7/142: situated under the medial arch, i.e. under the navicular or cuneiform bones
- A43B 7/143: situated under the lateral arch, i.e. the cuboid bone
- A43B 7/1445: situated under the midfoot, i.e. the second, third or fourth metatarsal
- A43B 7/146: {provided with acupressure points or means for foot massage}
- A43B 7/149: Pads, e.g. protruding on the foot-facing surface
- A43B 7/24: Insertions or other supports preventing the foot canting to one side {, preventing supination or pronation}
- A43B 13/181: {Resiliency achieved by the structure of the sole}
- A43B 13/183: {Leaf springs}
- A43B 13/184: {the structure protruding from the outsole}
- A43B 13/386: {multilayered}
- A43B 17/006: {multilayered}
- A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR

## Abstract

A plurality of orthotic systems are provided. One bi-layer system is constructed from a single sheet of fabric that is molded into two layers. One tri-layer system includes a base layer; a mid-layer; and an upper layer. The upper layer is joined to the mid-layer and the mid-layer is joined to the base layer. The coupling of the base layer, the mid-layer and the upper layer create a rear spring section, a mid-spring section and a front spring section in which the upper layer is suspended over the mid-layer and the heel portion is suspended on the proximal heel end of the base layer.

## Claims

### Claim 1

A tri-layer orthotic system constructed of a resilient material, the tri-layer orthotic system comprising:
a base layer having a distal toe end and a proximal heel end;
a resin;
a mid-layer having a distal toe portion, a mid-portion and a proximal heel portion, said distal toe portion of the mid-layer integrally fused to the distal toe end of the base layer by said resin to form a forefoot portion, said proximal heel portion including an opening cut into the mid-layer proximal heel portion that conforms to a heel of an individual; and
an upper layer having a front upper layer portion, an arch upper layer portion and a heel upper layer portion, said heel upper layer portion integrally fused to the proximal heel portion of the mid-layer by said resin to form an open heel portion, said upper layer including a plurality of segmented digit rays cut into the front upper layer portion, said arch upper layer portion is cut into the upper layer and is configured to be deformed upwardly above said upper layer or downwardly below said upper layer;
wherein the upper layer is suspended over the mid-layer and the heel portion is suspended over the proximal heel end of the base layer, wherein the suspension in combination with the resilient material creates a rear spring section, a mid-spring section and a front spring section.

### Claim 2 (depends on 1)

The tri-layer orthotic system of claim 1 wherein the resilient material used to construct said orthotic system is carbon fiber.

### Claim 3 (depends on 1)

The tri-layer orthotic system of claim 1 further comprising a shim positioned between said bottom layer and said mid-layer.

### Claim 4 (depends on 1)

The tri-layer orthotic system of claim 1 further comprising a shim positioned between said upper layer and said mid-layer.

### Claim 5 (depends on 1)

The tri-layer orthotic system of claim 1 further comprising a footwear of an individual user, wherein said orthotic system is configured to be inserted into said footwear.

### Claim 6 (depends on 1)

The tri-layer orthotic system of claim 1 wherein one or more of said plurality of digit rays are configured to be deformed upwardly or downwardly by a therapeutic angle.

### Claim 7 (depends on 6)

The tri-layer orthotic system of claim 6 wherein said one or more of said plurality of digit rays include an aperture.

### Claim 8 (depends on 7)

The tri-layer orthotic system of claim 7 further comprising a filament having a first end operably coupled to said aperture and a second end operably coupled to said base layer for flexing said digit ray downwardly.

### Claim 9 (depends on 1)

The tri-layer orthotic system of claim 1 further comprising at least one sensor positioned on or near said orthotic that senses movement and/or pressure during the gait cycle;
a knowledge base that provides data on a plurality of foot pathologies and a plurality of information regarding a normal foot and/or normal gait cycle;
a processing device in operable communication with said at least one sensor and said knowledge base, said processing device operative to (a) receive data from said at least one sensor related to the gait cycle of an individual; (b) compare said data received from said at least one sensor to the plurality of foot pathologies in said knowledge base; (c) determine a therapeutic correction to the orthotic based on the plurality of information regarding a normal foot and/or normal gait cycle to improve the gait cycle of the individual; and (d) output a visual representation of said correction to the individual.

### Claim 10 (depends on 1)

The tri-layer orthotic system of claim 1 wherein said orthotic is configured to be passively; static-dynamically or dynamic-dynamically controlled during the gait cycle to control foot, ankle and body biomechanics.

### Claim 11 (depends on 1)

The tri-layer orthotic system of claim 1 wherein said upper layer is constructed of a material that is different than said mid-layer and said base layer.

### Claim 12 (depends on 11)

The tri-layer orthotic system of claim 11 wherein said upper layer is constructed of a resilient material selected from open and closed cell foams and said mid-layer and base layer are constructed from carbon fiber.

### Claim 13 (depends on 1)

The tri-layer orthotic system of claim 1 wherein said resilient material is carbon fiber.

### Claim 14 (depends on 1)

The tri-layer orthotic system of claim 1 further comprising an upper layer heel aperture cut into the heel upper layer.