Insole and insole manufacturing method

An insole for a shoe, the insole comprising:

• a main portion that is a flat portion having a cushioning property and arranged in a manner that the main portion is to face a heel, a medial longitudinal arch portion, and a lateral longitudinal arch portion of a foot sole;
• a covered portion formed in an area on a surface of the main portion, the surface being configured to be adjacent to the foot sole, the area being configured to face the medial longitudinal arch portion;
• and
• a medial arch portion that is a portion having a cushioning property and arranged so as to cover the covered portion,
• in the medial arch portion, a surface to be adjacent to the foot sole being an upper surface, and a surface opposite the upper surface being a lower surface,
• the lower surface of the medial arch portion having a shape that matches the covered portion,
• the main portion and the medial arch portion being each formed of a material having a different hardness,
• the covered portion being formed as an indented area on the surface of the main portion that is to be adjacent to the foot sole, and an outer edge of the medial arch portion overlapping an outer edge of the covered portion,
• at least a portion of the outer edge of the medial arch portion being formed by a linear portion that forms outer edges of the upper surface and of the lower surface,
• the hardness of the material forming the main portion and the hardness of the material forming the medial arch portion being 10 durometers or greater and 50 durometers or less,
• an absolute value obtained by subtracting the hardness of the material forming the main portion from the hardness of the material forming the medial arch portion being 10 durometers or greater and 40 durometers or less,
• the insole further comprising a surface layer material that is a sheet-shaped member covering the upper surface of the medial arch portion arranged in the covered portion and an upper surface of the main portion, the upper surface of the medial arch portion and the upper surface of the main portion being each a surface to be adjacent to the foot sole,
• the surface layer material and the upper surfaces of the medial arch portion and of the main portion being joined to each other using a hot-melt,
• to facilitate contact of the insole with the medial longitudinal arch portion, shapes and thicknesses of the medial arch portion and of the covered portion in the main portion being adjusted so that a thickness of a portion of the insole relatively increases, the portion being configured to face the medial longitudinal arch portion, and
• the medial arch portion including a portion that gradually becomes thinner toward the outer edge of the medial arch portion.

An insole for a shoe, the insole comprising:

• a main portion that is a flat portion having a cushioning property and arranged in a manner that the main portion is to face a heel, a medial longitudinal arch portion, and a lateral longitudinal arch portion of a foot sole;
• a covered portion formed in an area on a surface of the main portion, the surface being configured to be adjacent to the foot sole, the area being configured to face the medial longitudinal arch portion;
• and
• a medial arch portion that is a portion having a cushioning property and arranged so as to cover the covered portion,
• in the medial arch portion, a surface to be adjacent to the foot sole being an upper surface, and a surface opposite the upper surface being a lower surface,
• the lower surface of the medial arch portion having a shape that matches the covered portion,
• the main portion and the medial arch portion being each formed of a material having a different hardness,
• the covered portion being formed as an indented area on the surface of the main portion that is to be adjacent to the foot sole, and an outer edge of the medial arch portion overlapping an outer edge of the covered portion,
• at least a portion of the outer edge of the medial arch portion being formed by a linear portion that forms outer edges of the upper surface and of the lower surface,
• the hardness of the material forming the main portion and the hardness of the material forming the medial arch portion being 10 durometers or greater and 50 durometers or less,
• an absolute value obtained by subtracting the hardness of the material forming the main portion from the hardness of the material forming the medial arch portion being 10 durometers or greater and 40 durometers or less,
• the insole further comprising a surface layer material that is a sheet-shaped member covering the upper surface of the medial arch portion arranged in the covered portion and an upper surface of the main portion, the upper surface of the medial arch portion and the upper surface of the main portion being each a surface to be adjacent to the foot sole,
• the surface layer material and the upper surfaces of the medial arch portion and of the main portion being joined to each other using a hot-melt,
• to facilitate contact of the insole with the medial longitudinal arch portion, shapes and thicknesses of the medial arch portion and of the covered portion in the main portion being adjusted so that a slope rising toward its medial side is formed in a portion of the insole, the portion being configured to face the medial longitudinal arch portion, and
• the medial arch portion including a portion that gradually becomes thinner toward the outer edge of the medial arch portion.

An insole for a shoe, the insole comprising:

• a main portion that is a flat portion having a cushioning property and arranged in a manner that the main portion is to face a heel, a medial longitudinal arch portion, and a lateral longitudinal arch portion of a foot sole;
• a covered portion formed in an area on a surface of the main portion, the surface being configured to be adjacent to the foot sole, the area being configured to face the medial longitudinal arch portion;
• and
• a medial arch portion that is a portion having a cushioning property and arranged so as to cover the covered portion,
• in the medial arch portion, a surface to be adjacent to the foot sole being an upper surface, and a surface opposite the upper surface being a lower surface,
• the lower surface of the medial arch portion having a shape that matches the covered portion,
• the main portion and the medial arch portion being each formed of a material having a different hardness,
• the covered portion being formed as an indented area on the surface of the main portion that is to be adjacent to the foot sole, and an outer edge of the medial arch portion overlapping an outer edge of the covered portion,
• at least a portion of the outer edge of the medial arch portion being formed by a linear portion that forms outer edges of the upper surface and of the lower surface,
• the hardness of the material forming the main portion and the hardness of the material forming the medial arch portion being 10 durometers or greater and 50 durometers or less,
• an absolute value obtained by subtracting the hardness of the material forming the main portion from the hardness of the material forming the medial arch portion being 10 durometers or greater and 40 durometers or less,
• the insole further comprising a surface layer material that is a sheet-shaped member covering the upper surface of the medial arch portion arranged in the covered portion and an upper surface of the main portion, the upper surface of the medial arch portion and the upper surface of the main portion being each a surface to be adjacent to the foot sole,
• the surface layer material and the upper surfaces of the medial arch portion and of the main portion being joined to each other using a hot-melt,
• the surface layer material further covering a lower surface of the main portion, the lower surface being located on a side opposite the upper surface of the main portion,
• the surface layer material and the lower surface of the main portion being joined to each other using the hot-melt,
• the insole further comprising an ear portion provided along an outer edge of the main portion,
• the surface layer material including:
• an upper surface layer material covering the upper surfaces of the medial arch portion and of the main portion;
• and
• a lower surface layer material covering the lower surface of the main portion, the ear portion including:
• an upper edge portion that includes an outer edge of the upper surface layer material;
• and
• a lower edge portion that includes an outer edge of the lower surface layer material,
• the upper edge portion and the lower edge portion being arranged in an overlapping manner and joined to each other using the hot-melt, and
• the ear portion being provided along an outer edge of the upper surface of the main portion.

A method for manufacturing an insole for a shoe using a first die and a second die, the method comprising:

• arranging a heated object in a housing space formed between a first portion of the first die and a second portion of the second die;
• and
• heating, through the first die and the second die, the heated object arranged in the housing space,
• the insole including:
• a main portion that is a flat portion having a cushioning property and arranged in a manner that the main portion is to face a heel, a medial longitudinal arch portion, and a lateral longitudinal arch portion of a foot sole;
• a covered portion formed in an area on a surface of the main portion, the surface being configured to be adjacent to the foot sole, the area being configured to face the medial longitudinal arch portion;
• and
• a medial arch portion that is a portion having a cushioning property and arranged so as to cover the covered portion,
• a surface of the medial arch portion opposite the surface to be adjacent to the foot sole being a lower surface, the lower surface of the medial arch portion having a shape that matches the covered portion,
• the main portion and the medial arch portion being each formed of a material having a different hardness,
• the insole further including an upper surface layer material that is a sheet-shaped member covering an upper surface of the medial arch portion arranged in the covered portion and an upper surface of the main portion, the upper surface of the medial arch portion and the upper surface of the main portion being each a surface to be adjacent to the foot sole,
• to facilitate contact of the insole with the medial longitudinal arch portion, shapes and thicknesses of the medial arch portion and of the covered portion in the main portion being adjusted so that a thickness of a portion of the insole relatively increases, the portion being configured to face the medial longitudinal arch portion,
• the medial arch portion including a portion that gradually becomes thinner toward an outer edge of the medial arch portion,
• the first portion of the first die having a shape corresponding to a shape of the insole, the first die including a first circumferential portion surrounding the first portion,
• the second portion of the second die being a recessed portion configured to form the housing space between the second portion and the first portion when the second portion faces the first portion, the second portion having a shape corresponding to the shape of the insole, the second die including a second circumferential portion surrounding the second portion,
• the heated object including the upper surface layer material, the main portion, the medial arch portion, and a hot-melt,
• in the heated object, (i) the hot-melt being arranged between the upper surfaces of the medial arch portion and of the main portion and the upper surface layer material covering the upper surfaces, the medial arch portion being arranged in the covered portion, and (ii) an upper edge portion being formed in the upper surface layer material so as to surround the upper surfaces, and
• in the method for manufacturing the insole,
• when the heated object is arranged in the housing space, (i) the upper surface layer material and the upper surfaces of the medial arch portion and of the main portion facing the first portion of the first die, (ii) a lower surface of the main portion facing the second portion of the second die, and (iii) the upper edge portion being positioned between the first circumferential portion and the second circumferential portion, and
• the heated object in the housing space being heated through the first die and the second die to thereby join the upper surfaces of the medial arch portion and of the main portion and the upper surface layer material to each other.

A method for manufacturing an insole for a shoe using a first die and a second die, the method comprising:

• arranging a heated object in a housing space formed between a first portion of the first die and a second portion of the second die;
• and
• heating, through the first die and the second die, the heated object arranged in the housing space,
• the insole including:
• a main portion that is a flat portion having a cushioning property and arranged in a manner that the main portion is to face a heel, a medial longitudinal arch portion, and a lateral longitudinal arch portion of a foot sole;
• a covered portion formed in an area on a surface of the main portion, the surface being configured to be adjacent to the foot sole, the area being configured to face the medial longitudinal arch portion;
• and
• a medial arch portion that is a portion having a cushioning property and arranged so as to cover the covered portion,
• a surface of the medial arch portion opposite the surface to be adjacent to the foot sole being a lower surface, the lower surface of the medial arch portion having a shape that matches the covered portion,
• the main portion and the medial arch portion being each formed of a material having a different hardness,
• the insole further including an upper surface layer material that is a sheet-shaped member covering an upper surface of the medial arch portion arranged in the covered portion and an upper surface of the main portion, the upper surface of the medial arch portion and the upper surface of the main portion being each a surface to be adjacent to the foot sole,
• to facilitate contact of the insole with the medial longitudinal arch portion, shapes and thicknesses of the medial arch portion and of the covered portion in the main portion being adjusted so that a slope rising toward its medial side is formed in a portion of the insole, the portion being configured to face the medial longitudinal arch portion,
• the medial arch portion including a portion that gradually becomes thinner toward an outer edge of the medial arch portion,
• the first portion of the first die having a shape corresponding to a shape of the insole, the first die including a first circumferential portion surrounding the first portion,
• the second portion of the second die being a recessed portion configured to form the housing space between the second portion and the first portion when the second portion faces the first portion, the second portion having a shape corresponding to the shape of the insole, the second die including a second circumferential portion surrounding the second portion,
• the heated object including the upper surface layer material, the main portion, the medial arch portion, and a hot-melt,
• in the heated object, (i) the hot-melt being arranged between the upper surfaces of the medial arch portion and of the main portion and the upper surface layer material covering the upper surfaces, the medial arch portion being arranged in the covered portion, and (ii) an upper edge portion being formed in the upper surface layer material so as to surround the upper surfaces, and
• in the method for manufacturing the insole,
• when the heated object is arranged in the housing space, (i) the upper surface layer material and the upper surfaces of the medial arch portion and of the main portion facing the first portion of the first die, (ii) a lower surface of the main portion facing the second portion of the second die, and (iii) the upper edge portion being positioned between the first circumferential portion and the second circumferential portion, and
• the heated object in the housing space being heated through the first die and the second die to thereby join the upper surfaces of the medial arch portion and of the main portion and the upper surface layer material to each other.

A method for manufacturing an insole for a shoe using a first die and a second die, the method comprising:

• arranging a heated object in a housing space formed between a first portion of the first die and a second portion of the second die;
• and
• heating, through the first die and the second die, the heated object arranged in the housing space,
• the insole including:
• a main portion that is a flat portion having a cushioning property and arranged in a manner that the main portion is to face a heel, a medial longitudinal arch portion, and a lateral longitudinal arch portion of a foot sole;
• a covered portion formed in an area on a surface of the main portion, the surface being configured to be adjacent to the foot sole, the area being configured to face the medial longitudinal arch portion;
• and
• a medial arch portion that is a portion having a cushioning property and arranged so as to cover the covered portion,
• a surface of the medial arch portion opposite the surface to be adjacent to the foot sole being a lower surface, the lower surface of the medial arch portion having a shape that matches the covered portion,
• the main portion and the medial arch portion being each formed of a material having a different hardness,
• the insole further including:
• an upper surface layer material that is a sheet-shaped member covering an upper surface of the medial arch portion arranged in the covered portion and an upper surface of the main portion, the upper surface of the medial arch portion and the upper surface of the main portion being each a surface to be adjacent to the foot sole;
• a lower surface layer material that is a sheet-shaped member and a portion covering a lower surface of the main portion, the lower surface being a surface located opposite the upper surface of the main portion;
• and
• an ear portion provided along an outer edge of the main portion,
• the ear portion including:
• an upper edge portion that includes an outer edge of the upper surface layer material;
• and
• a lower edge portion that includes an outer edge of the lower surface layer material,
• the ear portion being provided along an outer edge of the upper surface of the main portion,
• the first portion of the first die having a shape corresponding to a shape of the insole, the first die including a first circumferential portion surrounding the first portion,
• the second portion of the second die being a recessed portion configured to form the housing space between the second portion and the first portion when the second portion faces the first portion, the second portion having a shape corresponding to the shape of the insole, the second die including a second circumferential portion surrounding the second portion,
• the heated object including the upper surface layer material, the lower surface layer material, the main portion, the medial arch portion, and a hot-melt,
• in the heated object, (i) the hot-melt being arranged between the upper surfaces of the medial arch portion and of the main portion and the upper surface layer material covering the upper surfaces, the medial arch portion being arranged in the covered portion, (ii) the upper edge portion being formed in the upper surface layer material so as to surround the upper surfaces, and (iii) a hot-melt being arranged between the lower surface of the main portion and the lower surface layer material covering the lower surface,
• in the method for manufacturing the insole, when the heated object is arranged in the housing space, (i) the upper surface layer material and the upper surfaces of the medial arch portion and of the main portion facing the first portion of the first die, (ii) the lower surface layer material and the lower surface of the main portion facing the second portion of the second die, (iii) the upper edge portion being positioned between the first circumferential portion and the second circumferential portion, (iv) the upper edge portion and the lower edge portion overlapping each other between the first circumferential portion and the second circumferential portion, and (v) the hot-melt being arranged between the upper edge portion and the lower edge portion, and
• the heated object arranged in the housing space being heated through the first die and the second die to thereby (i) join the upper surfaces of the medial arch portion and of the main portion and the upper surface layer material to each other and join the lower surface of the main portion and the lower surface layer material to each other, and (ii) join the upper edge portion and the lower edge portion to each other and form the ear portion.

A method for manufacturing an insole for a shoe using a first die and a second die, the method comprising:

• arranging a heated object in a housing space formed between a first portion of the first die and a second portion of the second die;
• and
• heating, through the first die and the second die, the heated object arranged in the housing space,
• the insole including:
• a main portion that is a flat portion having a cushioning property and arranged in a manner that the main portion is to face a heel, a medial longitudinal arch portion, and a lateral longitudinal arch portion of a foot sole;
• a covered portion formed in an area on a surface of the main portion, the surface being configured to be adjacent to the foot sole, the area being configured to face the medial longitudinal arch portion;
• and
• a medial arch portion that is a portion having a cushioning property and arranged so as to cover the covered portion,
• a surface of the medial arch portion opposite the surface to be adjacent to the foot sole being a lower surface, the lower surface of the medial arch portion having a shape that matches the covered portion,
• the main portion and the medial arch portion being each formed of a material having a different hardness,
• the insole further including an upper surface layer material that is a sheet-shaped member covering an upper surface of the medial arch portion arranged in the covered portion and an upper surface of the main portion, the upper surface of the medial arch portion and the upper surface of the main portion being each a surface to be adjacent to the foot sole,
• the first portion of the first die having a shape corresponding to a shape of the insole, the first die including a first circumferential portion surrounding the first portion,
• the second portion of the second die being a recessed portion configured to form the housing space between the second portion and the first portion when the second portion faces the first portion, the second portion having a shape corresponding to the shape of the insole, the second die including a second circumferential portion surrounding the second portion,
• the heated object including the upper surface layer material, the main portion, the medial arch portion, and a hot-melt,
• in the heated object, (i) the hot-melt being arranged between the upper surfaces of the medial arch portion and of the main portion and the upper surface layer material covering the upper surfaces, the medial arch portion being arranged in the covered portion, and (ii) an upper edge portion being formed in the upper surface layer material so as to surround the upper surfaces,
• the main portion in the heated object further including a cut portion provided along an outer edge of the upper surface of the main portion,
• in the heated object, (i) the upper surface layer material covering the upper surfaces of the medial arch portion and of the main portion, (ii) the upper edge portion of the upper surface layer material covering the cut portion, and (iii) the hot-melt being arranged between the upper surface layer material and the medial arch portion, the main portion, and the cut portion,
• in the method for manufacturing the insole, when the heated object is arranged in the housing space, (i) the upper surface layer material and the upper surfaces of the medial arch portion and of the main portion facing the first portion of the first die, (ii) the lower surface of the main portion facing the second portion of the second die, and (iii) the upper edge portion and the cut portion being positioned between the first circumferential portion and the second circumferential portion,
• the heated object arranged in the housing space being heated through the first die and the second die to thereby join (i) the upper surfaces of the medial arch portion and of the main portion and an upper surface of the cut portion and (ii) the upper surface layer material, and
• the method further comprising, subsequent to joining the medial arch portion, the main portion, and the cut portion and the upper surface layer material to each other, cutting off the cut portion and a portion of the upper surface layer material that covers the cut portion.