A hybrid composite material is constructed from woven reinforced fabrics of Kevlar 49 and biaxially reinforced fibers of graphite and E-Glass bonded together with a thermosetting adhesive, for the application of custom orthotics. The material is designed with the idea of introducing different fibers at different locations of the orthotic in order to take advantage of the unique properties of each reinforcing fibers. The resulting material creates a hybrid composite that exhibits a balance of properties, in both the longitudinal and tranverse directions, unavailable with any single reinforcing fibers. A method of orthotic manufacturing involves a hand lay-up and forming procedure. The constructed composite material is formed and pressed on a prescribed cast, then allowed to cure under pressure. The post-cured material is stripped from the cast, then cut and ground and finally finished to the required orthotic. The produced orthotic combines the desired feature of a thin section with excellent combination of properties relevant to custom orthotics. Such properties include light weight, high strength and modulus, excellent resistance to impact, fatigue, and creep, and outstanding ability to damp vibrations.
Insole formed as a composite of a network of reinforcing fibers embedded in a matrix of a thermoplastic material having a softening temperature in the order of 90.degree. C. and retains its softening for a reasonable time at a lower temperature that is not uncomfortable to the human skin. The insole is formed to the shape of the bottom of the wearer's foot by placing it while still soft in the shoe and allowing it to harden while being subjected to the wearer's standing weight.
Cleanliness insole for shoes comprising a first layer (10) positioned facing the foot and formed to promote the passage of perspiration from its upper to its lower surface, and a second rigid layer (20) whose upper surface is in contact with the lower surface of the first layer, the second layer delimiting cavities (23) which open onto the upper surface of the second layer. These cavities form a moisture-storage volume and are filled with an absorbent material (30). The moisture is thus stored by the absorbent material, thereby avoiding its transfer to the rest of the shoe and preventing the moisture from rising under the effect of foot pressure.
An improved sole or insole for providing puncture resistance in boots and other types of shoes includes multiple layers of a tightly woven, puncture resistant fabric, formed from high tensile strength synthetic or polymeric fibers, such as Kevlar.RTM., a polyaramid. The layers of puncture resistant fabric generally are not bonded together or adhered together by adhesives or the like. The layers of puncture resistant fabric may be secured together along the outer peripheries thereof, or they may be secured within a pocket formed from a covering material, such as foam, or in a pocket formed between an inner and outer sole of the boot or shoe.
A laminated, plastic orthotic device custom fitted to a wearer's extremity, typically a leg, wherein the orthotic includes a indicia bearing layer viewable on the outer surface of the orthotic. In one preferred embodiment, the device is fabricated from multiple layers of woven, reinforced and non-reinforced fabrics, adhesives, curable plastic resins and an image bearing layer. In other preferred embodiments, the device is fabricated of thermosetting plastic materials and an image bearing layer. The image layer may be comprised of woven fabric or non-woven materials which include drawings, insignias, photographs, textures or combinations thereof.
A thermoplastic composite reinforcing sheet material useful for reinforcing orthotic devices and other articles, such as a prosthetic socket or a ski boot. The composite sheet material consists of a plurality of layers. Two layers form outer opposed sides of the sheet and are made from a thermoplastic material. The core of the sheet consists of a plurality of fiber-containing layers. Each layer is impregnated with a thermoplastic resin which will bond with the outer thermoplastic layers when the final shape is vacuum thermoformed. The orientation of the fibers in the core may be varied to change the strength and rigidity of the composite thermoplastic reinforcing sheet. An orthotic device can be built using a thermoplastic host material and the disclosed thermoplastic composite reinforcing sheet material. The host material defines the overall shape of the orthotic device and is any thermoformable thermoplastic. The reinforcing sheet is used to reinforce desired sections of the final orthotic device.
