Anti-fatigue support and comfort insole

Abstract

A multi-layer insole having a pliable, supporting heel cup layer; a high impact foam layer selected to provide about a 20% set; and an image foam layer selected to provide about an 80% set. An abrasion resistant micro fiber lining for transporting moisture and perspiration from the foot can also be provided on top of the insole. The layers can be secured to each other by flame lamination.

1 . A custom-fit, multi-layer insole comprising: 
 a supporting heel cup layer;    a high impact foam layer selected to provide a designed percentage of set; and    an image foam layer selected to provide a percent of set different than the high impact foam layer.    
   
   
       2 . The insole of  claim 1 , wherein the high impact foam layer is selected to achieve about a 20% set.  
   
   
       3 . The insole of  claim 1 , wherein the high impact foam layer is made of ethyl vinyl acetate.  
   
   
       4 . The insole of  claim 1 , wherein the high impact foam layer has a heel portion shaped to conform to a heel pocket of a shoe.  
   
   
       5 . The insole of  claim 1 , wherein the image foam layer is selected to achieve about an 80% set.  
   
   
       6 . The insole of  claim 1 , wherein the image foam layer is made of cross-linked polyethylene.  
   
   
       7 . The insole of  claim 1 , the heel cup layer having an outside raised portion that extends around a wearer's heel to the outside of the wearer's foot and terminates before the ball of the foot.  
   
   
       8 . The insole of  claim 1 , wherein the heel cup is made of low-density polyethylene.  
   
   
       9 . The insole of  claim 1 , further comprising an inside raised portion adapted to conform to the inside part of a wearer's foot, and terminates before the ball of the foot.  
   
   
       10 . The insole of  claim 1 , wherein 
 the high impact foam layer has a top surface and a bottom surface, the bottom surface of the high impact foam layer adapted to conform to the inside of a shoe;    the heel cup layer has a top surface and a bottom surface, the bottom surface being adhered to the high impact foam layer top surface; and    the image foam layer has a bottom surface adhered to the heel cup layer top surface and high impact foam layer top surface not covered by the heel cup layer.    
   
   
       11 . The insole of  claim 1  further comprising an abrasion-resistant layer selected to transport moisture away from a wearer's foot.  
   
   
       12 . The insole of  claim 11 , wherein the abrasion-resistant layer is micro fiber lining.  
   
   
       13 . The insole of  claim 11 , wherein 
 the high impact foam layer has a top surface and a bottom surface, the bottom surface of the high impact foam layer adapted to conform to the inside of a shoe;    the heel cup layer has a top surface and a bottom surface, the bottom surface being adhered to the high impact foam layer top surface;    the image foam layer has a top surface and a bottom surface, the bottom surface of the image foam layer being adhered to the heel cup layer top surface and high impact foam layer top surface that is not covered by the heel cup layer; and    the abrasion-resistant layer has a bottom surface adhered the image foam layer top surface.    
   
   
       14 . The insole of  claim 13 , wherein the adhering is flame lamination.  
   
   
       15 . A method of making a custom-fit, multi-layer insole comprising the steps of: 
 providing a supporting heel cup layer;    providing a high impact foam layer selected to provide a designed percentage of set;    providing an image foam layer selected to provide a percent of set different than the high impact foam layer; and    adhering the layers together by flame lamination.    
   
   
       16 . The method of  claim 15 , wherein the image foam layer is adhered on top of the heel cup layer, and the supporting heel cup layer is adhered on top of the image foam layer.  
   
   
       17 . The method of  claim 15 , further comprising the step of providing an abrasion-resistant layer.  
   
   
       18 . The method of  claim 17 , wherein the abrasion-resistant layer is adhered on top of the image foam layer.  
   
   
       19 . The method of  claim 15 , wherein the high impact foam layer is selected to achieve about a 20% set and the image foam layer is selected to achieve about an 80% set.  
   
   
       20 . A method of making a custom-fit, multi-layer insole comprising the steps of: 
 providing a supporting heel cup layer;    providing a high impact foam layer selected to provide a designed percentage of set;    providing an image foam layer selected to provide a percent of set different than the high impact foam layer;    adhering the layers together by flame lamination, thereby forming a multi-layer insole;    heating the multi-layer insole with external heat; and    wearing the multi-layer insole while heated and, thereby achieving the designed set and a custom fit.