Protective, orthotic removable insert for footwear

Abstract

A footwear insert may include a puncture-resistant layer and a cushion layer. The cushion layer may be adjacent a top surface and an outer perimeter of the puncture-resistant layer. The cushion layer may comprise a lip extending upwardly from a region proximate a bottom surface of the puncture-resistant layer and extending outwardly with respect to the puncture-resistant layer. In some implementations, the puncture-resistant layer may comprise steel and the cushion layer may comprise polyurethane.

1 . An insert for footwear comprising: 
 a single stainless steel sheet having a bottom surface shaped and sized to engage an inner bottom surface of footwear, the puncture-resistant layer further having an outer perimeter and upper surface; and    a cushion layer having a first surface portion shaped to contour to a bottom of a foot, the cushion layer adjacent to the upper surface and the outer perimeter of the single stainless steel sheet, and including a lip that extends outwardly relative to the outer perimeter and upwardly from a region proximate the bottom surface of the single stainless steel sheet.    
   
   
       2 . The insert of  claim 1 , further comprising a metatarsal support region integrated with the cushion layer.  
   
   
       3 . The insert of  claim 1 , wherein the single steel sheet is stainless steel and has a thickness between about 0.020 and 0.025 inches.  
   
   
       4 . The insert of  claim 1 , further comprising a protective layer disposed at least partially adjacent to the first surface portion of the cushion layer.  
   
   
       5 . The insert of  claim 4 , wherein the protective layer comprises a membrane.  
   
   
       6 . An insert for footwear comprising: 
 a steel protective layer having a top surface, a bottom surface, and a perimeter surface;    a molded support layer formed adjacent to the steel protective layer, the molded support layer adjacent to a top surface and a perimeter surface of the steel protective layer,    wherein the molded cushion layer includes a lip that extends upwardly from a region proximate the bottom surface of the steel protective layer and outwardly relative to the steel protective layer.    
   
   
       7 . The insert of  claim 6 , wherein the molded support layer has a footward surface, the footward surface having a contour complementary to a contour of a bottom of a foot.  
   
   
       8 . The insert of  claim 6 , wherein the molded support layer comprises polyurethane.  
   
   
       9 . The insert of  claim 6 , wherein the molded support layer comprises at least one of an arch, heel, and metatarsal support region.  
   
   
       10 . The insert of  claim 6 , wherein the lip is configured to engage an inner sidewall of a top portion of the footwear.  
   
   
       11 . A method of making a footwear insert comprising: 
 providing a form including a recess shaped and sized to form a portion of the footwear insert, the form further including a positioner shaped and sized to receive a protective insert portion, the protective insert portion having a top surface and a perimeter surface;    providing a complementary recess having a footward surface shaped and sized to engage a bottom of a foot;    disposing the protective insert portion in the positioner;    forming a mold region comprising the recess and the complementary recess; and    introducing a material into the mold region, the material forming a support region of the insert, the material proximate to the top surface and the perimeter surface of the protective insert portion, wherein the positioner substantially prevents the material from flowing under the protective insert portion.    
   
   
       12 . The method of  claim 11 , wherein the material comprises polyurethane.  
   
   
       13 . The method of  claim 11 , further comprising curing the support region.  
   
   
       14 . The method of  claim 11 , further comprising, prior to positioning the protective insert region in the positioner, processing the protective insert region.  
   
   
       15 . The method of  claim 14 , wherein the act of processing comprises processing at least a portion of the top surface of the protective insert region to enhance adhesiveness.  
   
   
       16 . The method of  claim 15 , wherein the processing comprises etching at least a portion of the top surface of the protective insert region.  
   
   
       17 . The method of  claim 15 , wherein the act of processing comprises disposing a bonding material on at least a portion of the top surface of the protective insert region.  
   
   
       18 . The method of  claim 11 , further comprising forming a protective region adjacent at least a footward surface of the support region of the insert.  
   
   
       19 . The method of  claim 18 , wherein the act of forming the protective region comprises molding the protective region subsequent to forming the support region.