Forming a shoe component with rocker bottom

Abstract

A method of forming a shoe component for an individual is provided and includes defining a footprint of the shoe component for the individual with an orientation relative to a rocker bottom of sheets that each have the rocker bottom and various thicknesses, selecting, from among the sheets, a sheet having a thickness appropriate for the individual based on the orientation of the footprint and removing a portion from the selected sheet reflective of a shape and size of a profile of the footprint.

1 . A method of forming a shoe component for an individual, the method comprising:
 defining a footprint of the shoe component for the individual with an orientation relative to a rocker bottom of sheets that each have the rocker bottom and various thicknesses;   selecting, from among the sheets, a sheet having a thickness appropriate for the individual based on the orientation of the footprint; and   removing a portion from the selected sheet reflective of a shape and size of a profile of the footprint.   
     
     
         2 . The method according to  claim 1 , further comprising forming the set of sheets to each have the rocker bottom and various thicknesses. 
     
     
         3 . The method according to  claim 1 , further comprising mixing ingredients for the sheet in a mixer and molding the ingredients to form a sheet. 
     
     
         4 . The method according to  claim 3 , wherein the molding comprises injection molding. 
     
     
         5 . The method according to  claim 1 , wherein the forming comprises cutting each sheet from a master sheet. 
     
     
         6 . The method according to  claim 1 , wherein the orientation is based on a shape of a foot of the individual. 
     
     
         7 . The method according to  claim 6 , wherein the orientation longitudinally locates the rocker bottom relative to the foot. 
     
     
         8 . The method according to  claim 6 , wherein the orientation angles the rocker bottom relative to the foot. 
     
     
         9 . The method according to  claim 1 , wherein the selecting comprises determining a required thickness for the sheet to correct a disparity in leg lengths of the individual. 
     
     
         10 . The method according to  claim 1 , further wherein the removing comprises shaving the footprint in at least one of a thickness and a width direction. 
     
     
         11 . The method according to  claim 1 , wherein the removing is accomplished by at least one of a manual operation, a machine assisted operation and automatic machining 
     
     
         12 . A method of forming a shoe component for an individual, the method comprising:
 determining a need of the individual for a therapeutic shoe component;   evaluating a height profile of the individual;   defining a footprint of the shoe component for the individual with an orientation based on the determined need relative to a rocker bottom of sheets each having the rocker bottom and various thicknesses;   selecting, from among the sheets, a sheet having a thickness in accordance with the height profile and the foot print orientation; and   removing a portion from the selected sheet reflective of a shape and size of a profile of the footprint.   
     
     
         13 . The method according to  claim 12 , wherein the determined need describes at least one of a shape of a foot of the individual, a gait of the individual and an injury of the individual. 
     
     
         14 . The method according to  claim 12 , wherein the determined need is provided in a written description authored by a foot professional. 
     
     
         15 . The method according to  claim 12 , wherein the height profile describes a discrepancy between leg lengths of the individual. 
     
     
         16 . A system by which an article to be worn by an individual is formed, the system comprising a set of sheets from a selected one of which a portion is removable, the portion being reflective of a shape and size of a profile of a footprint of the individual, wherein:
 the sheets have various thicknesses, and   each sheet comprises a body including a relatively flat face and a face defining a rocker bottom opposing the relatively flat face.   
     
     
         17 . The system according to  claim 16 , wherein the rocker bottom is curved and tapered toward a nose portion. 
     
     
         18 . The system according to  claim 16 , wherein each sheet has a shape and size that is larger than the footprint of the individual. 
     
     
         19 . The system according to  claim 16 , wherein the rocker bottom of each sheet has a substantially similar shape. 
     
     
         20 . The system according to  claim 16 , where each sheet comprises one or more layers. 
     
     
         21 . The system according to  claim 16 , where each sheet comprises an organic polymeric material. 
     
     
         22 . The system according to  claim 16 , where each sheet comprises natural rubber, synthetic polyisoprene, butyl rubber, halogenated butyl rubbers, polybutadiene, styrene-butadiene rubber, nitrile rubber, hydrogenated nitrile rubbers, carboxylated nitrile rubber, chloroprene rubber, ethylene propylene rubbers, ethylene propylene diene rubber, epichlorohydrin rubber, polyacrylic rubber, silicone rubber, fluorosilicone rubber, fluoroelastomers, perfluoroelastomers, polyether block amides, chlorosulfonated polyethylene, ethylene-vinyl acetate, polyurethane or a combination thereof. 
     
     
         23 . The system according to  claim 16 , further comprising an operator employed machining device to cut and/or shave the portion of the chosen sheet. 
     
     
         24 . The system according to  claim 16 , further comprising an automatic machining device to cut and/or shave the portion of the chosen sheet.