Human wearable laminar structure, insole made therefrom and methods for their manufacture |
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申请号 | US12077932 | 申请日 | 2008-03-21 | 公开(公告)号 | US20080229612A1 | 公开(公告)日 | 2008-09-25 |
申请人 | Renee Sommer; Jeanee Petree; | 发明人 | Renee Sommer; Jeanee Petree; | ||||
摘要 | A composite laminar structure treated to inhibit micro-organisms from thriving thereupon, comprising a suitable thickness of two or more expanses of woven or non-woven materials. A plurality of nano-particles, including materials such as silver, are distributed relatively uniformly across and sufficiently durably coupled with the two or more material expanses to resist removal during normal use and mild laundering. The nano-particles possess anti-microbial properties suitable to substantially inhibit population growth of one or more micro-organisms. The laminar structure may be configured as an insole for a shoe, or as other articles for wear or use in other applications where growth of micro-organisms is undesirable. | ||||||
权利要求 | I claim: |
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说明书全文 | This application claims the benefit of priority to U.S. Provisional application No. 60/919,598, filed on 22 Mar. 2007 and entitled ANTI-MICROBIAL, ANTI-BACTERIAL AND/OR ANTI-FUNGAL HYPOALLERGENIC LAMINAR STRUCTURE, INSOLE MADE THEREFROM AND METHODS FOR THEIR MANUFACTURE, the contents of which are hereby incorporated herein in their entirety by this reference. This invention relates generally to the field of insoles for footwear, e.g. shoes, boots, sandals, flip flops, slippers, and the like. More particularly, it concerns a composite, e.g. laminar, structure and insole made therefrom utilizing hypoallergenic materials that exhibit anti-microbial, anti-bacterial and/or anti-fungal properties. Briefly, the present invention provides a composite, e.g. laminar, structure and an insole made therefrom exhibiting antimicrobial, antibacterial and/or antifungal characteristics. The antimicrobial, antibacterial and/or antifungal effects (collectively herein in any combination ‘antimicrobial’) of the composite insole are derived from nano-silver particles that are infused or otherwise ingrained in, or effectively applied to a surface of, the composite material. The composite insole material layer (‘fabric’ herein for convenience) contains fibers made of cotton, linen, silk, wool, leather, blended fabric, synthetic fiber, or any combination thereof The present invention also provides a method for constructing the antimicrobial, antibacterial and/or antifungal composite insole. In accordance with one embodiment of the invention, one or more of laminates 12 and 14 include, e.g. are infused or otherwise effectively treated with, a suitable density of colloidal nano-particles 18 exhibiting anti-microbial, anti-bacterial, and/or anti-fungal properties. Colloidal nano-silver has been shown to be one such colloidal nano-particle and can be made to substantially permanently infuse or otherwise ingrain a cotton fiber and/or a wool fiber of which laminates 12 and 14 suitably can be made. Nano-silver with a mean particulate diameter of between two and five nanometers (2-5 nm) has been found to be capable of being substantially evenly distributable throughout both fibrous layers, thereby substantially permanently to render laminar structure 10 anti-microbial, anti-bacterial and antifungal. The embodiments are not, however, so limited. For example, colloidal silver particles with cross-sectional dimensions of approximately 11.6 nm, 30 nm, and 70 nm have shown demonstrated anti-microbial efficacy. Although nano-silver is described in embodiments herein, other materials shown to provide anti-microbial properties include zinc, copper, and others, which may also be formed as nano-particles and applied as described herein. In general, colloidal solutions including silver nano-particles with suitable cross-sectional (e.g. diametric) dimensions between approximately 2 nanometers and approximately 150 nanometers (˜2-150 nm.) provide similar benefits (e.g., anti-microbial, etc.), and effective embodiments are likewise contemplated herein at even larger sizes. It is, however, expected that particle size can affect some performance characteristics, such as particle distribution upon and/or throughout layers in a laminate structure described herein, and particle retention during laundering, for example, with small particles providing enhanced benefits and performance characteristics relative to larger particles. Effective diffusion and even dispersion of the nano-silver particles in accordance with one embodiment of the invention is achieved by soaking the laminates in a nano-silver-infused bath and then drying the same, as will be discussed in more detail below by reference to Those of skill in the art will appreciate that alternative composite materials may be substituted, e.g. linen, silk, leather, blending fabric, synthetic fiber such as a “wicking” polyester, or the like, alone or in combination. Thus, while a cotton upper and a wool lower laminate are described and illustrated here because of their hypoallergenic, smoothness and comfort qualities, those of skill in the art will appreciate that other suitable fibers or materials made by any suitable process nevertheless are within the spirit and scope of the invention. For example, woven fibers such as “wicking” polyester can be substituted for the cotton upper laminate to “dry wick” body fluid (e.g. sweat) away from the user's body. Optionally, a third laminate substrate 20 lies beneath and supports the above-described composite structure including laminates 12 and 14. Substrate 20 can be of any suitable material such as hydrogel, silicone, Ellastalloy™, Kraton™, or the like (e.g. a special formulation may be created for this layer using a combination of Kraton and another polymer). For particular applications, such as shoe insoles to be described below, it may include an inherent non-slip or non-skid lower surface or a lower surface suitably treated to be non-slip or non-skid. Depending upon the material from which it is formed, substrate 20 may naturally ‘cling’ to laminate 14 or it may instead be more permanently adhered thereto with any suitable adhesive, e.g. an adhesive film layer 22. Those of skill in the art will appreciate that In accordance with one embodiment of the invention, the processing conditions are as follows. The bath includes 2-3% by volume of a nonionic or cationic softening agent such as fabric softener, 0.5-1% by volume of a wetting agent and approximately 5-5.5% by volume (i.e. approximately 50-55 grams/liter (g/L) of nano-silver-containing colloidal fluid identified by the trade name SNSE, or another suitable nano-silver colloid volume. SNSE is available from the NP-Tech Co. Ltd. of Seoul, South Korea, but any suitable alternative is acceptable. The pick-up ratio of the process, i.e. the wet weight contribution to the fabric from the bath, is approximately 55-60%. The pick-up ratio is pre-tested to ensure proper pick up or percentage saturation of the fabric by the bath solution by adjustment, for example, of the pressure between squeeze rollers 34 and 36. Drying and curing stations 38 and 40 can be of conventional design, e.g. typically the dryer has a peak temperature of approximately 130° C. in the middle with temperatures tapering toward the entrance and exit thereof. Those of skill in the art will appreciate that the manufacturing steps illustrated in At 310, the insole is trimmed by the user to fit his or her particular shoe size and style. At 312, the insole is inserted into the user's shoe, snugged against the inner flat surface thereof and worn (used). After one or more uses of the insole, at 314, the insole is washed, preferably by hand in cold water using a mild detergent such as that sold under the trade name WOOLITE™. At 316, the insole is reused, thus repeating insert/wear and wash blocks 312 and 314. Experimental results indicate that twenty or more (e.g. fifty) reuses of the same insole are possible in accordance with the invention. Those of skill in the art will appreciate that Those of skill in the art will appreciate that the invented composite, e.g. laminar, structure lends itself to applications other than footwear. For example, general or specific attire or garments, e.g. riding breeches, athletic wear, hats, gloves, halters, pants, tops, etc. can be made using the composite with the advantage of its novel antimicrobial properties. Indeed, any non-woven or woven or other organic or natural materials such as cotton, wool, silk, leather, polyester, or the like can be made into the invented composite and the composite can then be made into any desirable shape for any desirable purpose. All such applications are contemplated as being within the spirit and scope of the invention. In accordance with one embodiment of the invention, top designer layer 44 is made of woven 100% cotton fiber. Also in accordance with one embodiment of the invention, the top designer layer 44 is fused to a 100% wool central padded layer 46 with an adhesive film therebetween (for example, the earlier described adhesive available from the 3M™ corporation, or a suitable alternative). In accordance with one embodiment of the invention, both layers 44 and 46 are treated with “permanent” colloidal nano-silver by which is meant the treatment lasts substantially indefinitely under normal use and reuse. Finally, in accordance with one embodiment of the invention, the bottom layer 48 is made of non-slip hydrogel, silicone, the material identified by the trade name ELASTALLOY™, the material identified by the trade name KRATON™, or other suitable material that ‘sticks’ to the surface of an original shoe footbed without slipping or leaving a residue. Those of skill in the art will appreciate that top designer layer 44 typically is of lighter weight than is central padded layer 46, which typically is of lighter weight material than is bottom layer 48. In accordance with one embodiment of the invention, top layer 44 is suitably approximately 1/64- 1/32 inch thick, intermediate layer 46 is suitably approximately 1/16-⅛ inch thick, and bottom layer 48 is suitably approximately 1/16-⅛ inch thick, all measured in their uncompressed states. Those of skill in the art will appreciate, however, that the laminates are relatively fluffy and yieldable, and that, when compressed, an inner region tri-laminate composite insole typically is no thicker than approximately 1/16-⅛ inch, and that, along the peripheral edge, the composite insole typically is no thicker than approximately 1/32 inch. Those of skill in the art will also appreciate that the weights of the various layers, within the spirit and scope of the invention, may be different whether absolutely or relatively. If orthotic effects are desired, such can be accommodated in accordance with the invention by modifying bottom layer 48. For example, an arch support can be built, e.g. molded, into a special bottom layer 48 before bottom layer 48 is adhered to the other two layers 44 and 46 of insole 42. Any and all such modifications to the laminates of the composite insole, whether functional (e.g. orthotic), or aesthetic, are contemplated as being within the spirit and scope of the invention. There are four style/shape templates for this insole, Women's Dress, Women's Sport or Casual, Men's and Children, although those of skill in the art will appreciate that any number of styles and shapes are contemplated as being within the spirit and scope of the invention. 1. Fiber layers are constructed of natural, environment-friendly, hypoallergenic materials. 2. Non-slip bottom layer 48 is a hydrogel, silicone, ELASTALLOY™ or KRATON™ layer that ‘sticks’ (naturally or as by the application of heat to the interface between bottom layer 48 and intermediate layer 46) to the original insole surface of the shoe or boot without slipping. 3. Non-slip bottom layer 48 is re-usable, repositionable without losing adhesive quality. 4. Non-slip bottom layer 48 is removable without leaving residue on the upper surface of the shoe's inside bottom. 5. Non-slip bottom layer 48, once adhered within the invented insole 42, is not water soluble, nor will it break down or dissolve if soaked in water with mild laundering detergent (e.g., WOOLITE™, and/or other hand-washing detergent). 6. Insole 42 is washable up to approximately twenty washings or more (hand washing recommended), and repositionable after washing with same level of original adhesion. 7. Edges of insole 42 are compressed to a very thin (≦ 1/32″) clean finish. 8. Insole 42 is ‘trim-able’ within ¼″ at the perimeter of the insole for adjustments to size and fit in the shoe or boot. 9. At least top layer 44 and optionally also the wool padded center layer are treated with a solution of colloidal nano-silver particulate 18 with a mean diameter of the silver particles of between 2-5 nm. 10. The application of nano-silver particulate 18 is permanent and will not lose anti-microbial, anti-bacterial, anti-fungal efficacy for up to twenty or more washings. 11. Distribution of nano-silver particles 18 on fabric (as a function of weight per square centimeter) is provided in a suitable concentration of parts per million (ppm) proven effective in eliminating micro-organisms (e.g., one or more of bacteria, fungus, microbes, etc.) to a 95% or greater level, more preferably up to a 99.7% or greater level and, in accordance with some embodiments, even up to a 99.9% level. Demonstrated suitable concentrations are found in the range of approximately 10-200 ppm. While it is expected that even higher concentrations may provide improved particle density when deposited on an expanse of material suitable for use in a laminar insole described herein, and therefore perhaps enhanced anti-microbial benefits, and improved particle retention following laundering, concentrations of silver nano-particles in the range of approximately 20-50 ppm have shown particular benefits. 12. Bottom non-slip layer 48 is protected by a suitable film cover material such as a biaxially-oriented polyethylene terephthalate (boPET) polyester (identified by the trade name MYLAR™), acetate or another comparable removable material to prevent insole 42 from sticking to the inside of the insole's packaging. Such cover material may typically be clear, although it may likewise be partially or entirely opaque to light in the visible spectrum according to alternative embodiments. Likewise, the cover material may be treated with a release material (e.g., silicone, etc.) to enable easy release from the bottom non-slip layer 48. 13. To use insole 42, the MYLAR™ cover is peeled away, exposing the sticky non-slip lower surface of the bottom layer. 14. Finished insole 42 is die-cut to pattern sizing specifications. The scope of the invention contemplates several variations which yield useful and beneficial properties in alternative embodiments. In one such embodiment, one or more of the laminate materials can comprise aromatic (e.g., in the broad sense of having an aroma) or other fragrant materials. For example, a laminate material individually or when combined with another laminate material, or an adhesive material utilized in construction of a laminar structure described herein, may be infused with essential oils, or may include an integrated fragrant material (e.g., fragrant portions of a lavender plant, etc.). The fragrant material may be a naturally occurring material or some derivative thereof, or a man-made fragrant material, or any combination thereof. By ‘fragrant material’, it is meant that the material inherently and/or is caused to release into the surrounding environment (e.g., whether gaseous, liquidous, etc.) compounds which individually or in combination are detectable by the olfactory organs of any living organism. Thus, a laminar structure which exudes a pleasant aroma for humans, as well as a laminar structure which exudes an offensive smell to one or more animals (for example, to discourage a dog from chewing slippers), are equally within the scope of the contemplated embodiments. Another contemplated embodiment provides a laminar structure in which one or more of the laminate materials include pharmaceutically and/or physiologically beneficial materials (e.g., medicines, soothing lotions/oils, anti-pruritics, anti-biotics, ultraviolet-energy blockers, etc.), configured to deliver a beneficial effect to a human. Such effect can be deliverable at the time a laminar structure so configured is worn, however in embodiments, residual beneficial effects may continue for some period of time even after removal by the human. For example, an approved and recognized anti-fungal compound can be infused, applied, embedded, or otherwise incorporated with a laminate structure, and while the nano-particles of the laminate structure inhibit microbial growth at the laminar structure itself, the anti-fungal compound can deliver similar benefits to a wearer of the laminar structure. Therefore, an embodiment of the invented laminar structure can not only mitigate the harmful potential of a common vector for harmful micro-organisms (e.g., a shoe insole, etc.), but can also deliver medication and treatment to a human wearer via the inclusion of a recognized and approved medicinal material. However, the embodiments are not so limited, and can generally include any pharmaceutically and/or physiologically beneficial material or compound, or combination thereof, which provides benefits when placed in contact and/or proximity to a portion of a human body. Further, although numerous material for forming a woven or non-woven laminate material are listed herein, it bears repeating and clarifying that the embodiments are in no way limited to the listed materials. The contemplated embodiments include both natural and synthetic materials, or any suitable combination thereof. A non-exclusive list of natural material can include cotton, silk, bamboo, hemp, wool, or hair, but more properly encompasses any material obtained and/or derived from natural sources, whether obtained or formed as fibers or in some other form. Likewise, the vast number of options utilizing synthetic materials (e.g., man-made or machine-made) provide embodiments far too numerous to list. As any listing provide herein could be improperly interpreted in a limiting sense, no such listing is provide. However, one having skill in the art will recognize that nearly any synthetic material currently used or contemplated for use in the production of or formable as textiles, fabrics, or other flexible sheet-like materials may be used in embodiments as provided herein. Additionally, the term ‘man-made’, wherever utilized within this description, is not intended exclude materials which are partially or entirely machine-made, but rather is used herein to mean any material which is altered in some way from a naturally occurring state, by whatever method. Likewise, any materials formed by utilizing, converting, reforming, reusing, reintegrating, reconstituting, or otherwise recovering previously used materials, whether natural, synthetic, or some combination thereof, are expressly included within embodiments and the scope of the contemplated invention. Collectively, all such material are considered ‘recycled materials’, but this phrase is given a most expansive meaning herein, and is not limited by any commercial, industrial, scientific, or other ‘special meaning’ assigned to the phrase ‘recycled materials’, past, present, or future. Rather, the phrase ‘recycled materials’ is used herein to means any material which was intended or actually applied to any past use, regardless the nature or term of that use, and is subsequently utilized in a laminar structure as described herein. It will be understood that the present invention is not limited to the method or detail of construction, fabrication, material, application or use described and illustrated herein. Indeed, any suitable variation of construction, fabrication, material, use, or application, or any equivalent thereof, is contemplated as an alternative embodiment, and thus is within the spirit and scope, of the invention. From the foregoing, those of skill in the art will appreciate that several advantages of the present invention include the following. The present invention provides anti-microbial, anti-bacterial, and/or anti-fungal properties in a fabric composite and in a footwear insole. The insole's composite structure encourages wicking away from the user's foot of sweat or other body moisture to keep the foot dry. The composite's smooth upper layer is smooth and comfortable against the foot. The insole is washable and reusable, but maintains its effectiveness, integrity and durability through multiple washings. The insole is aesthetically pleasing, and its smooth upper (visible) surface can bear designer names or logos or other proprietary print graphics, patterns, and/or colors. It is further intended that any other embodiments of the present invention that result from any changes in application or method of use or operation, method of manufacture, shape, size, or material which are not specified within the detailed written description or illustrations contained herein yet are considered apparent or obvious to one skilled in the art are within the scope of the present invention. Accordingly, while the present invention has been shown and described with reference to the foregoing embodiments of the invented apparatus, it will be apparent to those skilled in the art that other changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined in the appended claims. It will be understood that the present invention is not limited to the method or detail of construction, fabrication, material, application or use described and illustrated herein. Indeed, any suitable variation of fabrication, use, or application is contemplated as an alternative embodiment, and thus is within the spirit and scope, of the invention. It is further intended that any other embodiments of the present invention that result from any changes in application or method of use or operation, configuration, method of manufacture, shape, size, or material, which are not specified within the detailed written description or illustrations contained herein yet would be understood by one skilled in the art, are within the scope of the present invention. Accordingly, while the present invention has been shown and described with reference to the foregoing embodiments of the invented apparatus, it will be apparent to those skilled in the art that other changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined in the appended claims. |