WO2004073441A1

WO2004073441A1 - Method for producing made-to-measure orthopaedic shoes

Info

Publication number: WO2004073441A1
Application number: PCT/DE2004/000256
Authority: WO
Inventors: Thomas Fromme
Original assignee: Thomas Fromme
Priority date: 2003-02-20
Filing date: 2004-02-13
Publication date: 2004-09-02
Also published as: JP2006521836A; EP1596682A1; US20060143839A1

Abstract

The invention relates to a method for producing made-to-measure orthopaedic shoes consisting in three-dimensionally scanning the loaded foot of a patient. Measured data are taken by scanning, recorded in a computer and processed in such a way that a three-dimensional image of the foot is obtained. Afterwards, an X-ray image of the patient foot is superposed on said calculated image. The measured data obtained by the scanning makes it possible to control machining devices for the automated manufacture of lasts, shanks, soles, uppers and pinching.

Description

Process for the production of orthopedic bespoke shoes

The present invention relates to a method for producing custom-made orthopedic shoes.

In contrast to the industrial production of standard shoes for daily use, custom-made orthopedic shoes - as the name suggests - have so far only been able to be manufactured in a complex, one-off production by a skilled tradesman, whereby this old method must be followed in a very specific, predetermined order. This starts with measuring the foot with a measuring tape, whereby measurement inaccuracies can already occur here, which are continued and multiplied in the following procedure. After measuring the foot, a corresponding last is made. The individual footbed is then made. Then the material for the shaft is cut using a hand-made basic model and then sewn. After the insole has been applied, the upper is pinched and stapled on the lasts, depending on the equipment, with the front and rear caps. Then the flared shaft is glued and then the staples are removed. This process is very time consuming. The sole is then attached to complete this shoe. In contrast, the invention is based on the object of being able to manufacture such custom-made custom-made shoes faster and with greater accuracy by automated methods.

Shortening the manufacturing time also has considerable medical benefits. The physician can use his medical healing process to a far greater extent and only guarantee shoe care at the end of an overall therapy. This can be explained using the example of a heel fracture and its shoe care. It has usually been the case so far that measures have to be taken in the eighth week, at the latest in the ninth week, to create orthopedic footwear, since the medical treatment ends after twelve weeks after the heel fracture, so that the patient has his or her own in the twelfth week Can get shoe. With the help of the new process, the shoe can only be created in the eleventh week, which has the advantage that the shape of the foot changes with the decongestant measures, etc., and of course the fit is much better than that of one Shoe manufacturing time, which so far takes three to four weeks.

The new method is characterized by the fact that the patient's foot is subjected to 3-dimensional photographic scanning in the loaded state, the data determined by the scanning are stored in a computer and processed into a 3-D image of the foot, this calculated image X-ray image of the patient's foot is superimposed and processing machines for the automated production of shoe lasts or bedding, upper, for tweaking and for floor construction are controlled by the measurement data obtained by the scan taking into account the specifications of the displayed X-ray image. Medically, there is a considerable advantage, since the peculiarities of scanning the X-ray image can take into account peculiarities of ankle anatomy, in a form that has not been known until now.

Calluses or other soft tissue changes can also be taken into account so that there are no pressure points. The problems of claw toes and the height of the toe cap (if a work shoe is to be made) can be recognized here on the computer and discussed if necessary. In the past, the shoes were made, and the patient only noticed the pressure points when trying them on, which were difficult and time-consuming to change. With the new shoe manufacturing process, it can be recognized in advance on the computer whether e.g. B. the predefined steel caps and the toe changes match at all. This results in a significant reduction in costs in advance. Due to the fact that the foot is correspondingly documented from below by the 3-D representation, namely under load on the foot (possibly partial load), corresponding deformations during the load can be taken into account. Through the 3-D creation of the last as? The dimensional control (see below) also allows a comparison between the last and the size of the foot, which means that orthopedic shoe technology and the treating and prescribing doctor can interact closely with one another without negative influences being possible in any way.

As can be seen from the attached schematic diagram, the method according to the invention shows considerable variability. Based on the scanning process and the measurement data determined thereby, the last can be started in parallel with the last, the shaft construction and the bed construction. It is also possible to start building the floor immediately after scanning, which results in Given the fact that the measurement accuracy is very high, this results in a very precisely crafted shoe, and on the other hand in a considerably shorter time than with the conventional method.

In the following, the process sequence for producing an orthopedic custom shoe is explained using the new method.

The patient places the diseased or damaged foot on the glass floor plate of a photographic scanner consisting of five cameras, four in the corresponding corners and the fifth from below.

Since the detection zones of the individual cameras overlap, the data is processed in the computer in such a way that a virtual image of the foot is calculated. The finished picture now shows the foot silhouette with all its anatomical features.

The picture can be viewed from all sides. As a special feature of the method according to the invention, the X-ray image of the patient's foot is now superimposed in this 3-D image, so that in this phase the peculiarities of the bony skeleton can be incorporated and taken into account.

On the basis of the measurement data determined by the scanning process, the corresponding last bar design is now calculated by the computer, which can be modified in a wide variety of places on the basis of the special features of the outer foot and the skeleton structure of the foot.

In the so-called dimensional control, which shows the measurement data of the foot in virtual form, the is checked again individual measurement data, possibly also a check against control data obtained by hand (old method).

The next step is the virtual intermediate sample. Here the last, which has been calculated, is compared by the computer with the data of the foot. So the dimensional control is worked into the last to see whether the last matches the inner foot data. In this phase, too, special features that may have been prescribed by orthopedics or medicine, can be taken into account, which is an absolute novelty.

From the calculated last, the leather cuts for the upper are now calculated using a computer, which in turn is a virtual copy of the last.

Of course, the anatomical features of the foot are also taken into account when designing the upper.

The cutting of the leather with the aid of a CAD-controlled cutting table on the basis of the measurement data stored in the computer is carried out with an accuracy not previously achieved in practice. This cutting table cuts, punches and creates the markings for the shaft assembly fully automatically.

When assembling the shaft, the pieces of leather are put together, whereby the lining is also incorporated (or corresponding upholstery parts). The leather is equipped with eyelets and the other necessary typical utensils. For toe shoes, the toe cap is also worked in at the same time.

What is new is the design of the last, including the subsequent footbed as a single unit. This leads to more precise assembly by means of orthopedic shoe machines. Installation of the shoe can therefore begin without the footbed being created beforehand, as in conventional manufacturing. Based on the computer data, the lasts and the footbeds are milled regardless of the time. The milling method used so far was as follows. A single last was milled and then cut open with a band saw and fixed with screws. The subdivision is necessary in order to remove the lasts from the shoe after the shoe is finished. With the new method, several strips are milled from a larger block. Depending on the size, up to five pairs in one operation. The strips are also milled in split form. This has two major advantages. On the one hand, the dimensional inaccuracy that arises during the subsequent separation is eliminated. When sawing with a band saw, the last loses dimension due to the thickness of the saw blade. The second advantage is explained in more detail in the next paragraph. The milling process can be carried out simultaneously on two machines or in succession on one machine. The specialist chooses the usual materials for the last. A different choice of materials applies to the bedding. Here rubber-like material with different shore hardness is chosen; Depending on the medical requirements, rigid, semi-soft or soft inlays are selected. The bedding is then covered with leather or other materials to help them with foot sweat and the like. and prepare for comfort.

Because the milling machines are computer-controlled, there are considerable advantages for the accuracy of the production.

Another new feature of the method according to the invention is the fact that the last is initially placed on the narrowest finished sole form is worked. However, since there are different wishes of the patients, as well as the requirements of the doctor, a variable design must be possible, which is guaranteed by the fact that plastic caps are put on in order to obtain wider moldings. These caps are designed on the computer and created by a 3D printer. The type and shape of the required over-cap the calculated strips is taken into account by this type of method, a plurality of different shapes for the design of the shoe ^• toe area so that possible, without the process itself time consuming or delayed. As already mentioned above, the second decisive advantage of milling the strips in a split form. Since the subdivision is practiced in the computer and saved permanently, you can also mill a new front part in a modified form for the respective last at any time. Both methods - overcap or interchangeable tip - are used depending on the size of the changes. This way, the quick creation of the base strips is still guaranteed.

The assignment of the individual last to the respective patient is secured by a chip. Specifically, this means that the last, which was provided with an engraved identification number during the milling process, is now provided with a readable chip, which can be read and identified with a reading device. The computer recognizes the associated patient on the basis of the identifier stored in the chip in the network. This means that each employee has all the patient and shoe manufacturing data they need.

Now the insoles are attached to the last. These insoles are already available in their final form, since they are compared in the PC when comparing the last shapes with the finished sole Were designed in advance and cut at the cutting table. The same applies to the different rear caps.

Now the gusseting process for the front cap area takes place mechanically. The machine used is so variable that different, lateral, oblique problem solutions are possible. Teflon tapes are attached to the tip lasting machine. These side gussets can be changed by the orthopedic shoe technician according to certain technical specifications on the device, depending on the individual shape, in order to achieve an adequate shape of the forefoot or the shoe. Since these straps are so flexible that they return to their original shape after the end of the load, this technical device guarantees that shoes can be worked in the same shape directly one after the other and also in different forefoot shapes. This machine is able to process 200 pairs of shoes a day. A disadvantage, which at the same time turns out to be a great advantage, is to be seen in this lasting machine in that the forces in the lasting machine, which cannot be achieved by hand, lead to the defects in the skin while all areas of the front leaf parts are simultaneously being pinched , from which the leather cuts are made, leads to the destruction of the fur or the shaft. This could be compensated for by hand and taken into account accordingly. On the one hand, this means that the fur is naturally protected, but on the other hand that inferior material can be processed by hand, which is not possible with this lasting machine, so that for quality assurance, the machine is certainly of higher quality than the manual lasting.

The heel area is created in its own heel lasting machine. This lasting machine works according to the same principles pien like above. In the pinching process phases for both the front and the rear area, the lining, in particular for the heel and the heel cap or orthopedically necessary types of rear caps, is worked in beforehand, so that these can be incorporated at the same time during the pinching process. This is not the case if a steel cap is required. For the front sheet pinch, it is first necessary that the feed is pinched. Then the steel cap is reworked and the front sheet is tweaked over it.

The lasting process is carried out over both areas using contact adhesive. The time-consuming stapling as well as their later removal is therefore no longer necessary.

Possibly free open areas of the shaft between the toe and heel area can be attached with a side curling machine.

When building floors, the finished soles are applied or glued to the gusseted area. In this phase, special features in sole construction are taken into account, e.g. a steel spring, which is intended to give the floor a certain strength in the rear area, as well as other orthopedic specifications, which are also specified by the medical side.

In a floor press, a firm unity between the sole and the rest of the shoe is guaranteed.

For final assembly, the prepared beddings are now inserted into the finished shoes.

Various special floor presses guarantee through their either sole-side or side- or also combined- high pressure, a firm connection between the soles and the remaining structure of the shoe. These steps apply to all kinds of custom-made orthopedic shoes. (Work shoes, street shoes, slippers, sneakers, etc.).

In summary, it can therefore be said that the scanning process of the foot and the fade-in of the foot X-ray image give the computer all the data necessary to control a wide variety of processing machines and to produce a shoe that takes individual circumstances even more into account wears as a shoe that has been manufactured in the traditional traditional process.

Before the actual production begins, all the characteristics and properties of the dimensionally accurate shoe are defined.

Claims

Process for the production of orthopedic bespoke shoes

1. Method for the production of custom-made orthopedic shoes, in which the patient's foot is subjected to a three-dimensional photographic scan in the loaded state, the measurement data determined by the scan are stored in a computer and processed into a 3-D image of the foot An X-ray image of the patient's foot is superimposed, and processing machines for the automated production of shoe lasts or bedding, an upper, for tweaking and for floor construction are controlled by the measurement data obtained by the scanning, taking into account the specifications of the displayed X-ray image.

2. The method according to claim 1, characterized in that the measurement data obtained by the scanning are used to calculate a last design, which is compared below with the dimensions of the scanned foot and any modifications are made to the design.

3. The method according to claim 1 or 2, characterized in that on the basis of the scanned measurement data of the strips (strips and bedding as a compact unit) and the bedding are produced parallel to one another.

4. The method according to claim 3, characterized in that at the same time several pairs of strips are milled from a block and the strips are equipped with an identification chip.

5. The method according to any one of claims 1 to 4, characterized in that based on the scanned measurement data of the last is first worked on the narrowest finished sole shape, individual patient foot shapes and medical specifications in the forefoot area are taken into account by means of overcaps created by a 3D printer.

6. The method according to any one of claims 1 to 4, characterized in that strips composed of individual modules with interchangeable tips are used.

7. The method according to any one of claims 1 to 6, characterized in that in an automatic lasting machine, the toe area is pulled and fastened around the last with uniform force over the circumference of the forefoot area, taking into account the measurement data obtained by the scanning.

8. The method according to any one of claims 1 to 7, characterized in that the heel area is also created by means of a lasting machine.

9. The method according to claim 7 and 8, characterized in that the front cap is previously incorporated in the lasting phases.

10. The method according to any one of claims 7 to 9, characterized in that the shaft is mechanically pulled around the last and fastened during the lasting process.

11. The method according to any one of claims 1 to 10, characterized in that both strips and the bedding is milled.

12. The method according to any one of claims 1 to 11, characterized in that in the floor construction, the finished sole is connected to the rest of the shoe in a floor press.