GB2523801A - Podoquick - Google Patents

Abstract

A method of creating a cast of a foot comprises a stainless steel platform containing a layer of wadding (fig A). Foam is added to the wadding by mixing polyol and isocyante and pouring it into the platform (figs B-E). A thin protective layer of polymer is added to the surface of the foam and a layer of cushioning material is placed on top of the polymer (fig G). Once prepared the user places a foot onto the surface of the cushioning material (fig I), creating an impression of the underside of the foot in the foam. The foot is held in position for 2 ½ - 3 minutes for the foam to set. A custom made orthotic insert may be created using the cast.

Description

Intellectual Property Office Application No. GB1403931.7 RTM Date:t7june 20t4 The following terms are registered trade marks and should be read as such wherever they occur in this document: Poron Intellectual Property Office is an operating name of the Patent Office www.ipo.govuk Name: PODOQUICK General Discussion This invention relates to the improvements in a new method for creating a custom made insole.

For many years, probably since podiatry started, the only way to take a true custom made cast on a person was to utilize a bandage with plaster of paris (POP) which was soaked in water and wrapped around the person foot. When this bandage dried out (negative cast), the cast was removed from the foot and the other foot was then casted subsequently. Each foot would take approximately 10-minute. The significant limitation to this system are: lots of time required; it is very messy; it involves water dripping on the floor; the person foot becomes completely covered in POP; there are people who can possibly be exposed to unexpected allergic reaction to the POP; the negative cast is taken off-weight-bearing, which does not represent a reliable shape on the foot while actually walking. Lastly, the process to convert the negative cast into a positive cast (filling up the negative bandage with POP) requires specialized laboratories and personal and extensive health and safety requirements, which are not easily available.

Overall, the manufacturing procedure can take more than 3 hours and specialized equipment is necessary. The final insole created is made of thermo-molded material, which may change shape if worn for a prolonged period of time with the natural heat generated inside shoes, Finally, the actual negative cast fails to include very important foot details such as: the natural skin expansion that occurs during normal walking at weight bearing; and the cast does not account for the overall thickness of the material that is glued on top of the insole (for example: cushioning material).

These problems are overcome by the present invention, which provides a device with a précised and simple method that allow the creation of custom made insole in only 211⁄2 -3 minutes, at weight-bearing, using materials that are not affected by temperature changes, include the person skin expansion and the thickness of the covering material. If required, a cast can include intrinsic corrections to improve foot ifinctional needs. the manufacturing process takes as little as 30 minutes to be completed, with a significant reduction in time compared to previous methods.

Finally, this method is quick, reliable and create no mess.

) PART 1: Detailed Description of the Iiivention:

Please find below, detailed description of the PodoQuick and the best method of performing a PodoQuick cast. Please note that ALL steps listed below are essential to create a precised PodoQuick custom made insole. The colour of the casting box, which has no effect on the custom made insole, it is completely optional.

1, In order to create the PodoQuick custom-made insole, two chemicals are utilized. The components are: Polyol 300g. and isocyanate 1 50g (figure 1-A), 2. Mixing ratio 2:] 3. The chemicals must be kept at room temperature prior to be used, best between 15°C -30°C.

4. All content of the Isocyanate (catalyst) must be poured into the Polyol container, and close it using the provided lid (figure I-B).

5. Shake it twice only (figure 1-C). The components will easily mix as their density are: Polyol t.1+0.i gm/cc, and Isocyanate t.24 + 0.05 m/cc. Their viscosity at 25°C are: Polyol 3000+500 mPas, and Isocyanate 700+100 mPas.

6. The mixed chemicals are poured inside two light platforms made of stainless ste&, each containing a layer of specially designed waddings white-polyester, each: Length-34cm, Width-14.Scm, Height-3.Scm (figure 1-D). This material is able to absorb completely (more than 90%) the full quantity of the poured mixed-chemical.

7. The inferior side of the wadding is firmer (to increase the consistency of the cast) and the superior part is less dense (to allow full absorption of the chemical).

8. These chemical's specifications are designed to generate a delayed reaction; therefore, allowing plenty of time (approximately 20 seconds) for a person to stand on top of the platform before the reaction occurs.

9. Pour all content of the chemical in on top of both waddings (figure i-E, and then close the platform (figure 1-F).

10. A thin protective layer is attached to each corner of the pbtform using non-sharp support. The film is made up of a similar polymer as the chemical materials used to cast, thickness: 12-2Onm. This special composition allows the film to adhere immediately and firmly to the poured-chemical, creating a seals, which acts as a protective membrane and prevents any leakage. This important aspect of the system ensures that the foot never comes in contact with the chemicals.

11. A cushioning material Poron 4000-Urethane', 3mm Thickness, Length-33cm, Width-l3cm, is placed on top of the closed platform on the protection film (figure 1-6), This important details, allows during the casting procedure to account for the usual thickness of the covering material, typically applied on top of any foot-orthoses, 12. Due to the combination of the ratio, density and viscosity of the components, once the person stands with both feet at weight bearing, the chemicals will start to expand uniformly around the feet (figure 1-I), and will solidify within only 21⁄2-3 minutes (depending on the size of the foot). As shown in figure 2, the expansion of the liquid, allow improving of pressure distribution underneath the whole plantar aspect of the feet.

13. The feet are never into direct contact with the chemicals at any stage during the casting procedure, as there is the protection-film and the Poron layers (3mm thick) that separate the feet from the waddings (figure 1-I). These details are essential to guarantee that for the whole duration of the casting procedure, the feet will never become dirty of the chemical (figure 1-J).

14. Detailed Health and Safety precautions in case the user will come into contact with the chemical are reported on Appendix I'.

15. Shelf life -6 months in sealed conditions if stored at 15 -30 °C

PART 2: Summary of Invention

a) Thanks to the specific ratio of the mixed components, only after 21⁄4-3 minutes (depending on the foot size), the chemicals will have expanded completely underneath both feet (figure 1) and transformed from liquid into solid. This method guarantee the quality of the final custom made cast. The chemicals do not need to be cooled prior to use. Best results can be achieved between 15°C -30 °C.

A layer of 3mm Poron is placed on top of the whole surface of the thin protective layer, which will be in direct contact with the person feet; the Poron allows accounting for the thickness applied by the insole's covering material. During the casting procedure the user can hold the feet into a corrective position to improve foot functionality (figure 1-I), If correction of the foot posture is required (ie: heel raise), the PodoQuick technology allows any forms of EVA (Ethylene-Vinyl Acetate) materials to adhere completely to the casts. Please refer to figure 1' for step-by-step casting method and related drawings.

Appeiidixi: Heidth and Safety HA2ARDS IDENTIFICATION Risk advice to marx and the No particular hazards known en vironmerit

FIRST AID MEASURES

In case of contact with skin wash off with Atter contact with skxn soap and waler.

Flush eye immediately and thoroughly After contact with eves whilst protecting the un-affected eye.

Not measure should be taken avoid ___ After innalation --prolonged inhaiation, Do riot ingest or drink the components. In Alter ingestion the event of symptoms seek medicaL advice.

(3) ELRE4iGHT1NG MEASURES 0 ___________ foam, carbon dioxide, dry powder. waler suitable extinwuishiiw: media.

spray.

Extin2uishinn media which must not applicable not be used br sarety reasons In the event of fire the following can carbon dioKlde, carbon monoxide ue released: Special protective equipment for Do not inhale explosion andior combustion fire-fighters gases

ACCIDENTAL RELEASE MEASURES

Personal precautions Use personal protective equipment.

Do not allow entering drains or Environmental precautions waterways. Do 1101 discharge into the subsoil/soil.

Take up with absorbent material (eg sand. kieselguhr, universal binder).

Methods for cleantng Dispose of absorbed material in accordance with the local regulations.

HANDLING AND STORAGE

No special measures necessary if used Advice on safe handling correctly Normal storage conditions Storage within 15°C -30°C LI) storage class: 10 04 EXPOSURE CONTROLS / PERSONAL PROTECTION O) ---o not eat, Win or smoe w en Personal protection equipment --O Hyziene measures after work.

Respiratory protection None required Hand protection PVC gloves Eye protection standard goggles with side pieces Skin and body protection light protective clothing

TOXICOLOGICAL INFORMATION

Proper use provided, no adverse health Remsrks effects have been observed or have been come to our knowledge. a

ECOLOGICAL INFORMATION

The product is considered to he a weak water poiiutanL, However, do not allow Further ecoiowcal inforinanon entering soil, waterways or wastewater canal.

in accordance with local authority Product regulations, take to special waste incineration plant Contaminated packaging if empty contaminated containers are recycled or disposed of, the receiver must be informed about possb]e hazards, TRANSPORT ENFORMA]I[ON The product does not require a hazard-warning label in accordance with directive for IC) regulations on dangerous substances, (4 a)