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customer’s requirements is made using
CAD software and used to produce trial
casts which are sent to the customer for
approval. Once approved, the full range
of production moulds is completed. The
number of applications for which the
pads can be used is extensive.
CONTOUREX
The material used is a group of latex
foams unique to Brötje called
Contourex. They are made entirely
without fillers in order to guarantee the
highest level of purity and in a variety
of formulations to meet different
requirements. Furthermore, as no
mould release agents are used, the
foams all bond very easily. A special
process is used to vulcanise different
covering materials to the top surface of
footbeds. This makes them totally
solvent-free, saves the customer an
operation and allows a logo to be
included.
Due to the uniform and porous
structure of Contourex, moisture
absorbency capacity is approximately
40% of the material‘s own specific
weight. Moisture absorbed during the
day can be dissipated again at night by
removing the insole from the shoe. The
open pore structure also provides
excellent breathability of 8.5 l/min
(measured at 0.01 bar) and
compression set, with the latter
effectively returning to 97% of its
original thickness after 100,000 cycles
and 24 hours relief.
Contourex Soft (pink)
– has a
density of 0.20g/cm
3
and 40 Shore OO
hardness. Its softness makes it ideally
suited for sling, ankle, tongue and
collar pads as well as trim strips.
Contourex Medium (grey)
– with a
density of 0.28g/cm
3
and 50 Shore OO
Hardness, is designed to meet the
comfort requirements for sports pads,
sandal footbeds, as well as metatarsal
pads and arch supports.
Contourex Hard (anthracite)
– also
has a density 0.28g/cm
3
but at a higher
60 Shore OO hardness. This rigid foam
is especially popular in the orthopaedic
sector where it is used for arch
supports, metatarsal and heel lift pads.
Contourex Memory (red)
– is a very
special foam with a density of
0.20g/cm
3
and
biomechanical
properties similar to the visco-elastic
system contained in human skin. This
manifests itself, for example, in the fact
that pressure is optimally distributed by
body heat and body weight. The
viscous properties of this foam also
have an excellent shock-absorbing
effect at 95% after 100,000 load cycles.
Its delayed memory (resilience)
properties also enable it to adapt to the
foot as it constantly changes during the
course of the day so that an individual
footbed can be formed at any time.
APPLICATIONS
Heel pads, heel pads with arch
support and heel edge pads:
Heel
pads are generally used to protect the
heel from pressure and impact. Those
with arch support additionally support
the ankle and prevent fallen arches
(flat feet) from developing. Heel edge
pads provide an elastic seat for the
heel and, due to a recess in the centre,
can be used for several sizes by pulling
in the edges while attaching to the
insole.
Novelty, sports, sling and
spherical heel pads or sandal
footbeds:
Novelty and sports pads are
designed to relieve the foot when
footwear is worn for a long time. Sling
pads have been especially developed
for pumps and, as they taper to
virtually nothing at the edges, are
scarcely visible. Sandal footbeds
significantly increase comfort and
wearability and are widely used. They
can be made with integrated arch
support and metatarsal pads as
protection against flat or splay
footedness as well as for pure support
of the natural foot arch.
Shoe upper pads:
These are used
to assist fit and, with sensitive feet,
cushion tendons and ligaments. Ankle
pads offer protection from bruising
and tongue pads alleviate pressure on
the instep caused by tight laces. Collar
pads and trim strips soften the topline
of the shoe, while cap pads protect the
middle foot from the hard edge of a
reinforced safety cap.
Arch supports, metatarsal pads,
toe grips and ball cushions:
Arch
supports prevent flat feet or fallen
arches by supporting the longitudinal
arch of the foot while metatarsal pads
help to stop the development of
splayed feet. Toe grips offer improved
grip for the foot in open shoes.
Contourex 3D footbeds can even be
shaped on either side to match both the
underside of the foot and the inside of
the shoe, including individual lettering,
logos and profiles if required. In a mass
market world, Brötje has gone the other
way and is probably one of the most
specialist foam insert suppliers in the
world. At the same time, it has used
automation to enable it to produce its
inserts quickly, at high volume and to
the highest quality level—surely the
best of both worlds.
27
SPECIALIST INSERTS
MAY/JUNE 2012 | www.footwearbiz.com
Contourex foams come in four colours:
pink for Contourex Soft, grey for Contourex
Medium, anthracite for Contourex Hard
and red for Contourex Memory.
PHOTO CREDIT: BRÖTJE