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WO1990009745A1 - Procede de formation d'une garniture interieure personnalisee ou analogue de chaussure de ski - Google Patents

Procede de formation d'une garniture interieure personnalisee ou analogue de chaussure de ski Download PDF

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Publication number
WO1990009745A1
WO1990009745A1 PCT/US1990/001066 US9001066W WO9009745A1 WO 1990009745 A1 WO1990009745 A1 WO 1990009745A1 US 9001066 W US9001066 W US 9001066W WO 9009745 A1 WO9009745 A1 WO 9009745A1
Authority
WO
WIPO (PCT)
Prior art keywords
liner
custom
last
foot
rigid
Prior art date
Application number
PCT/US1990/001066
Other languages
English (en)
Inventor
Peter M. Graf
Richard M. Stess
Original Assignee
Graf Peter M
Stess Richard M
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Graf Peter M, Stess Richard M filed Critical Graf Peter M
Publication of WO1990009745A1 publication Critical patent/WO1990009745A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B5/00—Footwear for sporting purposes
    • A43B5/04—Ski or like boots
    • A43B5/0405—Linings, paddings or insertions; Inner boots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D35/00—Producing footwear
    • B29D35/0009—Producing footwear by injection moulding; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D35/00—Producing footwear
    • B29D35/02—Producing footwear made in one piece using a moulding technique, e.g. by injection moulding or casting

Definitions

  • the present invention relates, in general, to methods for forming ski boot liners or bladders, and more particularly, relates to methods for forming in place foamed ski boot liners.
  • Such liners generally conform to the shape of the user's foot and have an outside surface which conforms generally to the shape of a hard, relatively rigid ski boot shell.
  • the ski boot liner should hold the wearer's foot in a desired biomechanical condition relative to the boot, while still maintaining sufficient pliability, softness and resiliency to be comfortable during skiing.
  • foamed ski boot liners require reasonably close control of the foaming process.
  • foamed liners formed at sea level will have different characteristics than foamed liners formed with the same chemicals at 7,000 or 8,000 feet.
  • humidity and other environmental factors can significantly affect the resultant liner.
  • a ski boot liner is foamed in place directly around the wearer's foot, such foaming usually will have to take place at the ski shop or retail outlet for ski boots.
  • a plurality of ski boot outlets at differing elevations and environmental conditions will result in ski boot bladders having strength, resiliency and softness which varies undesirably.
  • a third disadvantage is that it is difficult to foam a ski boot liner in place around a user's foot and also include a layer underneath the plantar surface of the foot. As will be seen in U.S. Patent No. 3,640,003, the foot rests on the lower surface of the boot shell and foam extends around the edges of the foot only. While there are techniques for supporting the foot and liners can be combined with separate inner sole members, an integrally formed layer under the plantar surface is difficult to create when the liner is foamed directly around the user's foot.
  • Another disadvantage of foaming a liner in place around a user's foot is that it is difficult to control or maintain a steady, biomechanically sound, position of the user's foot during the foaming process.
  • a ski boot liner around a mandrel or last at a factory enhances the liner quality by being able to control foaming conditions, but the resulting liner does not have a custom fit to the individual user.
  • the mandrels or lasts are comprised of a series of replicas of normal or average feet of varying size. The resiliency of the liner is employed to attempt to make up for the variations of the individual's foot from the casting last or mandrel.
  • ski boot bladder is shown in U.S. Patent No. 3,760,056 in which a combination of foam material and pneumatic cushions is used to try to adapt to the variations in individual's feet. Accordingly, it is an object of the present invention to provide a method for forming a ski boot liner which is customized or replicates the user's foot and yet can be manufactured under controlled factory conditions.
  • Another object of the present invention is to provide a custom ski boot liner having improved conformance to the wearer's foot.
  • Still another object of the present invention is to provide a ski boot liner forming method which does not undesirably distort the soft tissues of the user's foot during the formation process.
  • the ski boot liner manufacturing method of the present invention has other objects and features of advantage which will become apparent from or as set forth in more detail in the accompanying drawing and the following description of the best mode of carrying out the invention.
  • DISCLOSURE OF INVENTION The method of forming a custom ski boot liner of the present invention is comprised, briefly, of the steps of forming a cast of a foot while the foot is in a substantially unconfined state, removing the cast from the foot, forming a relatively rigid custom last from said cast, placing the rigid custom last inside a relatively rigid boot shell to define a liner volume therebetween, introducing a liner material capable of setting into a dimensionally stable form into the liner volume and containing the material in the volume until a dimensionally stable liner is formed and thereafter removing the last from inside the liner.
  • the method includes the steps of, at a first location, making a casting conforming closely to the foot of the user and thereafter removing the casting from the foot, modifying the cast to become a rigid custom last from the casting at one of the first location and a second location, transporting the casting or the rigid custom last from the first location to the second location, at the second location, mounting the rigid custom last inside a rigid boot form to define a liner volume therebetween, maintaining the last in a predetermined relationship to the boot form and forming in place in the liner volume a resinous foam which substantially fills the liner volume and has a controlled density, resiliency and pliability, and thereafter removing the rigid last from inside the resinous foam.
  • FIG. 1A is a side elevation view of a foot having a liner mounted thereon and a casting fabric sock positioned adjacent thereto as a first step in a method in accordance with the present invention.
  • FIG. 1B is a side elevation view corresponding to FIG. 1A showing the casting sock mounted on the foot.
  • FIG. 1C is a side elevation view corresponding to Fig. 1A with the hardened fabric sock removed from the foot.
  • FIG. 2 is a side elevation view corresponding to FIG. 1A and showing the casting of FIG. 1C made into a rigid custom last.
  • FIG. 3A i ⁇ a side elevation view corresponding to FIG. 1A of the last of FIG. 2 positioned inside a boot shell.
  • FIG. 3B is a side elevation view corresponding to FIG. 3A showing a liner material foamed between the custom last and boot shell.
  • FIG. 3C is a slightly enlarged, side elevation view corresponding to FIG. 3B with the liner and custom last removed from the boot shell.
  • FIG. 4 is a top perspective view of a ski boot liner formed in accordance with the method of the present invention with the custom last removed.
  • the ski boot liner manufacturing method or process of the present invention is based upon an approach in which a custom casting replicating the user's foot is made at a ski shop or boot sales outlet and the casting is then sent to a factory for the controlled manufacturing of the liner at the factory using a rigid last formed from the casting.
  • This approach enables the resultant liner to have a custom fit to the individual user and a greatly enhanced quality and uniformity a ⁇ a result of performance of the foaming by skilled personnel at a factory location having known environmental conditions.
  • the steps shown in FIGS. 1A, 1B and 1C are generally performed at a ski shop.
  • the step shown in FIG. 2 may be performed at the ski shop or at the factory, and the steps performed in FIGS. 3A, 3B, 3C and 4 are performed at a liner manufacturing facility.
  • the first step of the method of the present invention is the step of forming a cast of a user's foot.
  • Casting feet to form custom footwear is broadly wall known.
  • U.S. Patent NOs. 3,995,002, 2,961,714, 2,955,326, 2,907,067, 2,894,288, 2,856,633, 2,593,742 and 1,647,639 are illustrative of various foot casting techniques known in the prior art.
  • the particular foot casting method or technique employed is not regarded as being critical to the method of the present invention, and many prior foot casting techniques can be adapted for use with the liner forming method of the present invention.
  • FIGS. 1A, 1B and 1C of the drawing Mounted on foot 21 is a very thin sock, bag or envelope 23 which will protect the foot from resins used in the casting process and facilitate removal of the cast from the foot.
  • Envelope 23 can be a protective thin polyester knit stockinette or a plastic film bag which is inert to the resins used in the casting process.
  • wire means 25 is taped or held next to the foot while envelope 23 is pulled over the wire means.
  • An end 29 can be poked through the thin plastic envelope 23, while a second end 33 extends out of the open end of envelope 23.
  • Wire means 25 should be sufficiently thin and strong to enable subsequent cutting through of the fibers in fabric sock 31 after they have been hardened by a resin.
  • a high tensile strength stainless steel harpsichord wire having a diameter of about 0.02 inches is well suited for this purpose.
  • Fabric tube 31 has a closed first end 35 and an open second end 37, and the second end can be seen to be rolled into a doughnut or toroidal shape 39 prior to mounting of the tubular fabric member onto foot 21.
  • a fabric particularly well suited for the casting of a foot is a standard polyester rib-knit stockinette having a thickness of approximately 1 mm.
  • a water-curable, isocyanate-functional prepolymer is impregnated into or coated onto fabric sock 31.
  • doughnut-shaped tubular sock 31 is first dipped into ambient water, and the excess water is squeezed off. The doughnut is then stretched over the toe area 39 of the foot and unrolled onto the foot. Wire end 29 can be poked through the casting sock fabric, as shown in FIGURE 1A.
  • the length of fabric sock 31 can be selected in accordance with the desired height of the liner to be produced.
  • the resin content of the impregnated tubular sock is preferably between about 40% and about 80%, with about 65% being preferred.
  • the tubular sock is rolled over protective envelope 23 and wire 25.
  • sock material 31 should be sufficiently resilient so that it will conform closely to foot 21 with minimal easing or manipulation of the material.
  • Tubular knit polyester fabrics having an extensibility of over 100% in at least one direction are suitable for this use, and fabrics comprising lofted glass yarn with elastomeric fibers laid-in repeating courses to provide resiliency are most preferred.
  • pads, shields or the like can be secured in place on the foot or envelope to modify the foot shape to accommodate deformities.
  • foot 21 be manipulated to and maintained in a neutral position during hardening of the water-curable resin.
  • the "neutral position" of the foot is when the rear bone complex of the foot is rotated approximately one-third to one-half of the distance from full pronation to full supination of the rearfoot bone complex. The foot is neither pronated nor supinated when in the "neutral position.”
  • Apparatus for maintaining the foot in the neutral position while casting the same is set forth in our U.S. Patent No. 4,662,079.
  • wire 25 provides a cast removal method that eliminates the need for hazardous cast cutting using shears or cast saws. Instead, ends 29 and 33 of wire means 25 can be gripped and inserted through holes in metal rolling pin, not shown. The rolling pin is then rolled up the cast to wrap the wires around the same and pull wire 25 through the thin plastic envelope 23 and the hardened fibers in the resin impregnated fabric cast.
  • wire 25 forms a slit 27 in the casting 41 which allows the halves of the casting to be opened to permit withdrawal of the foot from inside envelope 23.
  • the result is a hollow hardened casting or shell which replicates closely foot 21 when the foot is in a desired biomechanical condition, for example the neutral position.
  • Protective envelope 23 normally will be bonded to the inside of the fabric shell or casting 41, and the upper end which protrudes from the shell can be easily trimmed off or merely pushed down into the interior of shell 41.
  • the resulting product in FIG. 1C is a cast of the foot which is reasonably hard and dimensionally stable.
  • the thin nature of the fabric tube used to form the cast, as well as the unitary and seam-free structure, enables the exterior of cast 41 to be used ae last for formation of the ski boot liner. Moreover, the relatively hard and rigid nature of cast 41 allows to be easily transported without danger of being damaged or distorted.
  • Figs. 1A, 1B and 1C are all preferably performed at boot sales outlets, such as ski shops. It is further possible to form a rigid custom last, generally designated 43, as shown in FIG. 2 at either the individual ski shops or at a central liner manufacturing facility. Since it is highly desirable to be able to accurately index last 43 with respect to a boot shell, generally designated 45 (FIGS. 3A and 3B), it is preferred that the custom last forming step of the present invention be performed at the liner manufacturing location, or at an authorized trained dealer with trained and licensed personnel and known environmental conditions.
  • Last forming step will include rigidifying the shell foot cast 41 so that it will be capable of withstanding substantial external pressure.
  • the cast 41 can simply be glued together along slit 27 to rigidify the same, or it may further be filled with a foam material 47, as shown in FIG. 2.
  • Foam 47 can be a foam selected from a group consisting of isotatic foams and syntatic foams.
  • Last 43 also may be modified to accommodate foot deformities such as bunions, hammertoes, etc. prior to injection molding in order to relieve pressure in such areas when the foot is positioned in the ski boot.
  • the process of the present invention includes the step of placing last 43 inside a relatively rigid boot shell 45 with at least a portion of exterior surface 53 mounted in relatively spaced relation to a portion of interior surface 55 of shell 45. This spacing defines a liner volume 57 between the last and shell.
  • shell 45 can have an interior surface 55 which includes various, liner shape effecting surfaces.
  • the bottom inner surface 59 can be sloped so as to cant the liner in a forward direction, common to ski boot constructions.
  • protrusions 61 can be provided to provide relief areas in the liner accommodating the buckle structure or pressure from the interior such as ankle bone area 24.
  • the boot shell means 45 can, if desired, actually be the final ski boot in which the liner is to be mounted.
  • shell means 45 can be a form from which the liner must be removed and thereafter placed in a ski boot. If shell 45 is merely a boot form, the liner produced therein has to be removed, and if it is a ski boot, it may be desirable to be able to remove the liner. Accordingly, a release layer is usually positioned along interior surface 55 of the shell so as to permit release of the formed liner for removal. In order to achieve the best biomechanical orientation of the last, to obtain the desired liner thickness and to provide a plantar support area, it is further preferable that last 43 be mounted in a controlled or indexed relation to shell 45.
  • the mounting rod 51 can be placed in a fixture such as arm 63 and collar 65 which are mounted to a rigid support 67.
  • the shell 45 is mounted to a rigid support surface 69 by clamps 71 so that precise reproducible indexing of last 43, for example, in a forwardly canted position, can be achieved.
  • last positioning blocks, spacers, or wedges 70 can be placed between last 43 and shell 45.
  • the spacers or blocks 70 would be cast into the liner and accordingly are preferably formed of a foam which is compatable and comparable in characteristics to the liner foam.
  • spacers 70 and support arm 63 are not both required to position the last, but a combination can be used to insure precision of location of the last.
  • last 43 in upwardly spaced relation to internal surface 59 of shell 45. This spacing allows the liner to have a plantar support volume 73 (FIG. 3B) underneath the plantar surface of last 43.
  • the process of the present invention next includes the step of introducing a liner material 77 into liner volume 57.
  • Liner material 77 must be capable of setting or curing into a dimensionally stable form suitable for use as a liner.
  • Liquid resin reaction mixtures which produce a pliant foam are preferred.
  • Resins are well known in the art for making ski boot liners, for example as described in the polyurethane foam system of U.S. Patent No. 3,581,412, although other polyurethane, silicone rubber or analogous reaction or foam forming mixtures also can be used.
  • the introducing step is accomplished by injecting the liquid reaction mixture into liner volume 57 and allowing the mixture to react or foam in place in the liner volume while contained by the rigid boot shell form and rigid custom last.
  • an upper end closure means 79 will be mounted so as to enclose and contain liner volume 57 completely.
  • Some foam materials can be foamed in place in an open mold or liner volume.
  • Removal of the last from the liner can most easily be accomplished by first removing the last and liner from shell 45. This can be accomplished by forming shell 45 as a split shell or with an opening at the side or area of the tongue, if shell 45 is a ski boot. The shell is opened up to release the liner, and the liner and last are moved from shell 45 to produce the assembly of FIG. 3C. Last 43 can be removed from the interior of liner 81 in a similar manner.
  • a slit or front opening generally designated 83 can be provided in the front of the liner, either by slitting the liner material 77 or by using an opening or slit-forming removable insert during the foaming process.
  • Opening up of the liner will allow, in combination with the pliant, usually resilient nature of the most preferred liner foams, to pull last 43 out of the liner.
  • the result is the liner of FIG. 4, which can now be trimmed, otherwise finished and inserted into a ski boot shell.
  • buckle receiving recesses 85 and 87 and ankle recess 89 have been formed in the liner as a result of protrusions provided on interior surface, 55 of the boot shell form.
  • the upper edge 89 also can be cast or trimmed to a variety of shapes as conventionally used to best cushion the calf and shin of the ski boot wearer.
  • Positioning of the liner back in a boot can also be accompanied by adjustments of the boot to best biomechanically position the combination of the foot and the liner inside the shell, for example, as described in U.S. Patent No. 4,567,617. Since the liner is custom fitting and biomechanically cast, boot shell adjustments can be minimized.
  • Ski boot liners manufactured in accordance with the method of the present invention have substantially enhanced quality without increased cost. Since the steps of FIGS. 3A, 3B and 3C all are performed at a central liner fabricating location, the foaming system used in the liner can be set up very accurately to produce the desired foam density, resiliency, insulating properties and strength under the atmospheric conditions of the particular manufacturing location. There is no need, for example, to adjust or modify the resinous reaction mixture to accommodate a multiplicity of differing liner foaming environments.
  • the process of the present invention allows the foot casting steps to be accomplished at a plurality of first locations, ski shops or the like, and then shipped to a central second location, the liner fabricating facility.
  • the casting steps are not environmentally sensitive since water-curable hardening resins are relatively insensitive to environmental changes within the normal range of environmental conditions.
  • the environmentally sensitive in situ foaming is centralized in the process of the present invention to enable its close control.
  • the liner foaming steps can be factory accomplished by relatively skilled personnel doing a high volume of liners to thereby increase fabrication and efficiency and decrease fabrication costs.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Physical Education & Sports Medicine (AREA)
  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)

Abstract

Procédé de formation d'une garniture intérieure personnalisée de chaussure de ski. Ledit procédé comprend les étapes consistant à former un moulage (41) en conformité étroite avec le pied (21) d'un utilisateur au niveau d'un premier emplacement, de préférence tandis que le pied se trouve dans un premier état non confiné. Le procédé comprend également les étapes consistant à retirer le moulage (45) du pied (21) au niveau du premier emplacement, à transporter ledit moulage jusqu'à un second emplacement de formation de chemise, à fabriquer un embauchoir personnalisé rigide à partir du moulage au niveau du second emplacement, à monter l'embauchoir personnalisé rigide dans une forme de chaussure rigide (45) de manière espacée par rapport à celle-ci afin de définir un volume de garniture, à maintenir les positions relatives de l'embauchoir et de la forme de chaussure (45), et à former en place dans le volume de garniture une mousse résineuse (47) remplissant le volume de garniture à une densité, une résilience et une souplesse régulées. La dernière étape du procédé consiste à retirer l'embauchoir de l'intérieur de la mousse résineuse stable en dimensions (47), habituellement en retirant la garniture et l'embauchoir de l'enveloppe puis en retirant l'embauchoir de la garniture et en montant la garniture.
PCT/US1990/001066 1989-03-01 1990-03-01 Procede de formation d'une garniture interieure personnalisee ou analogue de chaussure de ski WO1990009745A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US31764189A 1989-03-01 1989-03-01
US317,641 1989-03-01

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WO1990009745A1 true WO1990009745A1 (fr) 1990-09-07

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Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2593742A (en) * 1948-08-02 1952-04-22 Friedman David Method of reproducing the human foot or any of the toes thereof by means of a preshaped flexible form impregnated with material capable of setting hard upon the application of moisture
US2955326A (en) * 1957-12-20 1960-10-11 Alan E Murray Method of making a molded shell adapted for use in the manufacture of molded shoes
US3325919A (en) * 1963-05-31 1967-06-20 Robinson Leon Custom footwear having an inner surface molded to the foot of a wearer
US3640003A (en) * 1970-03-02 1972-02-08 Roland M Anderson Method and construction of a ski boot
US3834044A (en) * 1970-03-16 1974-09-10 Anderson & Thompson Ski Co Method of foaming ski boots
US3896202A (en) * 1973-02-12 1975-07-22 Alfred Palau Manufacture of protective footwear
US4414762A (en) * 1980-10-31 1983-11-15 Etablissements Francois Salomon & Fils Slipper for a ski boot, and process for its manufacture
US4567617A (en) * 1984-08-30 1986-02-04 Limbach Robert C Method of fitting ski boots
US4662079A (en) * 1983-05-10 1987-05-05 Graf Peter M Process and apparatus for forming customized footwear

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2593742A (en) * 1948-08-02 1952-04-22 Friedman David Method of reproducing the human foot or any of the toes thereof by means of a preshaped flexible form impregnated with material capable of setting hard upon the application of moisture
US2955326A (en) * 1957-12-20 1960-10-11 Alan E Murray Method of making a molded shell adapted for use in the manufacture of molded shoes
US3325919A (en) * 1963-05-31 1967-06-20 Robinson Leon Custom footwear having an inner surface molded to the foot of a wearer
US3640003A (en) * 1970-03-02 1972-02-08 Roland M Anderson Method and construction of a ski boot
US3834044A (en) * 1970-03-16 1974-09-10 Anderson & Thompson Ski Co Method of foaming ski boots
US3896202A (en) * 1973-02-12 1975-07-22 Alfred Palau Manufacture of protective footwear
US4414762A (en) * 1980-10-31 1983-11-15 Etablissements Francois Salomon & Fils Slipper for a ski boot, and process for its manufacture
US4662079A (en) * 1983-05-10 1987-05-05 Graf Peter M Process and apparatus for forming customized footwear
US4567617A (en) * 1984-08-30 1986-02-04 Limbach Robert C Method of fitting ski boots

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