EP2983536A1

EP2983536A1 - Method for preparing and placing wedges for a device for protecting the knee joint in situ

Info

Publication number: EP2983536A1
Application number: EP14713518.0A
Authority: EP
Inventors: Pierre GOUNIOT
Original assignee: Individual
Current assignee: Individual
Priority date: 2013-04-12
Filing date: 2014-02-28
Publication date: 2016-02-17
Also published as: WO2014167196A1; FR3004318A1; FR3004318B1

Abstract

The present invention relates to a method for preparing and placing, in situ, wedges between a device for protecting the knee joint of a user and the side surfaces of the knee of said skier, including at least one rigid shell (10) including or supporting, on the upper portion (11) thereof, rigid side flanges (11a-11b) extending opposite the side surfaces of the knee, wherein said wedge(s) are applied at least against the inner surface of at least one of said flanges, characterized in that it includes the following consecutive steps: a) positioning at least one empty bag (31) in the space between at least one side surface of the knee and the inner surface of one of said side flanges, said bag consisting of a flexible wall provided with a filling port (31a); and b) injecting or pouring a filling material inside said bag via said filling port (31a) until said wall is in contact with said side surface of the knee and matches the shape thereof, said filling material consisting of a polymer resin that is cross-linkable and thermosets preferably at 10°C to 30°C; c) and setting said filling material in situ in the space between said flange and the knee by cross-linking, preferably at room temperature.

Description

Method for the preparation and in situ placement of wedges of a device for protecting the knee joint

Field of the invention

The present invention relates to a method for preparing and placing in situ protective shims between a device for protecting the knee joint of a user and side faces of the knee of said skier.

More particularly, the present invention relates to a said protection device comprising at least one rigid shell capable of being arranged at least partly in front of the anterior surface of the lower limb at the level of the tibia, said shell partially surrounding the anterior and lateral parts of the tibia and comprising or supporting, on its upper part, rigid lateral cheeks extending vis-à-vis the lateral faces of the knee at the femoral condyles on either side of the knee, the (or the) said (s) shims (s) being applied at least against the inner surface of at least one said cheek. The invention relates to a device for protecting the knee joint of a user intended to be installed on a sports shoe.

The invention also relates to equipment incorporating such a device and a sports shoe.

The invention finds application particularly for the practice of sports or leisure in which the knee joint is highly sought, including sliding sports (including downhill skiing, monoski, snowboarding, ski touring) and rollerblading (including inline skating and roller skating).

Background of the invention

The practice of the activities indicated above generates each year numerous cases of pathologies related to the knee joint, whether simple sprains or accompanied by ligament rupture.

Usually, alpine skiing for the least, it prevents inadmissible stresses on the knee joint by shoe attachments able to release the latter if the torque exerted on the binding is greater than a predetermined value. Fixing this trigger value of the release of the attachment is in itself problematic.

The document US-A1-4136404 describes a device that can complete the action of a ski binding and attached to a ski boot. But the system disclosed is complex in its structure and of obvious discomfort: the lower limb of skier is, on both sides of the knee up to the thigh, held in an articulated frame at the knee. His cooperation with the knee joint to protect him is otherwise weak.

WO 2007-061379 discloses a goalkeeper's simple goalkeeper's ice hockey gear that does not include a hard shell and has the tether strap 311 attached around the leg in the knee joint area. This device does not allow to transfer the forces applied to the device at the knee to the shoe and without hindering the frontal flexion movements at the knee.

There is therefore a need for devices for protecting the knee joint which at least partially overcome the disadvantages of the techniques hitherto known.

The object of the invention is to limit the risk of knee injuries including sprains and ligament rupture related to a relative axial rotation of the tibia or excessive femur and / or shear in the XY plane. The aim of the invention is to provide a protective device which must not interfere with the skier in normal ski conditions, in particular in frontal flexion at the knee.

We measure the rotations and translations between the tibia and the femur along the three axes at the knee. For this, if we define a local coordinate system linked to the upper end of the tibia: the substantially horizontal plane XY is a plane of the tibial plateau; the Z axis being the longitudinal axis of the tibia.

The natural mobility of the knee depends on its frontal flexion angle in the XZ plane in axial rotation according to Z. Indeed, if, in full extension, the knee does not allow axial rotation of the tibia with respect to the femur, the amplitude of the axial, external or internal rotation of the tibia, authorized by the knee increases with its frontal flexion angle. Thus, at an angle β of frontal flexion between the femur and the tibia of 90 °, the internal axial rotation of the tibia is approximately 30 °, concomitantly bearing the tip of the foot inward, combined with the adduction or removal movement. abduction of the foot, the external axial rotation of the tibia being approximately 40 ° in external rotation. Although the locking of the ankle by the ski boot strongly limits this axial rotation amplitude of the tibia, it can still reach 20 ° in internal rotation and 25 ° in external rotation, a total amplitude of 45 °.

The object of the present invention is to provide a device aimed essentially or mainly at limiting shears in the tibial plane, in particular a shear towards the front of the femur along the axis a, and axial and lateral rotations relative femur and tibia, without interfering with the frontal flexion at the knee and in particular without recourse to a pivot connection at the knee and / or without recourse to direct connection around the thigh.

The present invention also aims to provide a simple device to manufacture and install on the lower limb and can be used for a skier regardless of the pair of ski he uses.

According to the present invention, the device essentially comprises simply a rigid shell provided with lateral cheeks at its upper part without connection with the thigh and with means for connecting the shell with the collar which allow a controlled limitation of rotation along an axis substantially. parallel to the longitudinal axis Z of the shell and the collar.

Summary of the invention

To do this, the present invention provides a method for preparing and placing shims in situ between a device for protecting the knee joint of a user and side faces of the knee of said user, in particular a skier, such as described above characterized in that it comprises the successive steps in which:

a) positioning at least 1 empty bag at least in the space between at least one lateral face of the knee and the inner surface of at least one said lateral cheek, said pouch consisting of at least one flexible wall provided with at least one filling orifice and, preferably, at least one discharge orifice, and

b) a filling material is injected or poured, preferably at ambient temperature, inside said pocket via a said filling orifice until said wall is in contact with at least said face; lateral of the knee and conforms to the shape, said filling material consisting of a thermosetting polymer resin crosslinkable at -50 ° C to 100 ° C, preferably at 10 ° C to 30 ° C, and

c) The hardening of said filling material is carried out in situ in the space between said cheek and the knee, preferably at room temperature.

The method according to the present invention is particularly advantageous in that it makes it possible to obtain shims having an ergonomically shaped shape cooperating in a optimal with the knee because of the customization of the shape of the wedges according to the shape of the knee of the user concerned.

More particularly, the inner surface of the wedges is made to measure to fit the shape of the knee of the skier without hindering the flexion / extension movements of the lower limb. And, the shims applied against the inner faces of said cheeks have bearing surfaces in ergonomic forms able to conform at least partially to the shape of the sides of the knee at the level of the condyles so as to block the relative translation of the worm. before the knee relative to the hull and block the rotation of the knee relative to the hull, without impeding the bending movements of the lower limb.

This characteristic of customizing the wedges allows the device to be particularly pleasant to use in all ski positions. In addition, this customization of the shims of the protective device according to the invention is very interesting insofar as it ensures better fastening of the lateral cheeks with the knee. This prevents a penalizing game is present at this level of the device, such a game involving an angle of rotation of the femur relative to the shoe greater than the maximum angle provided by the device according to the invention.

This characteristic also makes it possible to adapt the same shell to various dimensions of condyles by interposing wedges. The same molded shell can thus be used for different sizes of devices but also to achieve personalized devices. In this case, only the shims must be modified to obtain various sizes or a personalized device. More specifically, said wedges have the essential function of blocking the rotation of the femur relative to the hull and therefore relative to the tibia.

It is understood that the wall of said pocket can be held in place by gluing or other means, preferably reversible attachment, such as self-gripping adhesive against said inner surface of the cheek or on a frame on the said internal surface of said cheek. Preferably, the positioning of the empty bag is done by inserting the injection pipes and evacuation of filling material through bores provided in the shell during its manufacture.

It is also understood that said filling material has a viscosity capable of rendering it injectable or castable before crosslinking.

In one embodiment, two empty pockets are used at the level of the two lateral cheeks respectively in the space between respectively each so-called lateral cheek and each so-called lateral face of the knee, each said pocket following substantially the contour of each said cheek.

In a variant, there may be a single pocket extending on and between the two cheeks. In particular, it implements a single pocket extending along the inner surface of said shell from the first side cheek to the second side cheek in a space between said shell and the side faces and the front face of said knee . It is then possible to limit the swelling in the central space between the two cheeks, in particular by welding, or to reduce the thickness of the central zone facing the patella. A single pocket can also be composed of two compartments connected by injection and evacuation channels.

More particularly, said filler material is a thermosetting resin that can be crosslinked at a temperature of from -50 ° C. to 100 ° C., preferably from 10 ° C. to 30 ° C., preferably a thermosetting resin chosen from polyurethane, silicone, polyester and epoxy resins. more preferably of the polyurethane or silicone type in the form of a gel or two-component elastomer crosslinking at room temperature.

More particularly, said filler material has a crosslinking time of less than 30 min, preferably less than 5 min at room temperature and has a hardness after crosslinking, between 1 shore A and 100 shore D, and a lower viscosity before crosslinking at 3,500 mPa.s, preferably less than 1,000 mPa.s.

Preferably, said filler material is a silicone material having a hardness after crosslinking of between 1 and 100 shore A, preferably from 2 to 15 shore A, and a viscosity before crosslinking of less than 2000 mPa.s, more preferably less than 500 mPa.s.

The use of said silicone material with respect to the polyurethane is advantageous in that the silicone is less rigid after crosslinking, it allows a deformation of the wedge and the desirable natural displacement in translation of the femoral condyles along the X axis (longitudinal axis of the ski ) with respect to the axis of the hull, during a change of angular position of the skier.

More preferably, said filler material further comprises organic or inorganic fillers, preferably in the form of hollow microspheres and / or pieces of fiber capable of reducing the density of said filling material and / or increasing its rigidity, preferably said material having a density of 500 to 1500 kg / m ³ . It can be added organic fillers or inorganic in the form of a hollow or solid microsphere, for example microspheres hollow glass beads with a density of 0.15 to 0.60 g / cm3 and a particle size of 2-130 μιτι, in order to reduce the density of the material filling.

Advantageously, each said pocket has at least one filling orifice and at least one preferably closable discharge orifice and the said bag is filled to a defined limit or until the filling material is evacuated in a overflow container through the drain hole.

In a variant, the air contained in said bag is expelled through said discharge orifice as it is filled by said filling material in said filling orifice.

Even more particularly, before the injection of the product, the bag can be evacuated with air. A manometer can be positioned on the injection circuit to control the pressure applied to the knee joint. A pressure limiter adjustable or not at a predetermined pressure can be added to the circuit. The pressure exerted by the pockets, filled with injected material, on the knee can vary from [0 to 0.6 bar].

In a preferred embodiment, said liquid filling material is injected at a pressure representing an overpressure of 10 to 150 mbar above atmospheric pressure.

An overpressure thus limited to 150 mbar is advantageous in that it results in an increase in the volume of the pocket positioned between the shell and the knee of 30 to 50% relative to the volume of the bag when the material is injected at atmospheric pressure. . This controlled increase in the volume of the bag from 30 to 50% makes it possible to increase the protection of the skier by limiting the rotation of the femoral condyles along the Z axis relative to the hull and thus limits the elongation of the anterior cruciate ligament. during a non-physiological movement. This rotational constraint increases the force produced by the femoral condyles on the cheeks and this effort is propagated more effectively to the ski binding which favors the automatic opening of the front binding.

An excessive increase of the volume of the pocket, that is to say an overpressure greater than 150 mbar would not be admissible because it would prevent the correct positioning of the knee relative to the hull by inducing a displacement in translation of the knee relative to shell.

Preferably, a pressure limiter is positioned at a discharge orifice of said pocket. Advantageously, said discharge orifice is located above said filling orifice, preferably said filling orifice being located in the lower portion of said pocket and said discharge orifice being located in the upper part of said pocket.

More particularly, a filling resin injection device comprising:

a cartridge or reserve filled with said filling material, and

preferably a gun cooperating with at least one cartridge or reserve filled with said filling material, and

at least one first pipe connected or capable of being connected to a said pocket filling orifice, and

at least one second pipe connected or capable of being connected to a said pocket evacuation orifice, and

at least one overflow container of resin or air overflow, communicating or able to communicate with said pocket evacuation orifice, and

- said bag discharge port is preferably equipped with a pressure limiting valve.

In one embodiment, after filling said pocket and before crosslinking said filling material, the user performs at least one bending movement between:

a relaxed natural extension position in which the femur is inclined at an angle β between 140 and 170 ° with respect to the tibia, and

- bending position in which the femur is inclined at an angle of about 45 ° to 100 ° relative to the tibia.

More particularly, the tibia and femur in the relaxed position has an angle of about 16 ° with the perpendicular to the ground to place the center of gravity of the person at the foot of his feet. Consequently, the angle β between the tibia and the femur is, in total, about 148 °.

More particularly, during and after filling the bag, the user alternates between said relaxed position and said bent position, at a frequency of between 1 mHz and 1 Hz until at least partial hardening of the filler material.

Thus, the surface of the wedges after crosslinking of the filling material, on the knee side, has a surface whose bumpy shape results from the molding of surfaces complementary to that of the lateral faces of the knee at the condyles in the different bending positions between the relaxed position and the maximum bending position. Thus made by molding the different forms of morphology on the side of the knee, the wedges do not interfere with the frontal flexions of the knee.

In a variant, simpler to carry out and in practice sufficiently efficient, during and after the filling of the pocket, the skier remains in the same static position corresponding preferably to said natural relaxation position in which the femur and the tibia are inclined. an angle β between 140 and 170 °, preferably about 148 °.

Advantageously, after step c), once said filling material is cured inside a said pocket to form a first wedge made in situ, a second wedge is reproduced in the same shape as said first wedge intended for the same user, which is machined from a solid material of lower density, preferably with a density of 50 to 300 kg / m ³ , and having compressive strength characteristics of at least 1 MPa preferably from 5 to 25 MPa.

Preferably, said second wedge is made in a balsa-type wood.

This embodiment therefore makes it possible to obtain wedges of optimal shape with a non-flowable or non-injectable material of lower density than said filling material and having identical or even improved compressive strength properties.

The present invention also provides a device for protecting the knee joint of a user, in particular a skier, comprising at least one rigid shell arranged or able to be arranged at least partly in front of the anterior face of the lower limb at the level of the knee. shin, said shell comprising or supporting, on its upper part, rigid lateral cheeks extending opposite the lateral faces of the knee at the level of the condyles of the femur on either side of the knee, the device further comprising a shim (or shims) applied or intended to be applied at least against the inner surface of at least one said cheek, said wedges being obtained by or useful for the implementation of a method according to the invention, each said wedge comprising a said pocket consisting of at least one flexible wall provided with at least one filling orifice, a filling material having been cast or injected into the said pocket until that said wall is in contact with at least said lateral face of the knee and matches its shape, said filling material being made of a crosslinkable thermosetting polymer resin cured by crosslinking said filler material in situ in the space between said cheek and said knee.

More particularly, the protection device according to the invention comprises at least one so-called ergonomic wedge fixed on the inner surface of a said cheek, said pocket being empty or filled with said filling material, the contact surface of said wedge with the lateral side of the knee constituted by said solid reticulated pocket being of embossed shape.

According to other particular characteristics:

said shims and said cheeks each have a same contour substantially in the shape of an ellipse portion on the upper part and the rear part of said contour of the cheek, the major axis of the ellipse being inclined at an angle of between 45 ° and 135 °, preferably from 70 ° to 110 ° with respect to the main longitudinal axis (ZZ ⁷ ) of the shell and / or with respect to the rectilinear section of the front face of the shell in section in a vertical median plane longitudinal hull;

the surface of each cheek substantially corresponds to the surface of the upper lateral part of the shell situated above the lower tangent (X2) of the ellipse parallel to the major axis of the ellipse (XI), and situated on the rearward of an axis parallel to the minor axis of the ellipse (ZI) (and therefore perpendicular to the major axis of the ellipse) located at about half of the large radius (R) of the ellipse from the front rectilinear section of the hull in a longitudinal vertical median plane of the hull.

More particularly, the center of the ellipse is disposed substantially vis-à-vis the condyle to ± 20mm according to the flexion at the knee. And, the lower tangent of the ellipse parallel to the major axis of the ellipse is located substantially vis-à-vis the tibial plane when the major axis of the ellipse is substantially 90 ° of said longitudinal axis of the hull parallel to the rectilinear section of the front face of the hull in section in a longitudinal median plane of the hull.

More particularly, the large radius of the ellipse is at least 5 cm, preferably 6 to 15 cm and the small radius of the ellipse is at least 2 cm, more particularly 3 to 10 cm.

More particularly, the major axis of the ellipse is located 2 to 5 cm from the upper end of the shell and the center of the ellipse is located 5 to 10 cm from the rectilinear section of the front face of the hull in section in a longitudinal median plane of the hull. Such dimensions of the ellipse and such an inclination of the major axis of the ellipse from 70 ° to 110 ° make it possible to maintain the ratio between the cheeks and the end of the lower femoral epiphysis despite the displacements of the condyles during the knee flexion / extension movements. This inclination also corresponds to an intermediate inclination of the positions of the thigh in motion or at rest. More particularly, the cheeks each have a surface capable of covering the entire surface of the sides of the knees, preferably an area of at least 50 cm 2, preferably at least 100 cm 2.

Such a size of the cheeks makes it possible to ensure good coverage of the distal femoral epiphysis and / or the femoral condyle while preventing the skier from being obstructed by the device according to the invention.

More particularly, the device is adapted for a said shoe comprising a collar and said connecting means are adapted to secure the lower part of the shell with the portion of the collar of the shoe covered by the lower part of the shell so as to limit the rotation of the shell relative to the boot about an axis substantially parallel to the axis ZZ 'of the shell and / or the collar.

The fastening of the lower part of the shell with the collar of the shoe provided by the combination of the first and second connecting means makes a connection to at least one degree of freedom in rotation of the shell relative to the shoe around an axis substantially parallel to the axis of the collar of the shoe, the connecting means being such that this rotation of the shell relative to the shoe is limited to a predetermined angular sector, preferably less than 14 °.

Such angular limitation allows for increased protection of the tibia and knee joint while allowing considerable movement latitude in certain ski situations. An angular limitation of 14 ° corresponds on average to the permissible angular amplitude of axial rotation along Z between the tibia and the femur less than 45 °.

This implementation of said second and / or third straps uses either the elasticity of the second strap adapted according to the desired rotation limitation, or a particular adjustment of the tightening of the second strap and / or third strap then inextensible to allow a limited rotation of the shell relative to the shoe. Such a particular adjustment of the tightening of the second strap and / or third strap allowing limited rotational movement on a predetermined angular sector is achieved by means of a mechanical element allowing lengthening or shortening or maintaining a predetermined length of the second strap and / or third strap. This type of device facilitates the establishment of the connection between the shell and the collar.

More particularly, the device comprises:

a rigid shell having an internal surface capable of at least partially covering an anterior part of the user's leg, the shell comprising an upper part intended to be situated at the level of the knee and a lower part comprising connecting means adapted to bind the shell to the sports shoe, the upper part comprising side cheeks adapted to extend vis-à-vis the lateral faces of the knee and able to be brought into contact with the lateral faces of the knee at least screwed to the condyles of the femur of the user;

at least one first strap intended to be fastened around an area of the upper part of the leg below the knee, preferably in the upper part of the calf, and

means for connecting the strap to the surface of the shell, said connecting means being flexible in non-elastic materials, preferably of textile material, and

said first strap, alone or in combination with said connecting means, being able to surround the whole of the leg and to be in contact with the leg over the entire periphery of the section of the latter, said first strap being a band; flexible material non-elastic, preferably textile material.

More particularly, the device is installed on a ski boot comprising a footwear portion surmounted by a collar, the device comprising first connecting means intended to be fixed on the collar of the shoe and a rigid shell intended to cover at least partially the front of the skier's tibia, this hull extending between an upper portion intended to be located at the knee of the skier and a low end covering a portion of the collar of the shoe, the shell comprising or supporting, on its part high, rigid lateral cheeks capable of being brought into contact with the knee on either side of the knee while being at least in contact with the condyles of the skier's femur, the lower part of the shell being intended to partially cover the collar of the shoe and comprising second connecting means complementary to the first binding means of the collar of the shoe for securing the hull with and over the collar of the boot, said connecting means preferably comprising at least a second strap and / or third strap fixed or capable of being fixed to said shell and / or fixed or adapted to be attached to said collar so that the association of the first and second connecting means makes a connection with a limitation of the rotation of the shell relative to the shoe about an axis of rotation substantially parallel to the axis of the shell of the boot, said cheeks entirely covering the sides of the knee, preferably the cheeks each having an area of at least 50 cm 2, preferably at least 100 cm ² , and said shell having in horizontal section a rounded profile shape, convex convex face forward so that the concave rearward shape covers the front and a portion of the lateral faces of the knee and / or tibia and extends over only part of the sides of the tibia and, in the lower part, on a part of the sides of the collar, the fastening of the lower part of the shell with the collar of the shoe provided by the combination of the first and second connection means forming, by tightening said second and / or third straps, immobilization in rotation of the shell relative to the boot about an axis substantially parallel to the axis of the collar of the boot, and the shell supporting at least one tibia connecting element in upper part, preferably a strap provided with a self-gripping tape for its maintenance around the tibia (T).

The function of this device is to ensure a transmission of effort between the top of the lower limb and the shoe so as to relieve the knee joint. A support of the hull on the condyles of the femur on the one hand, and a connection of the hull to the shoe, on the other hand, participates in this effect, drifting out of the knee joint of the mechanical stresses it could not bear without injury. In this context, said first strap and said connecting means, as they cooperate with the shell and tibia, allow effective application of the upper part of the shell on the knee, including during the movements of the body. 'user.

More specifically, the rigid shell has an essential main function of supporting the cheeks and transfer the support forces from the knee against the cheeks to the shoe and thus until the attachment of the shoe on the ski which controls the level of 'effort tolerated, fixing releasing the shoe beyond a certain threshold. The secondary function of the hull is to protect the front of the shin from possible shocks. The surface of the cheeks therefore has an essential role because during the support of the ribs of the knee on the cheeks, the transfer of effort is maximum if the support surface of the cheek with the side of the knee is optimal.

Consequently, the use of simple cheeks and wedges bearing on the soft tissues that cover the condyles and / or distal epiphysis of the femur in association with a rigid shell-shin protector limited in its movements relative to the Ski boot helps maintain the thigh relative to the shoe. This limitation greatly reduces the risk of pathogenic movements of axial or lateral rotation of the tibia and femur at the knee and / or shear including shear towards the front of the femur along the X axis.

The rigid shell according to the present invention, because it is attached to the boot on the one hand, and that it comprises on the other hand rigid side cheeks in its upper part, therefore more generally has the function of protecting the knee joint by controlling the relative movements of the knee in translation forward and relative rotation relative to the hull.

Said first strap has the main function of controlling the relative translation of the knee backwards relative to said shell during movement and / or deformation of the muscle mass and / or soft tissue during flexion movements of the lower limb.

In particular, the mode of connection of the first strap around the upper leg, below the knee and not at the knee, optimally controls the relative translation to the back of the knee relative to the knee. shell and thus maintain the knee in position vis-à-vis the side cheeks so that the device can fulfill its protective function without hindering the flexion of the lower limb of the fact that said strap is attached below the knee .

This first strap allows, in a simple and clever way, to clamp the relative translation rearward of the knee relative to the shell and maintain a substantially constant tension of the strap in contact with the leg during changes in angular position of the leg , despite the overall change in the shape of the leg section and movements and deformations of the muscles and soft tissues during significant knee flexion and / or rotation.

Finally, it should be noted that in the embodiment according to the invention, said connecting means fill the space between the shell and the front portion of the leg, which allows the strap can make the complete turn leg in all circumstances. This space between the front of the leg and the hull is necessary because the shell is applied against the collar of the shoe and against the knee via the wedges.

Said connecting means make it possible to fill the space between the inner surface of the shell and the front part of the leg, which allows that said first strap can - once tightened around the leg - go around the leg without being in contact with said shell, and can remain in contact with the entire periphery of the leg during the various movements and / or deformations of the muscle mass and / or the soft tissues at the part of the leg with which the said first strap is in contact.

Preferably, said shell has in horizontal section a rounded profile shape convex convex face forward so that the concave rearward shape covers the front and a portion of the lateral faces of the knee and / or the shin and extends over only a portion of the sides of the shin and, in the lower part, on a portion of the sides of the collar. The hull may extend to a height of 25 to 55 cm, preferably 30 to 50 cm in practice depending on the size of the skier, and the said connecting means will make it possible to space the shell of the frontal part of the tibia from 3 to 50 mm. .

Advantageously, said cheeks and / or shims are further coated with flexible material lining intended to be in contact with the sides of the skier's knee (S). More particularly, the pads are disposed on the inner faces of the cheeks or, preferably, shims vis-à-vis the knee. This feature increases the comfort of the skier without affecting the effectiveness of the invention in terms of lateral rotation.

The fittings may be made of flexible material of the cellular material type (foam, etc.), or of the gel type (silicone, etc.). Thus, the liner is advantageously made from at least one elastomeric or plastic material of the EVA (ethylene-vinyl acetate) or other type and thermoformable or not and of sufficient thickness and density to allow comfort during the movements. of the lower limb when skiing. More particularly, the material may be a silicone gel in the form of a plate of 1 to 10 mm and preferably 2 to 5 mm.

The shell is advantageously made from a rigid inorganic or organic material, in monolithic or hybrid form, selected from the following materials: magnesium, aluminum, titanium, metal alloys, polymers with or without charge, reinforced or not, composite resins or not , loaded or not, reinforced or not. Advantageously, the composite consists of a matrix based on epoxy, polyester or other thermosetting resin, or a thermoplastic resin of the polyamide (PA) or polycarbonate (PC) type, or the like, and at least one reinforcing material. The reinforcement may be based on carbon fiber, and / or fiber of glass, and / or aramid. These materials in general make it possible to ensure good rigidity of the hull while ensuring a good lightness and a certain comfort.

On at least one face of the lining in contact with the lower limb, a film or fabric of spandex or elastic type with a thickness of at least 10 μιτι may be affixed by gluing on the said surface to conform to the shape of the hold.

The material of the film or fabric may have a low coefficient of friction. By way of example, the material can be made from polytetrafluoroethene, PTFE. The thickness of the film or fabric is selected according to the desired mechanical characteristics.

In the case where the wedges comprise a flexible lining on the part intended to bear on the sides of the knee, said connecting means may not allow a degree of freedom of the shell relative to the shoe around a Z axis substantially parallel to the axis of the collar of the shoe, because the condyles of the femur are held by the wedges positioned at the cheeks and wedges allow reduced movements relative axial rotation of the femur and tibia because the soft tissues that between the condyle and the wedges deform during a rotational movement. The clamping of the angular sector is then sufficiently made by the shape and play of the wedge which is in contact with the soft tissues at the level of the condyles of the femur.

In general, the adjustment and adaptation capabilities of the device by the use of wedges make it possible to adapt the device to the variability of the skiers: age, sex, physical condition, muscle tone and contraction levels etc. The conditions predicted loads are also so many parameters of adjustment of the device: shear, lateral bending, velocities, position of the skier, vertical acceleration, prestressing between the device and the knee etc.

More particularly, the device further comprises between the lateral cheeks and, where appropriate, between the wedges, a cushion for applying the knee patella of the user, said cushion being preferably formed of a cellular material with a density of between 30 kg. / m3 and 900 kg / m3.

The invention also relates to a sports equipment gliding or roller comprising a sports shoe and a protective device according to the invention.

The present invention finally provides a kit for making shims in situ that is useful for carrying out a method according to the invention, characterized in that it comprises:

said empty pockets as defined above, and - A said shell as defined above, preferably equipped with said connecting means adapted to secure the lower part of the shell with the portion of the collar of the skier's boot covered by the lower part of the shell so as to limit the rotation of the shell relative to the boot, and more preferably equipped with connecting means able to secure the central portion of said shell with the skier's leg, and

an injection device of said filling resin as defined above.

Brief description of the drawings

Other features and advantages of the present invention will emerge from the description given below, with reference to the accompanying drawings which illustrate embodiments having no limiting character.

In the figures:

FIGS. 1 illustrate the principle of connecting the first strap 3 around the upper part of the calf;

- Figures 1A, 1B and 2 show a shell with connecting means consisting of second strap 13a and r third straps 13b;

FIG 3 shows a shell comprising a connecting piece 4 and a first strap 3 in perspective without the leg;

FIG. 4 represents the mode of manufacture of the shims in situ with pockets inserted between the shell and the knee;

FIG. 5 represents the two pockets being filled without showing the shell to which they are attached;

FIG. 6A represents an empty flattened pocket;

FIG 6B represents the two pockets after filling;

FIGS. 7A and 7B show in horizontal section without the leg, the two empty pockets before filling (FIG. 7A) and the two pockets filled non-symmetrically after filling (FIG. 7B);

FIGS. 8A and 8B show in view from behind the leg, the two empty pockets before filling (FIG. 8A) and the two filled pockets unsymmetrically after filling (FIG. 8B); and

FIG. 9 shows different alpha angles of frontal flexion of the femur and a 70 ° inclination of the long axis of the ellipse of the cheeks 11a, 11b.

Detailed description of an embodiment Without further clarification in the present description, leg is understood to mean the part of a lower limb of the user equipped with the device of the invention at which the tibial bone extends. It is therefore an area extending below the knee towards the foot. In its part located above the knee, the lower limb has, in its bone structure, the femur which is the bone of the thigh. At the knee is the patella. The tibia and the fibula are the bones of the leg. The tibia articulates at the top via the tibial trays at the lower part of the femur (femoral condyles).

Figure 9 shows a block diagram of the invention. In this figure, the lower body of a skier S is shown. The skier S wears a ski boot 2, itself attached to a ski 1, via a fastener 1a. The shoe 2 has a footwear portion surmounted by a collar 21.1e foot P, the tibia T and the femur F of the skier S are shown. The femur F has CF condyles at its distal end. These condyles CF take a plurality of intermediate positions between two extreme positions shown in FIG. 10 as a function of the flexion position of the skier S.

In Figures 1 to 3, the skier S carries a device according to the invention. This device comprises a rigid shell 10 comprises an upper part 11 and a lower part 12. The lower part 12 covers the upper part of the collar 21 and comprises connecting means for securing the shell 10 with the collar 21 of the shoe 2. upper part of the shell 10 has two lateral cheeks 11a, 11b which cover the lateral faces of the knee vis-à-vis the condyles CF of the femur F on both sides of the leg of the skier S, this recovery being ensured by the lateral cheeks irrespective of the bending position of skier S.

The shell is made of a material comprising carbon fibers optionally mixed with other types of fibers, especially of flax or polymer, for example aramid, said fibers being impregnated in an epoxy resin, the fiber content being from 45 to 65% of preferably 50 to 60%. The shell may consist of a monolithic structure of said composite material based on carbon fibers or a sandwich structure, that is to say consisting of two layers of said composite material based on carbon fibers constituting two outer skins on each side of a ROHACELL ^® or AIREX ^® aluminum honeycomb or honeycomb core.

In general, the present invention allows protection of the knee by transferring at least in part certain mechanical stresses induced at the level of the condyles C _F of the femur towards the base of the leg and in particular towards the shoe 2 which is equipped the user. To transmit the stresses that the knee joint would not be able to absorb without injury, the device according to the invention comprises a shell 10 made sufficiently rigidly. The shell 10 has an elongated dimension oriented Z substantially from the knee (upper part 11) to the collar 21 of the shoe 2 (lower part 12). In Figure 2, the height H of the hull will be 25 to 55 cm, more particularly 30 to 50 cm depending on the size of the skiers. The shell 10 advantageously has a lateral dimension high enough to allow the shell 10 to have a sufficient torsional resistance in the direction of the tibia T. The distance D between the two cheeks will be in particular 8 to 20cm. The portion of the shell between the cheeks has a domed horizontal section with concavity turned towards the leg, in particular of substantially central circular section at the frontal level of 2 to 15 cm, preferably 3 to 8 cm radius.

To allow the device to always be properly in contact with the knee sides at the condyles C _F , the device comprises at least a first strap 3, visible Figures 1 and 3, adapted to surround the leg and the other connected 10. Advantageously, the first strap 3 is configured to apply to an upper part of the leg, namely an area at the upper end of the calf. More specifically, the first strap 3 is advantageously positioned around the leg immediately below the knee joint.

Any material may be suitable for the first strap 3 and may include non-elastic polymeric textile materials or having a low elastic elongation so as to produce little variations in length of the strap 3 during the stresses it takes. For example, the first strap 3 may be formed as a single band or several bands. In all cases, the first strap 3 may have an overall width of between 2 cm and 6 cm.

FIG. 3 shows in greater detail a first embodiment of the first strap 3 and its connection to the hull 10. In fact, according to the invention, the first strap 3 is connected to the hull 10 at the inner surface 10b. of the shell 10. By internal surface 10b is meant the surface of the shell 10 located directly opposite the leg opposite the outer surface 10a which is oriented outwards. Thanks to this connection of the first strap 3, the cooperation between the shell 10 and the leg of the user is particularly intimate and the user avoids changes in contact between the knee sides at the condyles C _F and the lateral cheeks lia, 11b during his movements.

In the case of Figures 1 to 3, the first strap 3 consists of 2 strands 3a, 3b in one piece with a strand 3a oriented on one side of the leg and a strand 3b oriented on the other side of the leg. The two strands advantageously join at a portion 3c of the first strap 3c vis-à-vis the front or front of the leg facing the tibia and vis-à-vis the inner surface 10b of the shell 10 substantially in the middle of the section of the shell 10.

The connection of the first strap 3 to the shell 10 thus formed is effected in the case illustrated by means of connecting means comprising an intermediate piece 4 secured to the first strap 1 on the one hand and to the first strap 3 on the other hand. internal surface 10b of the shell 10. The attachment to the inner surface 10b operates on a connecting zone 10c of said inner surface 10b. This connection zone 10c is advantageously positioned substantially in the middle of the width of the shell 10 so as to have a system of first strap 3 substantially symmetrical along a vertical plane passing through the shin. The intermediate part 4 is furthermore fixed to the first strap 3. In the case represented, this fastening is balanced by resorting to two fastening zones, respectively 4a and 4b, arranged after fixing and positioning on the leg, on an equal footing. distance from the connection area 10c. Thus, the portion 3c of the first strap 3 extends between the attachment zones 4a, 4b.

An advantageous effect of the intermediate part 4 is that it ensures an optimal adjustment of the spacing of 3 to 50 mm relative between the leg area considered for the application of the strap 3 and the inner surface 10b of the shell. The use of the invention is therefore the opportunity to adjust the relative position of the device and the leg of the user in a front-rear position.

In FIG. 3, more precisely, said intermediate piece 4 consists of a flexible band made of non-elastic materials, preferably of the same flexible non-elastic material as said first strap. The said flexible intermediate piece 4 forms a loop because:

a central part 4c of said loop is fixed on a connection zone 10c of the inner surface 10b of the shell, said zone 10c being disposed symmetrically with respect to the middle of the section of the shell, and two lateral parts 4d on either side of the central portion 4c, having ends 4a, 4b of said intermediate piece on either side of said loop being fixed on a central portion 3c said first strap intended to come in contact with the front portion of the tibia, the ends 4a and 4b being disposed symmetrically with respect to said first portion 4c or in the middle of the section of the shell.

In Figure 3 the connecting piece 4 although consisting of a flexible band, is shown with side elements 4d of the flexible band in the maximum position away from the shell and therefore stretched.

The central portion 3c of the first strap is extended on each side by two strands 3a and 3b respectively. The 3d-1 end of one of the strands 3a has a loop 5 through which can be housed the 3d -2 end of the second strand 3b. Preferably, the loop 5 is made of flexible material being an orifice integrated at the free end 3d-1 of one of the strands 3a and of greater width than the end 3d-2 of the second strand 3b adapted to pass into said passing and comprising a velcro-type self adhesive or hook-and-loop fastener element configured to secure the free end 3d-2 of the other strand 3b with the end 3d-1 of a first strand 3a, on the rear part of the leg .

Figures 1 and 2 show a preferred embodiment of the hull connecting means on the shoe. In this variant embodiment, the fastening of the lower part of the shell to the collar of the shoe provided by the combination of the first and second connecting means immobilizes the shell in rotation with respect to the boot around a axis substantially parallel to the axis of the collar of the shoe.

More particularly still, said first and second connecting means comprise at least one second non-elastic strap 13a comprising two strands attached or removably attachable 23 on each side to the rear of the collar, and two strands 13b-1, 13b-2 of two third straps 13b, 13b-1, 13b-2 fixed or removable to be fixed 0 on each side of the shell in the lower part thereof, said strands of said second and third straps comprising at their free ends 13c, 13d complementary reversible connection means capable of reversibly securing the free ends 13c of the strands of the second strap 13a with those 13d of the strands 13b-1, 13b-2 of the third straps 13, the joining of the lower part 12 of the shell 10 with the collar 21 of the boot 2 thereby immobilizing the shell 10 in rotation with respect to the shoe 2 about an axis substantially parallel to the axis ZZ 'of the shell or collar 21 of the shoe (2).

Said second straps 13a are fixed on a hook 23 fixed or paste to be fixed on the rear of the collar 21. The third straps 13b-1, 13b-2 are fixed, in particular riveted, to passers or orifices 0 on the 2 side edges in the lower part 12 of the shell 10. The free ends of the second straps 13a comprise fastening clips 13c able to cooperate in reversible attachment with complementary elements 13d at the free ends of the third straps 13b-1, 13b-2

In Figures 1A and 1B, according to a simplified version, only one strap is used on each side permanently attached to the shell or the back of the shoe. The connecting means comprise only two second or third straps 13a, 13b secured to the parts 23 of the collar or the orifices 0 of the shell. In this case, it is the adjustment of the straps fixed in the orifices 0 or on the hook 23 which entirely determines the angular sector on which the hull can pivot with respect to the boot if necessary. Advantageously, the strap will have a particular length or a particular marking for its adjustment. In a variant, the laxity of adjustment of the straps 13a, 13b or their pre-calibrated elasticity makes it possible to limit the rotation of the shell 10 with respect to the boot 2 if necessary. It is understood that the implementation of two straps, one on each side of the shoe 2 is necessary to limit the rotation in both directions.

The device 10 comprises two lateral cheeks 11a and 11b, intended to be placed on either side of the knee to grip it at the level of the condyles of the femur C _F. The lateral cheeks 11a and 11b may themselves be in contact with the garment covering the condyles C _F or come into contact with these same condyles C _F via wedges, as will be described later.

The lateral cheeks are of contour 11c in ellipse portion, their major axis XI being oriented at an angle α about 90 ° (FIG. 2) or 70 ° (FIG. 9) with respect to the axis ZZ 'of the shell . This orientation included between 45 ° and 135 ° makes it possible to obtain a satisfactory support of the femoral condyles and therefore a good retention of the femur in axial and lateral rotations relative to the tibia. The following embodiments show preferential orientations of the lateral cheeks between 70 ° (FIG. 9) and 90 ° (FIG. 2). In FIG. 2, the contour 11c of the upper and rear portions of the cheek has a shape that includes substantially an upper half-ellipse and a half-lateral ellipse of the same virtual ellipse centered at C1 substantially facing the condyle CF. The major axis XI of the ellipse is substantially perpendicular to the longitudinal principal axis of the hull and perpendicular to the rectilinear section of the boundary of the front face 10a of the hull in a plane of longitudinal median section of the hull. Each cheek is delimited by the lower tangent X2 of said ellipse substantially vis-à-vis the tibial plane XV parallel to the major axis of the ellipse XI. The large radius R of the ellipse is 65mm and the small radius r of the ellipse is 50mm. The center Cl of the ellipse is located at a distance d = 68mm from the boundary of the front face 10a of the hull in a plane longitudinal median section of the hull. The total area of each cheek 11a, 11b as delimited by the surface located above the line X2 of the lower tangent of the ellipse parallel to XI and on the rear of an axis Z2 parallel to the minor axis ZI of the ellipse is located at about Vi R from the rectilinear section of the front face 10a of the hull in section in a longitudinal median plane of the hull, and said surface being about 100cm ² .

Thus, the lateral cheeks completely cover the distal femoral epiphysis by coming to bear each on either side of the end of the femur, namely on the condyles of the femur CF on each side of the knee. They make it possible to limit the lateral rotation of the femur F relative to the foot P of the skier S.

It is easily understood that the cooperation between the upper part 11 of the shell 10 and the part of the knee corresponding to the present area of the condyles C _F is important for the effectiveness of the device of the invention. The contact of the lateral cheeks on the femoral condyles is ensured by means of 2 ergonomic wedges inserted on the internal face of the cheeks.

The inner surface of the wedges can be made to measure to fit the shape of the lower limb of the skier without hindering the flexion / extension movements of the lower limb by the method according to the invention described hereinafter with reference to FIGS. 4 to 8.

Positioning the hull 10 on the skier's leg. The shell is held on the leg and on the collar of the ski boot by the connecting means described above.

Two flattened empty pockets 31 whose walls delimit inflatable chambers of organic material and preferably of polymer and of wall thickness of less than 1 mm and of shapes and surfaces sufficient to cover the lateral surfaces of the knee, preferably following the contour of said cheeks 11a and 11b are positioned and fixed for example by gluing or any other fixed or removable mechanical means on the inner face of the cheeks.

Each pocket 31, provided with at least one inlet orifice 31a with or without a tip 31c, is connected by any flexible or rigid means 32c, 32d to a central unit which comprises either a pump or injection gun 32a adapted to inject a filling resin. Also, at least one outlet orifice 31b may or may not have a nozzle 31c in order to evacuate the air from the circuit before or during the injection of the product. Preferably, the inlet orifice 31a of the resin is situated lower along the Z axis than the outlet orifice 31b so that the air contained in the pockets 31 is driven off by the flow of resin and this avoids the creation of pockets. of air which would have the effect of affecting the filling of the (or the) wedge (s) and therefore the shape of the hold and thus the protection of the skier.

The injectable resin in liquid form is a material of the silicone type or other thermosetting resin, for example Polyurethane polymerization time or sufficiently rapid crosslinking, so that the subject carrying the shell can maintain any position, less than 30 minutes and preferably less than 5 minutes, at room temperature or not. The injected material is of sufficient hardness after crosslinking or polymerization to withstand a pressure of several bars.

In one embodiment the circuit comprises a main inlet in the form of a pipe 32c on which can be positioned a stopcock or other device 33-3 for blocking the inlet or the outlet which connects the injection gun 32a at one end 32c-1 of said pipe 32c, the other end 32c-2 of the pipe is provided with a first connection element or T 33-1 which allows to derive the resin in each pocket through 2 flexible pipes 32d which are connected to at least one inlet port 30a located on each pocket 31, each outlet port 31b connected to a flexible pipe 32e which is connected to a second T-connection element 33-2 in order to collect again the two outlets 31b of the two pockets so that the overflow of resin is evacuated by a single circuit in a receptacle 34.

It is understood that the orifices 31a and 31b of the pockets 31 are disposed on the faces of the pockets applied against the inner faces of the corresponding flaps 11a and 11b and the pipes 32e and 32d connected thereto pass through the orifices 11-1 and 11-. 2 of the cheeks 11a and 11b, which allows, in addition, to maintain the pockets 31 in position vis-à-vis the cheeks 11a and 11b the time of filling the pockets.

More specifically, a filling resin injection device comprising:

a) A gun 32a cooperating with at least one cartridge or reserve 32b filled with said filling material and a first end 32c-1 of a first pipe 32c whose second end 32c-2 cooperates with a first T-connection element 33 connected to the first ends 32d-1 of two second flexible pipes 32d) whose second ends 32d-2 are connected to the said two said filling orifices 31a of the two pockets,

b) First ends 32e-1 of two third flexible pipes 32e connected to said discharge holes 31b of the two pockets, the second ends 32e-2 communicating, preferably via a second T-connection element (33-2) with a discharge container (34) overflow of resin or air.

In another embodiment, the outlet port 31b of each pocket is connected to a different hose connected directly to a different container for the two pockets. In this variant, the two outlet pipes 32e of the two pockets are independent and allow independent evacuation of the air or overflow of resin in a container. The advantage of this circuit is that it allows the air contained in the circuit of a first pocket to escape even if the filling of each pocket is not simultaneous. Indeed, it has been found that the filling of the two pockets is not always uniform and the overflow of resin of a first pocket can be evacuated by the output network of the second pocket and through the T 33-2 which connects the 2 outlet pipes 32e, and in this case the air contained in the second pocket can no longer or hardly evacuate and this can create air bubbles in the pocket named above.

In another preferred embodiment, a complete injection system is independent of the shell, the supply and exhaust pipes passing below and above the shell but more through ports in the shell, this embodiment having the advantage of simplifying the installation of the injection system and to facilitate the implementation of a pre-assembled sealed complete injection system.

An example of the injected resin manufactured by AXSON TECHNOLOGIES is the following comprising 2 polyol and isocyanate components:

Material: trade name F38 fast setting polyurethane casting resin Manufacturer: Huntsman Advanced Materials (Switzerland) GmbH.

Brand RenCast® FC 52/53 Isocyanate / FC 53 Polyol.

Its viscosity is about 50 mPa.s and its hardness is 70-75 Shore A. This low viscosity allows a good flowability during filling of the pocket.

Another preferred example of a resin used is silicone, which may be in the form of a gel or two component elastomer, crosslinking at room temperature.

More particularly, the reference silicone ELITE DOUBLE material manufactured by ZHERMARK (DE) whose hardness is 8 Shore A and the viscosity before crosslinking of 350 mPa.s.

The silicone material, because of its low viscosity is advantageously introduced by injection at overpressure relative to the atmospheric pressure. Due to its lower stiffness after crosslinking with respect to a polyurethane material after filling the pocket allows advantageous deformation as explained above.

The liquid thermosetting material is injected before crosslinking with a low overpressure of 25 to 140 mbar relative to the atmospheric pressure and more particularly an overpressure of 70 mbar which increases by 30 to 50% the volume of each pocket relative to the volume of the pocket when the material is injected at atmospheric pressure. As previously mentioned, this makes it possible to significantly increase the protection by limiting the rotation of the femoral condyles relative to the shell and to improve the propagation of the forces up to the ski binding. To do this, a pressure limiting valve is positioned at the outlet at the discharge port of each pocket.

The bags are formed from plastic films assembled by ultrasonic welding or high frequency welding or by thermoforming or other technology well known to those skilled in the art. More particularly, said pockets are made from films of polymeric material such as PVC or preferably EVA.

With this method we obtain a method of manufacturing ergonomic wedges and economic cost.

According to other particular characteristics:

the walls of said pockets are made of plastic polymer material, preferably of EVA (ethylene-vinyl acetate), the latter having a lower minimum temperature of use than the PVC, and the walls of said pockets have a thickness of less than 1 mm, preferably of between 50 μm and 1 mm and more preferably between 0.1 and 0.5 mm;

said wall is formed in a pocket by assembling film (s) by welding, particularly by thermo welding or high frequency;

the volume of each said bag is at least 10 ml, preferably 20 to 250 ml, more preferably 25 to 75 ml. ;

said pocket, after filling, has a surface facing each other and in at least partial contact with a lateral face of the knee of 50 to 150 cm ² and a thickness of less than 25 mm in particular of 1 to 25 mm when filled and after crosslinking.

a relaxed natural extension position in which the femur is inclined at an angle β of 148 ° with respect to the tibia, and

- Bending position in which the femur is inclined at an angle β of about 90 ° relative to the tibia.

More particularly, the tibia and femur in the relaxed position has an angle of about 16 ° with the perpendicular to the ground to place the center of gravity of the person at the foot of his feet. As a result, the angle between the tibia and the femur is, in total, about 148 °.

More particularly, the user will alternate between the relaxed and flexed position at a frequency of between 1 mHz and 1 Hz until at least partial curing of the filler material.

Thus, the surface of the wedges after crosslinking of the filling material, on the knee side, has a surface whose embossed shape results from the molding of the positive surfaces, in relief, of the lateral faces of the knee at the level of the condyles in the different flexion positions. between the relaxed position and the maximum bending position. Thus made by molding the various forms of dynamic morphology on the side of the knee, the wedges do not interfere with the frontal flexions of the knee.

In a second embodiment of shims 30a and 30b, simpler to perform and in practice equally effective, the wedge surface results from a single angular position and preferably relaxed and static natural posture. The natural angle of the relaxed position β of 148 ° between the tibia and the femur is the result of the angle (Fig. 1) of about 16 °, the inclination of the collar of the shoe compared to a vertical axis perpendicular to the ground, and the inclination of the femur relative to the vertical. Indeed, it has been found that in said relaxed position, the surface of the condyles (CF) in contact with the wedge represents about 90% of the surface of the wedge while, with a bending angle of, for example, 90 °, the surface of the condyles in contact with the wedge represents about 10% of the wedge surface only.

Advantageously, the force with which the cheeks come to rest support (in the absence of effort due to rotation at the knee) on the condyles will be adjustable. The cheeks apply a force on the condyles substantially normal to the flanks of the thigh intensity in the range] 0.100N].

The bumpy shapes of the bearing surfaces of the blocks after filling correspond to the molding of the surfaces complementary to the surfaces of the lateral faces of the knees observed at the level of the condyles CF of the femur F between the two preferred positions, which may for example be the extreme positions of flexion of the thigh of the skier S shown in Figure 9.So, it ensures maximum comfort of the skier who, between the two most extreme positions, retains a lateral pressure adapted to its morphology, or custom, on the condyles of the femur. The functional parts 30a and 30b of the spacer 30 are thus unsymmetrical because the sides of the knee have distinct shapes and deformations during the articulatory movement thereof. On the other hand, a symmetry may exist between the corresponding functional parts of the two knees.

The wedges 30a, 30b delimit an intermediate portion of the inner surface 10b of the shell 10 at the front of the tibia, which portion may remain recessed relative to the surface of the portions 30a, 30b. Nevertheless, between the lateral cheeks 11a, 11b here formed by the lateral wedges 30a, 30b of the wedges 30, the invention may comprise a cushion (not shown) for the application of the patella of the knee of the user. It is understood that the invention thus makes it possible to differentiate the physical contact modalities between the condyles C _F and the shell 10 via the lateral cheeks 11a, 11b possibly constituted by the wedges 30a, 30b and the front surface of the knee at the level of the patella . More specifically, a cushion material of lower density than that of the side flanges 11a, 11b is advantageously used so as to produce a more supple support with damping of the forces transmitted during the contact. For example, a cushion in a cellular material density of 30kg / m ³ and 900kg / m ³ has been satisfactory. According to one embodiment, the surface of the cushion brought to be vis-à-vis the ball is located in the continuity of the surface of the portions 30a, 30b covering the side cheeks 11a, 11b. The use of a material flexible enough to conform to the shape of the patella when it is in contact with the cushion. The cushion also provides a damper function against violent shocks by damping the rearward movement of the entire hull in case of impact. This cushion can be made by filling a pocket in situ as wedges.

Another function of the cushion is to avoid the persistence of a space between the lateral wedges 30a, 30b likely to receive snow during the practice of winter sports. It should be noted that a silicone-based cellular material gives good results in view of the density constraints explained above and its resistance to high temperature variations. This same material can be used as a coating of the surface of the first strap 3 brought to be in contact with the leg of the user.

Because the pockets are made in situ and the fixing of the pocket on the cheek can be removable, in the case where it is desired to further lighten the mass of said filled bag, it is possible to replace said pocket by a second block made as follows. Firstly, the shape of the full pocket made in situ is scanned and reproduced in digital format in an STL file. Then, the second shim is milled in a solid material of lower density than said filling polymer using a dedicated machining machine that allows its machining software to directly process the STL type file from of the scan. The machined material will preferably be balsa whose mechanical characteristics make it possible to resist compression up to 25 N / mm ² (25 MPa) and to obtain a density of 50-300 Kg / m 3 and preferably 100 to 250 Kg / m 3 , in particular using BALTEK SB 100 (12 MPa) or 150 (20 MPa) material manufactured by ALCAN BALTEC CORPORATION (USA).

Claims

A method of preparing and placing in situ at least one wedge (30a, 30b) between a user's knee joint protection device (100) and at least one side face of the user's knee , said protective device comprising at least one rigid shell (10) arranged or adapted to be disposed at least partly in front of the anterior face of the lower limb at the level of the tibia, said shell (10) comprising or supporting, on its upper part ( 11) rigid side cheeks (11a-11b) extending opposite the lateral faces of the knees at the level of the condyles of the femur on either side of the knee, the (or) said wedge (s) (s) being applied at least against the inner surface of at least one said cheek, characterized in that it comprises the following successive steps in which:

a) at least one empty bag (31) is positioned at least in the space between at least one lateral face of the knee and the internal surface of at least one said lateral cheek, said bag consisting of at least one flexible wall; provided with at least one filling opening (31a) and preferably at least one discharge opening (31b), and

b) a filling material is injected or poured, preferably at ambient temperature, into said pocket by means of a said filling orifice (31a) until said wall is in contact with least said lateral face of the knee and conforms to the shape, said filler material consisting of a thermosetting polymer resin which can be crosslinked preferably at a temperature of 10 ° C to 30 ° C, and

c) the curing is carried out by crosslinking said filling material in situ in the space between said cheek and the knee, preferably at room temperature.

2. Method according to claim 1 characterized in that implements 2 empty pockets respectively at the two lateral cheeks in the space between respectively said side cheek and each said lateral face of the knee, each said pocket substantially following the outline of each said cheek.

3. Method according to one of claims 1 or 2 characterized in that:

said filling material is a thermosetting resin, preferably polyurethane or silicone, and said filler material has a crosslinking time of less than 30 min, preferably less than 5 min, at ambient temperature and, after crosslinking, has a hardness of between 1 shore A and 100 shore D, and a viscosity before crosslinking less than 3500 mPa.s, preferably less than 1000 mPa.s

4. Method according to claim 3 characterized in that said filling material is a silicone material having a hardness after crosslinking of between 1 and 100 shore A, preferably from 2 to 15 shore A, and a viscosity before crosslinking less than 2000 mPa. .s, more preferably less than 500 mPa.s.

5. Method according to one of claims 1 to 4 characterized in that said liquid filling material is injected at a pressure representing an overpressure of 10 to 150 mbar above atmospheric pressure.

6. Method according to one of claims 1 to 5 characterized in that:

the volume of each said bag is at least 10 ml, preferably 20 to 250 ml, more preferably 25 to 75 ml, and

said pocket has, after filling, a surface facing and in at least partial contact with a lateral face of the knee of 50 to 150 cm ² and a thickness less than 25 mm when filled and after crosslinking.

7. Method according to one of claims 1 to 6 characterized in that after filling of said bag and before crosslinking said filler material, the user performs at least one bending movement between:

- bending position in which the femur is inclined at an angle β of about 45 ° to 100 ° relative to the tibia.

8. Method according to one of claims 1 to 6 characterized in that during and after the filling of the pocket, the skier remains in the same static position corresponding preferably to the natural position of relaxation in which the femur and tibia are inclined at an angle β of between 140 and 170 °, preferably about 148 °.

9. Method according to one of claims 1 to 8 characterized in that after step c), once said filling material is cured inside said pocket to form a first wedge made in situ, reproducing a second wedge of the same shape as said first wedge for the same user, which is made by machining a solid material of lower density, preferably of density of 50 to 300 kg / m ³ , and exhibiting compressive strength characteristics of at least 1 MPa, preferably 20 to 50 MPa.

10. The method of claim 9 characterized in that carries said second wedge in a balsa type wood.

11. Device for protecting the knee joint of a skier comprising at least one rigid shell (10) arranged or able to be arranged at least partly in front of the anterior face of the lower limb at the level of the tibia, said shell (10) ) comprising or supporting, on its upper part (11) rigid lateral cheeks (11a-11b) extending opposite the lateral faces of the knee at the level of the condyles of the femur on either side of the knee, the device further comprising a shim (s) applied or intended to be applied at least against the inner surface of at least one said cheek, said shims being obtained by or useful for the implementation of a method according to one of claims 1 to 10, each said wedge comprising a said pocket consisting of at least one flexible wall provided with at least one filling orifice, a filling material having been cast or injected inside said pocket until said wall is in contact with at least said lateral face of the knee and conforms to the shape, said filling material consisting of a crosslinkable thermosetting polymer resin cured by crosslinking said filler material in situ in the space between said cheek and said knee.

12. Protective device according to claim 11 characterized in that it comprises at least one so-called ergonomic wedge comprising a said pocket, fixed on the inner surface of said cheek, said pocket being empty or filled with said filling material, the contact surface of said wedge with the lateral face of the knee consisting of said reticulated full pocket being of bumpy shape.

13. Device according to claim 11 or 12 characterized in that said wedges (30a-30b) and said cheeks (11a-11b) each have a same contour (11c) substantially in the form of an elliptical portion on the upper portion and the rear portion of said contour of the cheek, the major axis (XI) of the ellipse being inclined at an angle of between 45 ° and 135 °, preferably 70 ° to 110 ° with respect to the main longitudinal axis (ZZ ⁷ ) of the hull and / or with respect to the rectilinear section of the front face (10a) of the hull in section in a longitudinal vertical median plane of the hull.

14. Device according to one of claims 11 to 13 characterized in that said shell comprises: connecting means (0,13a, 13b, 23) able to join the lower part of the shell with the portion of the collar (21) of the shoe covered by the lower part of the shell so as to limit the rotation of the shell relative to the boot about an axis substantially parallel to the axis ZZ 'of the shell and / or collar, and

at least one first strap (3) intended to be fastened around an area of the upper part of the leg below the knee, preferably in the upper part of the calf, and connection means (4) of said first strap ( 3) on the surface of the shell (10), said connecting means (4) being flexible non-elastic materials, preferably textile material; and said first strap, alone or in combination with said connecting means, being capable of surrounding the entire leg and being in contact with the leg over the entire periphery of the section of the latter, said first strap (3) being a flexible band made of non-elastic materials, preferably of textile material.

15. Kit for making shims in situ that is useful for carrying out a method according to one of claims 1 to 10, characterized in that it comprises:

- A said shell (10) adapted to be arranged at least partly in front of the anterior face of the lower limb at the tibia, said shell (10) comprising or supporting, on its upper part (11) side cheeks (lla-llb ) rigid able to extend vis-à-vis the lateral faces of the knee at the femoral condyles on either side of the knee preferably equipped with said connecting means (0,13a, 13b, 23) suitable to secure the lower part of said shell with the portion of the collar (21) of the boot covered by the lower part of the shell so as to limit the rotation of the shell relative to the shoe, preferably further equipped with connecting means (3,4,5) adapted to secure the central portion of said shell with the leg of the skier, and- said empty pockets (31), each said pocket comprising a flexible wall provided with at least one filling orifice, each said pocket substantially along the contour of each said cheek and being a to fit the shape of said knee when filled with a said filling material cast or injected into said pocket through a said filling port, until said wall is in contact with at least one lateral side of the knee, said filling material consisting of a crosslinkable thermosetting polymer resin cured by crosslinking said filling material in situ in the space between said cheek and said lateral side of the knee, and

an injection device (32) for filling resin comprising:

a cartridge or reserve filled with said filling material, and - preferably, a gun (32a) cooperating with a cartridge or reserve (32b) filled with said filling material, and

at least a first pipe (32c, 32d) connected to or connectable to a said pocket filling port (31a), and

at least one second pipe (32e) connected to or connected to a said pocket discharge port (31b), and

at least one evacuation vessel (33) for overflow of resin or air, communicating or able to communicate with said pocket discharge orifice (31b), and

- said pocket discharge port (31b) is preferably equipped with a pressure limiting valve.