US3640003A

US3640003A - Method and construction of a ski boot

Info

Publication number: US3640003A
Application number: US15375A
Authority: US
Inventors: Roland M Anderson
Original assignee: Individual
Current assignee: Individual
Priority date: 1970-03-02
Filing date: 1970-03-02
Publication date: 1972-02-08
Anticipated expiration: 1989-02-08

Abstract

Footwear, such as a ski boot, include interfitting inner and outer shells. The shells are divided into corresponding toe and heel sections, hinged together for coordinate opening to permit foot entry from the rear of the boot. The inner shells are fabricated with a resilient, custom-fit lining formed to conform precisely to the contours of the wearer''s foot. Removable inner soles and inner heels of adjustable height are provided with one embodiment of the inner shell. In fabricating the custom-fit shells, a liquid lining composition of uncured elastomer is injected into the shells, filling voids around the wearer''s feet; and permitted to cure before the feet are removed. Stockings of polyethylene film can be placed over the feet before the customfitting operation to prevent the lining composition from adhering to the feet and to permit easy separation of the shells, when finished.

Description

United States Patent Anderson Feb. 8, 1972 [72] Inventor: Roland M. Anderson, 1616 S.W. Sunset Blvd., Portland, Oreg. 97201 [22] Filed: Mar.2, 1970 [21] Appl.No.: 15,375

[52] US. Cl. ..36/2.5 AL, 12/142 P 3,521,385 7/1970 Dalebout ..36/2.5 AL

Primary Examiner-Patrick D. Lawson Attorneyl(olisch & Hartwell [57] ABSTRACT Footwear, such as a ski boot, include interfitting inner and outer shells. The shells are divided into corresponding toe and heel sections, hinged together for coordinate opening to permit foot entry from the rear of the boot. The inner shells are fabricated with a resilient, custom-fit lining formed to conform precisely to the contours of the wearers foot. Removable inner soles and inner heels of adjustable height are provided with one embodiment of the inner shell. In fabricating the custom-fit shells, a liquid lining composition of uncured elastomer is injected into the shells, filling voids around the wearers feet; and pennitted to cure before the feet are removed. Stockings of polyethylene film can be placed over the feet before the custom-fitting operation to prevent the lining composition from adhering to the feet and to permit easy separation of the shells, when finished.

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saw a or 2 Fi J 7 RolandM.Hnderson IN VEN TOR METHOD AND CONSTRUCTION OF A SKI BOOT BACKGROUND OF THE INVENTION The present invention concerns improved footwear which are custom-fit in the sense that the footwear have an inner surface formed to conform precisely to the contours of an individual wearers feet. More particularly, the invention relates to custom-fit footwear comprising interfitting inner and outer members which are adapted for quick easy entry of the wearers feet from the rear of the footwear. The invention also concerns an improved method of manufacture of such footwear which is especially suited for the production of certain athletic footwear such as ski boots or skate uppers.

Satisfactory custom-fit footwear should have resilient linings which conform precisely to the contours of an individual wearers feet, are comfortable to wear, and yet are sufiiciently firm to provide adequate support and restraint to the feet. Particularly where athletic footwear are concerned, effective custom-fitting is desirable. Thus, it is essential that ski boots or skate uppers have a comfortable, yet snug fit so that the athletes movements are directly translated into corresponding equipment movements and not lost through shifting of the feet within the boots. In the case of ski boots, for example, proper edge control of the skis which is essential to controlled skiing can only be achieved through boots which respond directly to movements of the wearer without any slippage.

Numerous lacing and strap arrangements have been suggested in conjunction with padded footwear to provide satisfactory fitting. However, most such arrangements do not invariably produce a satisfactory fit and are otherwise objectionable for various reasons.

For example, systems utilizing special lacings and straps do not produce exactly the same fit each time the footwear is put on, and often interfere with circulation even when appreciable care is exercised by the wearer. lftight enough to transmit foot movements accurately, laced boots often hurt. Furthermore, the use of such lacing systems is usually time-consuming and energy-consuming and, therefore, quite undesirable in conjunction with athletic footwear.

On the other hand, custom-fit footwear provided with insertable pads or performed pads are not completely satisfactory in view of the difficulty in determining accurately the proper size and contour of the pads. Also, such footwear are usually ditficult to put on, cumbersome to wear, and tend to hurt the feet.

SUMMARY OF THE INVENTION Accordingly, it is an object of the invention to provide im proved footwear having inner surfaces of a resilient material formed to conform precisely to the contours of an individual wearer's feet.

It is another object of the invention to provide a novel method of manufacture of such footwear.

It is a further object of the invention to provide custom-fit footwear which can be opened to permit quick, easy entry of a wearers feet from the rear of the footwear.

It is yet another object of the invention to provide customfit footwear including durable outer members of standard size and custom-fit inner members of a standard size insertable thereinto.

It is yet a further object of the invention to provide customfit members having resilient linings and replaceable inner soles and inner heels.

These and other objects of the invention are attained in a footwear design which includes a foot encompassing member that may be of standard size, having a resilient inner lining formed to conform precisely to the contours of an individual wearers foot. The foot encompassing member is divided, as into toe and heel sections, so that it can be opened to permit easy entry or removal of the wearers foot. If desired, a member can be provided with removable inner soles and inner heels; the latter being divided to accept heel lifts of different sizes.

In a preferred embodiment of the invention, the foot encompassing member comprises an inner shell of a boot, such as a ski boot, which also includes a durable outer shell. The outer shell is of a standard size and the inner shell is of a corresponding standard size insertable thereinto. Both inner and outer shells are comprised of at least two corresponding sections, such as toe and heel sections, which may be coordinately separated for easy entry and removal of the wearers foot.

In fabricating the foot encompassing members in accordance with the invention, an unlined member of the proper size is selected for the wearer's foot. The stocking covered foot is placed within the unlined member, for example, comprising toe and heel sections of the inner shell of a ski boot. The foot encompassing member is retained in fixed relationship to the wearer's foot, as by strapping the ski booth shell into a pouring fixture; and liquid lining composition is injected into the member to fill completely the voids around the wearers foot. In the case of a ski boot, the liquid lining com position can be injected through appropriate openings in the front and rear sections of the inner shell by use of compressed air. After injection, the liquid lining composition is permitted to cure into a resilient semirigid state. When the lining is cured, the foot retaining means are loosenedand the customfitted shell is removed from the wearer's foot.

If preferred, removable inner soles and inner heels can be fitted into one embodiment of an unlined inner shell prior to injection of the liquid lining composition. Also, a stocking of polyethylene film or other suitable covering means can be provided on the wearer's foot to prevent the lining composition from adhering thereto.

BRIEF DESCRIPTION OF THE DRAWING These and other objects of the invention will become apparent from the following detailed description of the invention, taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a ski boot for a right foot constructed in accordance with the invention, shown in an open position;

FIG. 2 is a right elevation view, in section, of the ski boot shown in FIG. 1 when closed;

FIG. 3 is a partially exploded, right elevation view, in section, of the inner shell of the ski boot shown in FIG. 1;

FIG. 4 is an end elevation view of the front section of an altemative embodiment of an inner shell of a ski boot;

FIG. 5 is a perspective view of an optional inner heel and heel lift arrangement utilized with the embodiment of FIG. 4;

FIG. 6 is a right elevation view in section of a pouring fixture used in the installation of the liquid lining composition;

FIG. 7 is a top elevation view in section of the pouring fixture of FIG. 6; and

FIG. 8 is a fragmentary sectional view taken along lines 8- 8 of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION Referring now to the drawings one preferred embodiment of the invention is described comprising a ski boot having an outer shell and a custom-fit foot-encompassing inner shell insertable thereinto. Both the inner and outer shells are divided into corresponding front and rear sections so that they may be coordinately opened to permit easy entry of the wearer's foot.

Referring now to FIGS. 1-3, an outer shell 11 of a ski boot 10 for a right foot is shown, adapted to confine a line foot-encompassing inner shell. The outer shell of the boot generally includes an upper 12 having a cuff l4 and a sole 16 attached thereto. The boot is divided along the ankle line of the upper and across the sole, as shown, to form a toe section 19 and a heel section 20. The toe and heel sections are secured together by a hinge member 22 of flexible material bonded across the divided ankle line on a side of the boot. The hinge member permits pivotal movement of the toe and heel sections between the open position shown in FIG. 1 and the closed position shown in FIG. 2. Sealing rings 24, formed of rubber or other. suitable material, are provided along the contacting edges of the toe and heel sections as shown in FIG. 8, to insure a moisturetight seal when the outer shell is closed.

Conventional binding means are provided to retain the outer shell in the closed position, comprising a clamp 27 provided on the toe section and a corresponding lug, not shown, attached to the outerv end of a strap 28 bonded to the heel section. The clamp is adapted firmly to engage the lug to hold the shell closed, and can be released by the wearer so that the shell can be opened. Other conventional types of closures may also be used. Conventional

binding posts

31, 32 are provided at the toe and heel of the outer shell, respectively to receive ski safety bindings.

A recess 30 is provided in the inner surface of the front of the toe section and similar recesses 33 are provided in the inner surface of the rear of the heel section for a purpose to be described.

Cufi' 14 is adapted to wrap snugly around the ankle of the wearer and be secured in that position by conventional binding straps 35. The cuff is preferably formed of molded urethane or some other resilient material. To insure a snug fit, the cuff is formed with ribbings 37 in the outer surface thereof to provide flexibility in the wrapping direction and stiffness in a direction transverse thereto. The out? may be constructed of other flexible materials, such as leather, which yield a product having the structural characteristics described above.

The outer shell of the boot is preferably fabricated of a molded plastic material. Use of this material results in a lightweight durable, hard surfaced product that can be produced in various colors. Furthermore, with the use of molded. plastic, the toe and heel sections of the outer shell can be formed as integral units having extremely thin soles. This pemiits placement of the wearers feet closer to the skis than was previously possible, and gives better ski control. The low profile boots also fit lower on the ankle than conventional boots and are more comfortable to wear. However, it should be realized that other materials used in conventional footwear, such as leather, metal and various plastics, can be use in fabricating the footwear described herein.

Referring now to FIGS. 1-3, a finished, custom-fit inner shell of a ski boot for a right foot is shown. The inner shell is divided along the ankle line in a manner similar to the outer shell to form a toe section 41 and a heel section 42. These sections are designed to encompass snugly the wearers foot when joined together. Accordingly, the toe and heel sections are provided with resilient inner linings adapted to conform precisely to the contours of the wearer's foot.

The toe and heel sections of the inner shell are also adapted to fit respectively, within the toe and heel sections of the outer shell. Therefore, the inner shell is of a standard size corresponding to the standard size of the outer shell and is adapted for a close tolerance fit therewith. The toe and heel sections of the inner shell are also designed for coordinate movement with the corresponding elements of the outer shell as the boot is opened or closed. Accordingly, the sections of the inner shell are fabricated to fit completely within the sections of the outer shell with sufficicnt lengthwise tolerance that closure of the outer shell willcause the toe and heel sections of the inner shell to fit snugly about the wearers foot. Toe section 41 of the inner shell is provided with a locating boss 44, adapted to fit within recess 30 in the toe section of the outer shell to insure proper registration between those sections. If desired, the toe sections can be secured together by means such as screw 48, adapted to fit through a suitable opening 49 in the outer toe section and engage a threaded nut 50 in the inner toe section.

In similar fashion, locating bosses 46 are provided on the heel section of the inner shell, adapted to mate with recesses 33 in the heelsection of the outer shell. Fastening means such as screw 51 and nut 47 can be provided to secure the heel sec' tions together in a manner similar to the toe sections.

The inner shells can be fabricated of thin molded plastic and lined with a synthetic resin composition such as a liquid polyurethane composition, that has cured into a firm, resilient texture. The inner lining is installed by a method described hereinafter to conform precisely to the contours of the wearers foot.

The inner shells can also be fabricated of other materials such as leather or synthetic materials. Likewise, other suitable materials can be used for lining the inner shells provided the materials have the necessary physical characteristics.

While the inner shells of the embodiment illustrated in FIGS. 1-3 are fabricated with integral soles, this is not required.

' Thus, referring to FIGS. 4 and 5, an alternative inner shell construction is illustrated that includes a removable inner sole 52'and inner heel 53. To accommodate the removable members, the bottomless toe and heel sections are fonned with lugs 54 depending inwardly from the bottom edges thereof. Corresponding grooves 55 are provided along the periphery of the insertable inner sole and inner heel, adapted to engage lugs 54 and retain the sole and heel members in fixed position relative to the wearers foot. As shown in FIG. 5, the inner heel can be divided to accept heel lifts 56 of different sizes. This facilitates the location of a wearers foot at different desired angles with respect to the ski depending on the particular type of skiing the wearer is engaged in. For example, high heels can be used for racing and low heels used for powder skiing.

The inner soles and inner heels can be constructed of con ventional padding material encased in a cover of leather or synthetic material.

In providing footwear having custom-fit linings an outer shell size is selected which is appropriate for the size of the wearers foot. An unlined inner shell of a corresponding size and style is then selected and if desired, fitted with inner soles, inner heels and heel lifts in accordance with the wearer's needs. The wearers foot is covered with a stocking of suitable weight and placedwithin the toe and heel sections of the inner shell, and the latter are retained together by suitable means such as-the pouring fixture shown in FIG. 6.

The pouring fixture includes a front member 60 recessed to receive the toe section of the inner shell and including a holding strap 62 attached thereto for securing the toe section to the base member. A rear base member64 is also provided, being similarly recessed to receive the heel section of the inner shell and including a holding strap 65 for retaining the heel section to the base member and in fixed relationship to the toe section of the shell.

Members

60 and 64 are designed to be ad'- justably positioned and retained on a plate 66 by conventional means not shown, so that theycan be used with several shell sizes. When the wearers foot covered by stocking 69 is suitably located within the inner shell, a seal is provided between the top surface of the shell and the wearers ankle, for example by wrapping a pad 68 around the ankle. This prevents the lining compound from escaping upwardly when placed within the shell. A liquid lining composition is then injected by compressed air through suitable holes in the inner shell, until the voids within the shell are completely filled. Such injection is carried out by connecting the head of a container of catalyzed lining composition to an appropriate hole in the boot and applying air pressure from a suitable source to the base of the container. It is preferred that the lining composition be inserted through a first hole in the toe section and a second hole in the heel section to insure good distribution of the composition. However, this is not required. The liquid lining composition is such as to cure relatively rapidly into a semirigid state; after which the holding straps can be loosened and the completed custom-fit sections of the shell separated from the wearers foot.

If desired, the customers foot can be encased in a polyethylene bag 70 to prevent the lining composition from adhering thereto during the custom-fitting operation. The bag can be provided with tabs 72 adapted to extend through the joint between the toe and heel sections of the shell to prevent the front and rear sections of the lining from joining together. Likewise, the inner soles when provided, can be covered with polyethylene film during the lining operation to prevent the foam from adhering thereto. Mandrels can be inserted into the inner shells in place of the wearers feet during the lining operation, but such practice does not achieve as precise a fit as when an actual foot is employed.

The lining composition may be one of a number of known elastomeric resins which can be catalyzed to a liquid foamed state and which will cure relatively rapidly to a satisfactory resilient form. One such composition is polyurethane. The selected composition is preferably catalyzed into the desired foamed condition shortly before introduction into the inner shell. The composition is easily handled in the liquid state and, when injected into the shell by compressed air, tends to flow readily and completely fill the voids around the foot. Although the curing time for such resinous compounds varies, it is usually of short duration and does not subject the wearer to discomfort.

Various advantages result from use of the method described. For example, the method enables custom-fitting of footwear at the vending site with a precision heretofore unattainable. Furthermore, the method enables the custom-fitting of ski boots or similar footwear utilizing outer shells of a limited number of standard sizes. For example, a manufacturer might provide three sizes to accommodate men, three sizes for women, and three sizes for children. Since the inner shells of the footwear are interchangeable with any outer shell of corresponding size, a family of growing children could all use the same set of outer boots, procuring only their own individual set of custom-fit inner shells. Furthermore, if desired, the resilient linings might be removed from a set of inner shells and the inner shells economically refitted for another wearer. Also, since the outer shells can be provided in a variety of colors, a person might wish to own a single pair of inner shells usable with any of a plurality of sets of outer shells of different colors.

In the embodiment illustrated the footwear is divided along the ankle line into distinct toe and heel sections. For the reasons mentioned, this is the preferred mode of construction. However, it is not required. Thus, it is within the scope of the invention to divide the footwear into other configurations as long as suitable rigidity and ease of entry are maintained.

Furthermore, if desired, the inner shells can be singularly utilized as footwear. Thus, in the case of ski boots, the inner shells can be provided with satisfactory closures and suitably styled for use as after ski wear.

I claim:

1. An improved footwear comprising an outer shell including an upper member and a sole secured thereto;

and an inner shell removably confined within said outer shell, said inner shell having one relatively stiff wall in engagement with the outer shell and a resilient lining extending from said wall and custom fit to conform precisely to the contours of a wearers foot.

2. An improved footwear comprising an upper member having a sole of elongate dimension secured thereto, 7

said upper member being divided along the ankle line of a wearer and said sole being divided transverse to said elonelastomeric material into said foot encompassing m ns d. curing sard elastomenc material rnto a resilient rnner lrning which conforms precisely to the contours of the wearers foot.

4. A footwear as described in claim 1, wherein said outer shell is divided into a plurality of sections and said inner shell is divided into a plurality of corresponding sections, the corresponding sections of said inner shell and said outer shell being coordinately movable for opening said footwear to permit entry and removal of the wearers foot.

5. Footwear as described in claim 2, wherein at least said upper member includes an outer shell and an inner shell confined within said outer shell, said inner shell having a resilient lining which conforms to the contours of the wearers foot.

6. Footwear as described in claim 5 further including flexible hinge means secured to said upper member across the divided portion thereof. 7

7. Footwear as described in claim 5, wherein said sole includes a first portion secured to the upper member of said outer shell and a second portion secured to the upper member of said inner shell.

8. Footwear as described in claim 5, wherein said sole comprises a thin layer of material secured to the upper portion of said outer shell and further including a resilient inner sole and a resilient inner heel removably attached to the upper member of said inner shell.

, 9. Footwear as described in claim 5, further including alignment means for registering said inner shells with respect to said outer shells when confined therein.

10. Footwear as described in claim 4 further including flexible hinge means secured between the plurality of sections of said outer shell.

1 l. Footwear as described in claim 4, wherein a second sole is secured to said inner shell.

12. Footwear as described in claim 11, wherein said second sole comprises a resilient inner sole and a resilient inner heel removably attached to the upper member of said inner heel.

13. A method as described in claim 3 further including the step of placing a protective covering over the object before injection of the lining composition.

14. A method as described in claim 3 further including the steps of placing a stocking of polyurethane film having side tabs thereon over the object and securing the tabs between the joint defined between the toe and heel sections before injection of the lining composition.

Claims

1. An improved footwear comprising an outer shell including an upper member and a sole secured thereto; and an inner shell removably confined within said outer shell, said inner shell having one relatively stiff wall in engagement with the outer shell and a resilient lining extending from said wall and custom fit to conform precisely to the contours of a wearer''s foot.

2. An improved footwear comprising an upper member having a sole of elongate dimension secured thereto, said upper member being divided along the ankle line of a wearer and said sole being divided transverse to said elongate dimension to permit opening of the footwear; and means removably clamping the divided upper member and divided sole in firm engagement encompassing the wearer''s foot.

3. A method of forming improved custom-fit footwear comprising the steps of a. selecting a foot encompassing member of standard size, said foot encompassing member adapted to fit closely within an outer member of said footwear comprising separate toe and heel sections, b. placing an object having the dimensions of a wearer''s foot within said sections, c. injecting a liquid lining composition of catalyzed elastomeric material into said foot encompassing member, and d. curing said elastomeric material into a resilient inner lining which conforms precisely to the contours of the wearer''s foot.

4. A footwear as described in claim 1, wherein said outer shell is divided into a plurality of sections and said inner shell is divided into a plurality of corresponding sections, the corresponding sections of said inner shell and said outer shell being coordinately movable for opening said footwear to permit entry and removal of the wearer''s foot.

5. Footwear as described in claim 2, wherein at least said upper member includes an outer shell and an inner shell confined within said outer shell, said inner shell having a resilient lining which conforms to the contours of the wearer''s foot.

6. Footwear as described in claim 5 further including flexible hinge means secured to said upper member across the divided portion thereof.

9. Footwear as described in claim 5, further including alignment means for registering said inner shells with respect to said outer shells when confined therein.

11. Footwear as described in claim 4, wherein a second sole is secured to said inner shell.