U.S. patent application number 09/982295 was filed with the patent office on 2002-07-11 for composite ski boot.
Invention is credited to Giese, Erik, Joseph, Mark, Katsaros, Steve, Simpson, Janson.
Application Number | 20020088146 09/982295 |
Document ID | / |
Family ID | 27496906 |
Filed Date | 2002-07-11 |
United States Patent
Application |
20020088146 |
Kind Code |
A1 |
Joseph, Mark ; et
al. |
July 11, 2002 |
Composite ski boot
Abstract
A boot, preferably for skiing and other sports activities,
designed for performance as well as comfort. The preferred
embodiment of the boot includes rigid upper and lower frames with a
conformable cuff and shell. The boot is open in front to allow an
inner flexible boot to be easily inserted as well as removed. A
controlled flex unit controls the movement of the upper frame
relative to the lower frame while maintaining the lateral stability
of the boot.
Inventors: |
Joseph, Mark; (Aspen,
CO) ; Giese, Erik; (Aspen, CO) ; Simpson,
Janson; (Aspen, CO) ; Katsaros, Steve;
(Denver, CO) |
Correspondence
Address: |
GLENN L WEBB
P.O. BOX 951
CONIFER
CO
80433
|
Family ID: |
27496906 |
Appl. No.: |
09/982295 |
Filed: |
October 16, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09982295 |
Oct 16, 2001 |
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09535670 |
Mar 22, 2000 |
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09535670 |
Mar 22, 2000 |
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09170344 |
Oct 13, 1998 |
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5925763 |
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60241193 |
Oct 16, 2000 |
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60272882 |
Mar 2, 2001 |
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Current U.S.
Class: |
36/117.3 ;
36/117.5; 36/118.3 |
Current CPC
Class: |
A43B 5/0482 20130101;
A43B 5/049 20130101; C07C 233/76 20130101; C07C 231/10 20130101;
C07C 231/10 20130101; A43B 5/04 20130101 |
Class at
Publication: |
36/117.3 ;
36/117.5; 36/118.3 |
International
Class: |
A43B 005/04 |
Claims
What is claimed is:
1. A boot for sport activity, said boot comprising: a rigid upper
frame; a substantially open front on said upper frame; a cuff
affixed to said upper frame; said cuff formed from a conformable
material; a rigid lower frame; a substantially open upper surface
on said lower frame; a shell affixed to said lower frame; said
shell formed from a conformable material; and an attachment unit
for pivotally attaching said upper frame to said lower frame while
maintaining the lateral stiffness of the upper frame relative to
the lower frame.
2. The boot of claim 1 wherein said attachment unit includes: an
elastomer member constrained for elongation and displacement
movement during movement of said upper frame relative to said lower
frame.
3. The boot of claim 1 wherein said attachment unit includes: a
post attached to one of said upper frame and said lower frame; an
aperture in the other of said upper frame and said lower shell
surrounding said post; and an elastomer member mounted between said
post and said aperture and constrained for elongation and
displacement movement during movement of said upper frame relative
to said lower shell.
4. The boot of claim 3 wherein said attachment unit includes: an
elastomer member having a shape and material choice to allow said
elastomer member to displace under pressure from said post and said
aperture in a substantially non-compressive manner due to
elongation and shear stresses in said elastomer member.
5. The boot of claim 3 wherein said elastomer member includes: an
elastomer ring.
6. The boot of claim 1 wherein said boot includes: a flexible inner
boot.
7. The boot of claim 1 wherein said boot includes: a flexible inner
boot having a supportive sole.
8. The boot of claim 1 wherein said boot includes: a flexible inner
boot having an outer sole for walking on surfaces.
9. The boot of claim 1 wherein said boot includes: a flexible inner
boot having a heat moldable inner layer for custom fitting to a
user's foot.
10. The boot of claim 1 wherein said boot includes: a flexible
inner boot having at least one section that transmits moisture.
11. The boot of claim 1 wherein said lower frame includes: a toe
portion; a section on said toe portion that can be trimmed to
reduce the length of said lower frame; a toe portion on said shell;
and a section on said toe portion that can be trimmed to reduce the
length of said lower frame wherein said lower frame and said shell
are assembled together for a boot of a first size and said toe
portion on said lower frame and said toe portion on said shell are
trimmed and assembled together for a boot of a second size.
12. The boot of claim 11 wherein said boot further includes: a
first heel pad for assembly onto said lower frame for said boot of
said first size and a second heel pad for assembly onto said lower
frame for said boot of said second size.
13. The boot of claim 1 wherein said boot further includes: a
lateral canting adjustment mechanism on said boot for adjusting the
canting of said boot laterally.
14. The boot of claim 13 wherein said lateral canting adjusting
mechanism includes: a first bracket on the under surface of said
lower frame; a second bracket on said shell mating with said first
bracket; and a screw mechanism engaging said first bracket and said
second bracket for adjusting the canting of said boot.
15. The boot of claim 13 wherein said lateral canting adjusting
mechanism includes: a convex surface on the lower surface of said
lower frame; and a concave surface on the mating surface of said
shell.
16. The boot of claim 1 wherein said boot further includes: a
resilient bumper between said upper frame and said cuff.
17. A boot for sport activity, said boot comprising: a rigid upper
frame; a substantially open front on said upper frame; a cuff
affixed to said upper frame; said cuff formed from a conformable
material; a rigid lower frame; a substantially open upper surface
on said lower frame; a shell affixed to said lower frame; said
shell formed from a conformable material; a flexible inner boot;
and an attachment unit for pivotally attaching said upper frame to
said lower frame while maintaining the lateral stiffness of the
upper frame relative to the lower frame, wherein said attachment
unit includes an elastomer member constrained for elongation and
displacement movement during movement of said upper frame relative
to said lower frame.
18. The boot of claim 17 wherein said attachment unit includes: a
post attached to one of said upper frame and said lower frame; an
aperture in the other of said upper frame and said lower shell
surrounding said post; and said elastomer member mounted between
said post and said aperture and constrained for elongation and
displacement movement during movement of said upper frame relative
to said lower shell.
19. The boot of claim 17 wherein said elastomer unit includes: an
elastomer member having a shape and material choice to allow said
elastomer member to displace under pressure from said post and said
aperture in a substantially non-compressive manner due to
elongation and shear stresses in said elastomer member.
20. The boot of claim 17 wherein said elastomer m ember includes:
an elastomer ring.
21. The boot of claim 17 wherein said flexible inner boot includes:
a supportive sole.
22. The boot of claim 17 wherein said flexible inner boot includes:
an outer sole for walking on surfaces.
23. The boot of claim 17 wherein said flexible inner boot includes:
a heat moldable inner layer for custom fitting to a user's
foot.
24. The boot of claim 1 wherein said flexible inner boot includes:
at least one section that transmits moisture.
25. The boot of claim 17 wherein said lower frame includes: a toe
portion; a section on said toe portion that can be trimmed to
reduce the length of said lower frame; a toe portion on said shell;
and a section on said toe portion that can be trimmed to reduce the
length of said lower frame wherein said lower frame and said shell
are assembled together for a boot of a first size and said toe
portion on said lower frame and said toe portion on said shell are
trimmed and assembled together for a boot of a second size.
26. The boot of claim 17 wherein said boot further includes: a
first heel pad for assembly onto said lower frame for said boot of
said first size and a second heel pad for assembly onto said lower
frame for said boot of said second size.
27. The boot of claim 17 wherein said boot further includes: a
lateral canting adjustment mechanism on said boot for adjusting the
canting of said boot laterally.
28. The boot of claim 27 wherein said lateral canting adjusting
mechanism includes: a first bracket on the under surface of said
lower frame; a second bracket on said shell mating with said first
bracket; and a screw mechanism engaging said first bracket and said
second bracket for adjusting the canting of said boot.
29. The boot of claim 27 wherein said lateral canting adjusting
mechanism includes: a convex surface on the lower surface of said
lower frame; and a concave surface on the mating surface of said
shell.
30. The boot of claim 17 wherein said boot further includes: a
resilient bumper between said upper frame and said cuff.
31. A boot for active use, said boot comprises: a lower portion;
guides formed in an upper part of said lower portion; a tightening
mechanism; and a lace extending through said guides and connected
to said tightening mechanism.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of Ser. No.
09/535,670 that is a continuation-in-part of Ser. No. 09/170,344
and relates to provisional application No. 60/241,193 and
provisional application No. 60/272,882.
FIELD OF THE INVENTION
[0002] This application relates to the field of boots and other
footwear and particularly to ski and snowboarding boots.
BACKGROUND OF THE INVENTION
[0003] Ski boots are a critical component in enhancing skier
performance. Typically, ski boots have sacrificed comfort for
performance or performance for comfort. Most alpine ski boots
include a rigid plastic body with an inner lining. The entire body
is normally formed of a single stiff material. In order to achieve
performance, the rigid plastic body includes a rigid lower shell
and sole for attachment to the bindings of the ski, a rigid upper
cuff to allow force to be applied to the ski in order to drive the
ski during turns, a pivot or flexion element to allow the upper
cuff to pivot relative to the lower shell, and an inner lining.
[0004] These elements combine to create a ski boot that is
relatively heavy, extremely stiff compared to everyday walking
boots or shoes, and awkward to walk in. Additionally, these boots
are difficult to put on and take off as well as to adjust for
proper fit. The stiff material used for the body does not conform
to the shape of the user's calves, shins, ankles and feet. Thus,
the user's legs and feet are constricted by the boots creating a
tendency to restrict blood flow to the skier's feet causing
discomfort and increased susceptibility to the cold. The boots are
also extremely difficult to maneuver about in when not attached to
skis. They are heavy, cumbersome and slippery on most surfaces.
They create a liability in parking lots and ski lodges.
[0005] These prior boots have also been relatively expensive.
Previous boots have not been adjustable to different sizes of feet,
thus manufacturers must produce and stock components for every size
of skier feet.
[0006] A number of prior ski boots have attempted to solve this
problem by providing a ski boot that incorporates a flexible inner
boot that is inserted into a rigid boot brace. This type of boot is
disclosed in U.S. Pat. Nos. 4,959,912; 5,068,984; and 5,142,798,
all issued to Kaufman et al. However, the boots disclosed in these
patents are not able to conform to the shape of the skier's shins,
calves and feet. The shin pieces and forefoot pieces are formed of
rigid materials and are not able to conform to the skier. Further,
these boots do not disclose using a controlled flex unit to allow
the boot to be progressively flexed nor do the boots allow the
canting and the flex of the boot to be adjusted.
[0007] Another type of this boot design is disclosed in U.S. Pat.
No. 5,992,872, issued to Proctor. The boot disclosed in this patent
also uses a rigid ankle cuff and does not provide a controlled flex
unit or adjustability of the flex and canting of the boot.
Similarly, U.S. Pat. No. 6,021,589, issued to Cagliari et al.
discloses a ski boot using a brace and soft inner boot. The brace
is formed of a single material, thus it can be either rigid or able
to conform to the user, but not both. Further this boot does not
allow progressive flexing of the boot or adjustment of the flex and
canting of the boot.
[0008] It is critical that a skier be able to flex the boot in
order to obtain desired performance from the skis. The ability of
the skier to "flex" their knees forward from a normal substantially
upright position "drives" the ski into a carved turn as well as to
absorb bumps and differences in surface terrain and texture. This
flexure allows the ski to change from one side edge to the opposing
side edge in order to "carve" or turn the ski. This type of flexing
to create a carved turn is created by the skier rotating about the
skier's ankles. At the same time, the skier must maintain control
of the skis. Also, the flexing motion is critical in allowing the
skier to absorb the impact of bumps and differences in surface
terrain and texture while maintaining control.
[0009] A primary consideration in the recent design of ski boots
has been to maximize and optimize this forward flex. However, this
was typically done at the expense of the lateral stability that
affects control. Not only must a skier be able to flex forward in
the boot to enhance skiing performance, but the boot must provide
lateral and torsional stability for the skier to maintain the
control necessary for skiing performance. Thus, a critical feature
of ski boots is the ability of the upper portion of the ski boot to
flex forward while the overall lateral stiffness of the ski boot is
maintained.
[0010] This critical feature of the ski boot to flex requires a
relative stiffness in the boot. The pressure from the skier is
considerable during the flexing motion. Thus, a tendency in prior
ski boots is to allow the boot to be easily flexed which detracts
from the performance of the boot and the control of the skier.
Further, the flexibility of prior ski boots has been temperature
dependent. The flexing characteristics of the prior boots would
vary greatly from the room temperature environment in which the
boots were initially demonstrated to the changing temperatures in
the skiing environment. The mechanical elements of the prior ski
boots which provided the flexing of the ski boot, typically a
metallic or plastic spring element, have physical characteristics
which change with temperature differences.
[0011] A further important design feature is the control of the
flex and springback, that is the return of the boot from the
forward flexing to the normal skiing position. Different skiers
have different needs as far as the amount of flex and the degree of
resistance of the flex. Therefore, the design of a performance ski
boot incorporates the ability to adjust the degree of the flex of
the ski boot as well as the consistent progressive resistance of
the flex, particularly as relating to the consistency of the flex
through a wide range of temperatures. Additionally, the flex needs
to be progressive in order to complete the turn, that is the
resistance level of the flex may increase during the flex of the
upper portion of the boot relative to the lower portion of the
boot.
[0012] A number of prior ski boot designs attempted to provide a
ski boot that would allow the skier to flex the boot forward
relative to the ski about a fixed pivot point in order to improve
ski performance. These designs typically include ski boots having a
lower shell with an upper cuff that is movable about a fixed axis,
usually a rivet, on the lower shell. A number of different devices
have been used to allow the controlled movement of the upper cuff
relative to the lower shell to provide the desired flexing of the
ski boot. These devices include spring-loaded systems, flexion
devices, elastomer bushings, and others.
[0013] Spring-loaded boots were initially used with coil springs
incorporated into the mounting between the upper cuff and lower
shell of the boot to provide a resistive force for the rotating
motion. These boots fail to provide appropriate dampening and are
affected by changes in the temperature.
[0014] Examples of the prior flexion devices in prior designs of
flexible boots are disclosed in U.S. Pat. No. 4,777,742, issued to
Petrini et al. and U.S. Pat. No. 5,329,707, issued to Chaige et
al., which describe flexion element boots. These boots use a front
flexible element to provide flexibility and resistance in the
pivoting action about a rigid axis between the upper cuff and the
lower shell.
[0015] There have been several attempts to incorporate an elastomer
into the ski boot in order to provide flexibility of the upper
portion of the ski boot relative to the lower portion. These types
of designs are typified by the boots disclosed in U.S. Pat. No.
4,611,415, issued to Tonel and in German Patent 1481166. These
boots use a loose elastomer disc to provide dampening between the
upper cuff and the lower shell. This allowed some movement of the
upper cuff relative to the lower shell but the critical feature of
the lateral stability of the boot was lost. Additionally, there was
no capability to regulate the degree of flex or to provide any
control of the flex movement.
[0016] Another problem with the prior elastomer-type flexing
elements is that these elements "bulge" during compression. This
creates pressure against the ankle of the skier during the flexing
causing discomfort to the skier.
[0017] Another critical problem with the prior ski designs is that
the skier's forward movement in flexing the upper portion of the
boot is caused by the skier moving about the ankle joints, while
the boots typically pivot about a fixed axis. The ankle joint,
however, from an anatomical point of view, does not pivot about a
fixed axis, or even about a purely laterally movable axis. The
ankle joint partially rotates about an axis which moves in a
sliding lateral arcuate motion relative to the foot. Thus, the
prior ski boots artificially constrain the motion of the ankle in
the pivotal movement of the cuff relative to the shell. This often
creates discomfort and inhibits the proper flexing movement of the
skier. It can also lead to possible injury to the ankle joint
itself. Also, the ski boots utilizing elastomers were unable to
provide significant lateral stability. This lateral stability is
critical in skiing performance.
[0018] Even the elastomer flexing units disclosed in the
above-identified parent application, U.S. patent application Ser.
No. 09/170,84, incorporated herein by reference, require a
two-point pivoting mechanism. These units require additional
mechanical elements and increase the complexity of the ski
boot.
[0019] Another problem with the prior designs is the possibility
for serious knee injuries. Most ski boot designs have increased the
height of the cuff to improve the control and stability in the use
of the boot. Unfortunately, this increased height has increased the
stress on the knee joint, not only in the forward direction but as
the skier returns back to the normal upright position after flexing
forward. This increased pressure, whether under the torque of
stopping or slowing the speed of the skier or when the skier moves
or falls to the rear, can cause injury, especially and most
commonly to the anterior cruciate ligaments of the skier. The
rearward movement of the skier against the stiffness of the boot
pushing forward against the calf of the skier's leg can be
devastating to the anterior cruciate ligaments if the skier does
not have time to recover. This is even more devastating if a
torquing or twisting motion occurs. This is particularly
significant due to the stiffness of the boots when flexing or
moving rearward to the normal upright position. The prior ski boot
designs are concerned with the forward flexing of the ski boot, not
with absorption, and resistance to the rearward movement of the
skier. The reduction of injuries of this type have not been
addressed by the prior ski boots.
[0020] Yet another problems with existing ski boots are the
fastening mechanisms. Existing boots utilize buckle mechanism to
tighten and secure the boot onto the user. It is awkward to tighten
these buckle mechanisms, particularly on the ski slope.
Additionally, it is difficult to adjust the buckles for proper fit.
Even when the buckles are properly adjusted, the foot of the user
often swells during use of the boot creating "hot spots" on the
user's foot or other discomfort.
[0021] The present invention provides a ski boot design which
addresses these problems and others with an improved ski boot that
provides controlled flex action of the upper cuff and lower
shell.
SUMMARY OF THE INVENTION
[0022] The present invention solves these and other problems by
providing a boot for skiing, snowboarding, and other activities.
The boot of the present invention provides high performance with
improved comfort. The boot includes a stiff frame for support and
for translating energy directly to the ski, snowboard or other
equipment, a conformable cuff and shell for improved fitting and
comfort and a walkaway inner boot for comfort. The present
invention provides a boot formed of composite materials rather than
a single material of prior boots. This enables the use of materials
having specific properties for particular functions.
[0023] In a preferred embodiment, the boot of the present invention
includes a stiff upper frame formed of high strength, lightweight
materials. An open-face conformable cuff is mounted to the upper
frame for engaging the user. The cuff, in a preferred embodiment,
is able to be adjusted relative to the upper frame and is able to
rock slightly relative to the upper frame.
[0024] The boot also includes a stiff lower frame formed of
materials similar to the upper frame. The upper frame is pivotally
attached to the lower frame by a controlled flex unit. In the
preferred embodiment, the controlled flex unit includes an oval
plug or stub that is surrounded by an elastomer ring. In this
embodiment, the elastomer ring includes a differing thickness to
provide progressive flexing in the forward direction and a stiffer
flexing in the rearward direction to minimize injuries. The unique
controlled flex unit enables the upper framer to move forward,
rearward, upward and downward relative to the lower frame without
sacrificing lateral and torsional stability of the boot. The
stiffness and performance of the controlled flex unit can be varied
by substituting different elastomers and/or by adjusting the
canting of the post.
[0025] In a preferred embodiment, a bumper is also provided to
connect the lower frame and upper frame near the rear of the boot.
This provides shock absorption as well as additional control
between the lower frame and upper frame.
[0026] The boot also includes a shell attached to the lower frame.
The shell includes a substantially open face and is formed of a
soft conformable material to engage the inner boot and the user.
The inner boot is a soft, durable, insulated walkaway boot. In use,
the user may wear the inner boot until the use of the entire boot
is necessary. The user simply inserts their foot and inner boot
into the open face of the cuff and shell and tighten the buckles.
The stiff upper and lower frames provide the requisite support for
the activity. The controlled flex unit provides the transfer of
power from the user and upper frame to the lower frame and the
equipment.
[0027] In another preferred embodiment, the boot is similar to the
above boot, except that a closed shell is used instead of the above
shell having a substantially open face. The closed shell may be of
a soft conformable material to engage the inner boot and/or foot of
the user.
[0028] In additional preferred embodiments, the boot includes the
capability to adjust sizes. The lower frame may be shortened by
trimming the toe portion and using a shorter heel pad. The toe
portion of the shell may also be trimmed. This enables a single
boot to be adjusted for several sizes.
[0029] In another preferred embodiment, the lower frame and shell
include an adjustable canting mechanism. This enables the boot to
be adjusted to differing biomechanics.
[0030] In another preferred embodiment, a unique lacing system
replaces the use of buckles. This unique lacing system provides
ease of securing and adjusting the boot to the user's foot as well
providing uniform strain over the user's foot.
[0031] These and other features of the boot of the present
invention are evident from the ensuing drawings and detailed
description of preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a perspective view of a preferred embodiment of
the boot of the present invention.
[0033] FIG. 2 is an exploded assembly view of the boot of the
embodiment of FIG. 1.
[0034] FIG. 3 is a partial cutaway view of the bumper connection
between the upper frame and lower frame of the embodiment of FIG.
1.
[0035] FIG. 4 is a partial cutaway view of the embodiment of FIG. 1
showing the lower surface of the boot.
[0036] FIG. 5 is an exploded assembly view of the controlled flex
unit of the boot of the embodiment of FIG. 1.
[0037] FIG. 6 is a reverse view of the controlled flex unit of FIG.
5.
[0038] FIG. 7 is an assembled view of the controlled flex unit of
FIG. 5.
[0039] FIG. 8 is a cutaway view of FIG. 7.
[0040] FIG. 9 is a view of the inner boot.
[0041] FIG. 10 is an exploded assembly view of the lower frame and
shell of the boot of the embodiment of FIG. 1.
[0042] FIG. 11 is a perspective view of the lower frame of another
preferred embodiment.
[0043] FIG. 12 is a lower perspective view of the assembled lower
frame and shell of the embodiment of FIG. 11.
[0044] FIG. 13 is a side view of the adjusted sizes of the
embodiment of FIG. 11.
[0045] FIG. 14 is an exploded assembly view of another preferred
embodiment of the boot showing the adjustable canting
mechanism.
[0046] FIG. 15 is a front perspective assembly view of the
embodiment of FIG. 14.
[0047] FIG. 16 is a perspective view of another embodiment of a
boot securing system.
[0048] FIG. 17 is a view of another embodiment of the boot securing
system of FIG. 16.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0049] A preferred embodiment of the present invention is
illustrated in FIGS. 1-10. It is to be expressly understood that
the descriptive embodiments are provided herein for explanatory
purposes only and are not meant to unduly limit the claimed
inventions. The preferred embodiment of the present invention
includes a ski boot for use in alpine, Nordic, telemarking and
other types of skiing, snowboarding, inline skating or other types
of activities. The boot is referred to herein as a "ski boot" for
descriptive purposes but is not meant to be limited for use with
this activity. This invention is a continuation-in-part of U.S.
application Ser. Nos. 09/170,344 and of 09/535,670, both of which
are incorporated herein by reference.
[0050] The boot of the preferred embodiments of the present
invention includes a very stiff power frame with controlled flex
for transferring force from the user to the ski, a cuff and shell
that conforms comfortably to the skier's body, and a comfortable
liner that can, in some preferred embodiments be used to walk in.
The boot provides the user with high performance as well as
comfort.
[0051] Power Frame
[0052] The boot 10 of the descriptive embodiment, as shown in FIG.
1 includes an upper frame 20 that provides structural support for
the lower leg of the skier, a cuff 30 that wraps around the lower
leg of the skier, a lower frame 40 that forms the structural base
under the foot and around the ankle of the skier, a shell that
covers only the foot and is mostly open; and an inner boot 300. It
is to be expressly understood that this preferred embodiment is
intended for descriptive purposes only. Other types of boots,
included one similar to this descriptive embodiment but having a
substantially closed lower shell are also within the scope of the
present invention.
[0053] The upper frame 20, shown in FIGS. 1-3 is formed of a high
strength, relatively lightweight, stiff plastic material, such as
glass filled polyamide. In the preferred embodiment, the upper
frame includes a glass-filled material, such as nylon with about
forty percent (40%) glass or Isoplast (produced by Dow Chemical)
with about forty percent (40%) glass. It is to be expressly
understood that other suitable materials may be used as well having
very stiff characteristics. For example, carbon fiber,
polycarbonate or other stiff materials may be used as well. The
upper frame includes two opposing apertures 22, 24 for connection
with the controlled flex units 200 and lower frame 40, as discussed
below. Soft rubber bumper 28 is mounted within an interior recess
of upper frame 20 and connects to a projection on lower frame 40,
as shown in FIG. 3, and discussed in greater detail below. The
upper frame also includes a substantially open face 26, as can be
seen in FIG. 2.
[0054] Cuff 30 is attached to the upper portion of the upper frame
20. In the preferred embodiment, the cuff is adjustable by height
and/or by angle relative to the upper frame. This can be
accomplished by using tracks or other adjustable securing devices.
The cuff may also rock to accommodate different shin angles and
movement during use. Cuff 30, in the preferred embodiment, is
formed of a lightweight material, such as a flexible urethane or
other flexible materials. In the present invention, the cuff 30 is
softer than the upper frame, preferably in the range of about
forty-seventy five shore A durometer. This allows the cuff to
conform about the shape of the user's calves and shins. One or more
buckles 38 are attached to the cuff 30 to secure the boot 10 about
the liner 200 and the skier. The opposing buckle is attached to the
upper frame 20.
[0055] The lower frame 40 is also formed from a stiff material
similar to the upper frame, such as a glass-filled material, such
as nylon with about forty percent (40%) glass or Isoplast (produced
by Dow Chemical) with about forty percent (40%) glass. It is to be
expressly understood that other suitable materials may be used as
well having very stiff characteristics. For example, carbon fiber,
polycarbonate or other stiff materials may be used as well. The
lower frame 40 includes an upper portion 42 for attachment to the
upper frame 20 through the use, in the preferred embodiment, of
controlled flex units 200, 260, as discussed in detail below. Lower
frame 40 includes toe portion 44 extending from the front of the
lower frame and a recessed heel portion 46 near the rear of the
lower frame. The lower surface of the lower frame includes a first
set of two holes (not shown) near the front of the lower frame and
a second set of holes in the recessed heel portion 44 of the lower
frame.
[0056] Shell 50, shown in FIG. 2, is formed from a soft urethane or
other flexible material, similar to the materials used in forming
the cuff 30. The shell 50 includes a substantially open upper face
to facilitate entry into the boot with buckles 54 to cause the
shell to conform about the inner boot and foot of the user. The
shell includes an extended toe portion 56 and an open rear portion
58. In the preferred embodiment, the shell 50 includes a
substantially oval shaped apertures 60, 62 for receiving the
controlled flex units 200, discussed below. The lower surface of
the shell 50, in the preferred embodiment, will normally have a
tread pattern for gripping. Also, in the preferred embodiment, the
lower surface of the shell includes two sets of holes 64, 66 near
the front portion of the shell and a third set of holes near the
heel portion of the shell.
[0057] Replaceable heel pad 80 is formed from hard rubber or other
material that provides adequate wear while affording some gripping
capability in the preferred embodiment attaches to the lower frame
40. In the preferred embodiment, heel pad 80 includes an extended
flange 82 that inserts between the shell 50 and lower frame 40 to
minimize debris buildup. Holes 84, 86 extend through the heel pad
80.
[0058] Controlled Flex Unit
[0059] The controlled flex unit of the preferred embodiment is
disclosed in FIGS. 2 and 5-8. It is to be expressly understood that
the descriptive embodiment is disclosed for explanatory purposes
only and is not meant to limit the scope of the claimed inventive
concept. The controlled flex unit 200, shown in FIG. 2, on ski boot
10, in the preferred embodiment includes an identical unit (not
shown) on the opposing side of the boot 10.
[0060] The flex unit 200 is inserted through the inner portion of
the upper frame 20. It is to be expressly understood that other
mounting techniques could be used as well, such as mounting the
flex unit on the outer side of the cuff. Flex unit 200 includes cap
202, shown in FIGS. 5 and 6, having a first side surface 204, a
second reduced diameter side surface 206 and stub 208 mounted
centrally in the inner surface 210 of cap 202. In one embodiment,
stub 208 includes ridged surface 212 on it's outer surface. An
aperture 214 extends through the center of cap 202 and stub 208.
Bracket 216 includes a side surface 220 having a series of spaced
notches 224 and teeth 226. Post 228, shaped in an oval design as
discussed above, includes an indentation 230 dimensioned to snugly
receive stub 208 of cap 202, as shown in FIG. 8. Ridges 232 are
formed in the inner surface of indentation 230 to mate with the
ridged surface 212 of the stub 208. The ridged surfaces 212, 232
allow up and down adjustment between the post and the stub for
canting or lateral adjustment between the shell and the
corresponding flex assembly. This feature is not found in any other
boot assembly and provides greater adjustment to enhance the
performance of the boot and the skier.
[0061] Elastomer ring 236 includes an outer dimension substantially
equal to the inner dimensions of bracket 216 and an inner dimension
substantially equal to the outer dimension of post 228. Elastomer
ring 236, in the preferred embodiment, includes materials that have
the characteristics of being temperature independent in the range
of temperatures normally found in skiing environments. Examples of
these materials, for use in the preferred embodiment, are disclosed
in U.S. Pat. Nos. 5,611,155 and 5,740,620, both of which are
incorporated by reference herein. In the preferred embodiment, the
elastomer ring 236 is injection molded directly between the post
228 and the bracket 216. This ensures that the elastomer ring 236
"sticks" to the post 228 and the bracket 216. The elastomer ring
236 thus "flows" from the stresses during the flexing motion of the
boot as discussed in greater detail below.
[0062] It is to be expressly understood that the elastomer ring 236
can also be formed as a separate piece as well as injection molded.
The separate elastomer ring 236 can thus be inserted during
assembly between the post 228 and bracket 216.
[0063] In the preferred embodiment, shown in FIG. 6, the elastomer
ring 236 is asymmetrically shaped, that is, portions on one side of
the ring 236 are thinner than other portions of the ring 236, as
discussed in greater detail below. It is to be expressly understood
that other shapes and dimensions of the elastomer ring can be used
as well. Elastomer ring 236 is fitted between post 228 and bracket
216.
[0064] In another preferred embodiment, elastomer ring 236 is
substantially oval in shape in lieu of the asymmetrical shape
discussed above. This provides ease in the fabrication of the
elastomer ring.
[0065] Aperture 234 extends through the center of post 228.
Aperture 240 is formed in the upper frame 20 of the ski boot. The
aperture 240 includes a series of spaced teeth 242 and notches 244
to mate with the notches 224 and teeth 226 of the bracket 216. An
inner surface 246 in aperture 240 forms a hard stop against the
inner surface of bracket 216.
[0066] As shown in FIGS. 7-10, the components of flex unit 200 are
assembled as follows. Bracket 216 is inserted into aperture 234 so
that the notches 224 and teeth 226 of the bracket 216 engages into
the notches 244 and teeth 242 of the aperture 240. Elastomer ring
236 mounts within bracket 216 and around post 228. The indentation
230 of post 228 engages over the stub 208. Two screws (not shown)
are inserted through aperture 214 and engage in threads in aperture
234 of stub 208.
[0067] Once the unit is fully assembled and the screw is tightened
securely, the post 228 is fully engaged against the stub 208 on the
lower frame. The side surfaces of the post 228 are also engaged
against the elastomer ring 236 which is supported by the bracket
216 attached to the upper cuff. Thus, forces from the skier against
the upper frame are transmitted by the bracket 216 and thicker
portions of elastomer ring 236 against the post 228 and the lower
frame.
[0068] As the forces are increased between the elastomer ring 236
and the post 228, the elastomer ring flows from the pressure. The
elastomer ring 236 flows from the shear stresses in the material,
as opposed to compression of other elastomer materials. While the
forces on the elastomer ring 236 are discussed as primarily due to
shear stresses, it is to be understood that compressive and tensile
stresses are present as well during the use of the boot in skiing.
The flow of the elastomer ring is due to the combination of these
stresses, particularly to the shear stresses, as opposed to the
compressive stresses in the prior art ski boot elastomers. This
flow of material results in the elongation of the elastomer
material in some areas and displaces in other areas instead of the
bulging of the elastomer material in the prior art ski boots. As
the forces are decreased, the material of the elastomer ring moves
back into it's original shape and position. As the elastomer ring
236 returns back to it's original position, the opposing sides of
the elastomer ring engage the post 228 to dampen the movement of
the upper shell and the skier. This dampening of the upper shell
minimizes the shock of a hard stop or twisting due to falling of
the skier.
[0069] Additionally, the dampening of the upper shell relative to
the lower shell also absorb shock forces that occur during skiing,
providing a smoother skiing experience.
[0070] The asymmetrical shape of the elastomer ring 236 provides
increased resistance in the forward movement of the upper shell
while providing a lesser resistance in the rearward movement. This
is critical as the rearward movement of the skier from a normal
position should only be a few degrees, preferably 2-5 degrees. In
the preferred embodiment, the boot allows the skier to move
rearward about one inch (at the skier's knee area or about
one-fourth inch at the typical boot top) to allow time for the
skier to recover to minimize damage to the skier's leg, and
particularly to the anterior cruciate ligament of the skier.
[0071] Also, in the preferred embodiment, the post 228 is canted
about twelve degrees relative to the longitudinal axis of the
bracket. The canting of the post 228 provides a softer flex in the
forward movement of the upper cuff while providing a stiffer flex
in the rearward movement of the upper cuff.
[0072] The amount of resistance can be easily altered by material
choice for the elastomer ring as well as varying the thickness of
the elastomer ring 236. The elastomer ring 236 against post 228
provides the only connection between the upper cuff and lower
shell. This reduces wear and tear on the connection mechanism.
[0073] This unique controlled flex unit enables the upper frame to
move forward, rearward, upward and downward relative to the lower
frame without sacrificing the lateral and torsional stability of
the ski boot. The ankle of the skier is not forced to pivot about
an axis in an artificial manner. The ankle moves in a sliding-type
movement that is natural and not constrained. Additionally, the
controlled flex unit provides progressive resistance and/or shock
absorption to enhance the performance of the ski. A further benefit
is the shock absorption in the rearward movement of the upper cuff
past the normal position to minimize injury in a hard stop or
fall.
[0074] Additional benefits include the consistent performance of
the boot regardless of the environmental temperature. Also, the
characteristics of the flex unit can be changed by replacing the
elastomeric rings. Further, the complexity of the ski boot is
reduced by this novel unit, thus reducing the weight and cost of
the boot.
[0075] It is to be expressly understood that other embodiments and
variations of the preferred embodiment are considered to be within
the scope of the claimed inventions. In particular, the embodiments
disclosed in U.S. patent application Ser. No. 09/535,670 filed on
Mar. 22, 2000, and Ser. No. 09/170,334, filed on Oct. 13, 1998,
commonly assigned to the present assignee are hereby incorporated
herein by reference.
[0076] Inner Boot
[0077] The inner boot 300, shown in FIGS. 2 and 9, is in the
preferred embodiment, a walk-away inner lining with a supportive
sole. In this preferred embodiment, the inner boot 300 is formed of
a softer material, such as a compression molded EVA foam layer for
precise fit. All or part of the inner layer may include a heat
moldable material to provide for a customer fit. A support stiffner
extends down the medial side of the inner boot to the outsole to
transfer energy and to provide increased support. A breathable
window can be added to reduce moisture buildup. The outer layer of
the inner boot is formed of a waterproof material. This provides
protection during use, since the power frame is essentially open.
The inner boot also includes an overlap tongue having a smooth
inner lining for comfort that also facilitates entry into the boot,
maintains the foot dry and transfer energy to the cuff more
efficiently by eliminating movement of layers.
[0078] The sole of the inner boot includes the Multiple Contour
Sole, developed by Comfort Products Ltd. of Aspen, Colorado and
disclosed in U.S. Pat. Nos. 5,575,089; 5,572,805; 4,316,335; and
4,316,332, all incorporated herein by reference. The upper part 310
of the Multiple Contour Sole includes a soft urethane foam. The
outersole 320 includes hard blown rubber with tread molded into it.
The outersole of the inner boot also includes small studs and/or
rubber to grip on snow and ice. It is to be expressly understood
that other types of inner boots can be used with the composite boot
of the present invention as well.
[0079] Assembly
[0080] The boot 10 is assembled by attaching cuff 30 to the upper
portion of the upper frame 20 by using tracks or other adjustable
attachment mechanisms to enable the cuff to be adjustable by height
or angle. However, it is to be expressly understood that the cuff
may also be permanently fixed, such as for racing or other desired
performance use. Preferably, the cuff is able to rock to
accommodate differing shin sizes and movement during use. Elastomer
bumper (or other resilient material) 28 is located in the pocket in
the upper frame slightly overlapping lower frame. A hole (not
shown) in the bumper engages onto a bumper post on the lower frame.
As the upper frame flexes relative to the lower frame, the bumper
post moves within the bumper pocket under the constraints of the
bumper 28. The bumper 28 absorbs not only shock during skiing, and
shock from sudden stopping, it also performs in the manner of the
asymmetric elastomer ring discussed above in allowing the slight
rearward movement of the skier's leg during a hard stop or slowing
or fall to reduce the occurrence of damage to the anterior cruciate
ligament of the skier.
[0081] The shell 50 is attached to the lower frame 40, as shown in
FIG. 10, by simply sliding the lower part of the lower frame 40
into the rear portion 58 of the shell until the toe portion 42 of
the lower frame engages in the extended toe portion 56 of the
shell. The shell 50 is secured to the lower frame by screws 70, 72
inserted through holes 64, 66 in the front portion of the shell 50
that threadingly (self-tapping or other types of screws) engage in
the holes in the front portion of the lower frame 40. Heel pad 80
is attached by inserting the flange 82 between an overlap formed
between the shell and the heel recess 44 of the lower frame. The
upper portion of the heel pad 80 engages in the heel recess 44.
Screws 74 are inserted through the holes 84, 86 of the heel pad and
engage in the holes in the heel recess 44 of the lower frame.
Additional screws may attach through the mid sole of the shell and
lower frame for additional securement.
[0082] The upper frame is pivotally mounted to the lower frame by
engaging the apertures 22, 24 over the posts 238 on the lower
frame. The flex units 200, 250 is then mounted onto the posts 238,
as discussed above to secure the upper frame to the lower frame
while allowing controlled flexing of the upper frame (and cuff)
relative to the lower frame and ski.
[0083] In the preferred embodiment discussed herein, the ski boot
is formed of composite materials that fulfill unique features, as
opposed to the boots made from a single material previously. The
upper frame and lower frame are formed of a tough, lightweight
material, such as glass filled nylon or other materials, to provide
rigid stability to the boot. The shell and cuff are formed of a
softer material, as discussed above, for comfort and to conform to
the user. The elastomeric flex unit can be formed of a polymeric
material that has the appropriate flexing and temperature resistant
properties. The inner boot 300 can be formed of a lightweight,
insulating material for comfort and to allow the user to walk away
in just the inner boot.
[0084] Use
[0085] The user simply puts the inner boots 300 on for walking.
Once the user is at the appropriate venue, the user can easily
insert the inner boots in the open faces of the cuffs and shells
and secure the buckles. The buckles are then tightened until the
cuff and shell conform securely to the inner boots. This operation
is then reversed when the user is finished with their activity. The
user is much more comfortable in the inner boots as well as safer
from slipping and falling.
[0086] Alternative Embodiments
[0087] An alternative embodiment of the present invention is
illustrated in FIGS. 11-14. This embodiment enables several sizes
to be accommodated from a single boot structure. In this
embodiment, shown in FIG. 11, lower frame 40 includes two sets of
screw holes 120, 122 in the lower surface. Also, toe portion 44
includes a marker line. Shell 50 includes two matching sets of
screw holes, 124, 126, as shown in FIG. 12. In use, as shown in
FIG. 18, for larger sizes the lower frame 40 and shell 50 are
assembled as discussed above. For smaller sizes, the toe portion 44
of lower frame 40 is cut at the marker line. Also, toe portion 56
of the shell 50 is also trimmed accordingly. The shell and lower
frame are then assembled together. Since the shell will slide
further back onto the lower frame due to the shorter toe portions,
a shorter heel pad 80 is used to accommodate the shorter length.
Screws are inserted through the second set of screw holes to secure
the lower frame and shell together. Thus, several sizes of boots
can be assembled from a single set of components.
[0088] Another alternative embodiment is disclosed in FIGS. 14-15.
The lower frame 40 includes a rear canting adjuster 66 extending
downward from heel portion 46. The lower surface of the lower frame
is substantially curved and includes a first portion 70, a second
portion 72 extending angled from the first portion 70, a third
portion 74 extending substantially parallel to the first portion 70
and a fourth portion 76 extending downward to and substantially
parallel to the third portion 76.
[0089] An intermediate member 80 can be inserted as well to provide
support to the shell or can be integrated into the base of the
lower frame. The shell 50 includes a heel portion 102 having an
upright member 104, a mid-portion 106 and a toe portion 108. The
upper surface of the lower frame is curved to mate with the lower
surface of the lower frame. The mid-portion 106 includes a bracket
member 110 that mates with the lateral adjustment bracket 66 of the
lower frame 40. The mid-portion also includes a plurality of slots
114 for reducing the weight of the ski boot.
[0090] The components of the ski boot, discussed above, are
assembled together to form a composite boot. Adjustment screw 130
(not shown) is inserted to engage the lateral adjustment bracket
66. Movement of the adjustment screw 130 causes the lower frame to
pivot relative to the base due to the interaction of the screw 130
with the lateral adjustment bracket 66 and the threaded hole 132 of
the base and due to the curved surfaces of the lower frame, the
shell and the base. This pivoting movement provides a canting
adjustment to accommodate the differing biomechanics of different
skiers.
[0091] Lacing System
[0092] In a preferred embodiment, the present invention provides a
boot that includes a unique fastening mechanism. It is to be
expressly understood that while the descriptive embodiment
discusses the fastening mechanism for use on a ski boot, that this
fastening mechanism has utility for other types of boots and shoes
for many other activities as well.
[0093] A preferred embodiment of the unique fastening mechanism is
shown in FIG. 16. Fastening mechanism 400 includes lace 410. In the
preferred embodiment, lace 410 can be braided cable formed of
metallic cable with a plastic sheathing, high strength plastic,
fabric or other types of materials. In the preferred embodiment,
lace 410 is braided and/or sheathed to minimize abrasion against
the boot.
[0094] The boot 450, which can be a ski boot or other type of boot
or shoe, in the preferred embodiment, includes an open face 452 on
lower shell 454, and an upper cuff 456 pivotally mounted to lower
shell 454. This structure is by way of example only, and is not
meant to limit the present invention to this structure. In the
preferred embodiment, boot 450 includes a series of guides 420
along the open face 452 on lower shell 454. These guides 420 can be
reinforced gussets, tubes, other reinforced mechanisms or merely
slots in the lower shell 454.
[0095] Guides 424, 426 are incorporated through the shell 454 at
opposing sides of the upper end of open face 452. Plastic housings
428, 430 extend on the exterior of the upper cuff 456 from
apertures 432, 434 on the upper cuff 456 extending to the guides
424, 426, respectively. The plastic housings 428, 430 terminate at
ratchet mechanism 440.
[0096] Lace 410 is inserted through the plastic housings 428, 430,
through apertures 432, 434, through guides 424, 426 and laced
through guides 420. The terminal ends of lace 410 are secured in
ratchet mechanism 440. Ratchet mechanism 440 includes an internal
reel (not shown). It is to be understood that other mechanisms can
be used as well under the present invention to tighten the
lace.
[0097] In use, the user merely rotates the ratchet mechanism in one
direction to uniformly tighten the lace 410. As the lace tightens,
the lower shell conforms about the user's foot and/or inner boot.
The uniform tightening of the lace 410 creates a uniform strain on
the user's foot, thus minimizing any stress points. The lace can be
easily adjusted, either by continuing to rotate in the same
direction to tighten, or in the opposing direction to loosen the
lace.
[0098] In the preferred embodiment, the ratchet mechanism includes
a "dial" 442 that is pushed or pulled to actuate the ratchet for
use, and pulled or pushed in the opposing direction to lock the
ratchet in place.
[0099] In another embodiment of the present invention shown in FIG.
17, the same type of mechanism is utilized, except the boot
includes a tongue 460. The tongue 460 includes internal tubes for
routing lace 410 through the tongue.
[0100] Summary
[0101] The present invention provides a boot for skiing and other
activities that provides a stiff frame for transferring power to
the boot sole; a controlled flex unit that enables progressive and
controlled flexing of the boot to transfer this force; a cuff and
shell that conform comfortable to the user's body and an inner boot
that is comfortable and can be walked in separate from the boot.
These and other features will be set forth in the adjunct
claims.
* * * * *