SKI BOOT SYSTEM

Abstract

A ski boot system that enables onsite assembly and customization of ski boots according to individual user requirements. The system includes a lower foot-receiving shell, an upper leg-engaging cuff, and a plurality of interchangeable closure components selectively mountable at reinforced and marked attachment locations on the shell and cuff. A customizable boot board positioned within the shell includes removable height layers and optional arch support elements to accommodate anatomical differences between a user's left and right feet and to optimize stance and load distribution. Closure components may be temporarily or permanently mounted using non-rivet fasteners, enabling real-time adjustment during fitting or use. In certain configurations, flexible bale-based closures are arranged in a cross-wrapping configuration to reduce localized pressure while maintaining secure retention and performance. Multiple cuff lengths, pivot locations, and closure arrangements are supported, allowing independent adjustment of flex, fit, and biomechanics. The system provides improved comfort, adaptability, and performance compared to conventional fixed-configuration ski boots.

Claims

1. A ski boot system configured for onsite assembly and customization, comprising: a lower shell configured to receive a foot of a user; an upper cuff configured to engage a lower leg of the user; a boot board positioned within the lower shell beneath an inner boot; and a plurality of closure components configured to secure the lower shell and the upper cuff, wherein the lower shell and the upper cuff each include a plurality of reinforced attachment locations selectively usable to mount different types and arrangements of the closure components, thereby enabling user-specific customization of fit, stance, and performance.

2. The ski boot system of claim 1, wherein the reinforced attachment locations are marked on an exterior surface of the lower shell and the upper cuff to indicate allowable mounting regions.

3. The ski boot system of claim 1, wherein the reinforced attachment locations include molded structural reinforcements and corresponding interior recesses configured to receive mounting hardware.

4. The ski boot system of claim 1, wherein at least one reinforced attachment location is configured to accept two or more different closure components.

5. The ski boot system of claim 1, wherein at least one closure component is configured for temporary attachment to the lower shell or upper cuff using removable fasteners.

6. Ther ski boot system of claim 5, wherein the removable fasteners include tee nuts and threaded fasteners.

7. The ski boot system of claim 1, wherein the boot board includes an arch region configured to receive a removable arch support element.

8. The ski boot system of claim 1, wherein at least one closure component includes a flexible bale arranged in a cross-wrapping configuration across the lower shell.

9. The ski boot system of claim 8, wherein the cross-wrapping configuration positions two bales at an angle relative to one another to distribute closure forces across the foot.

10. The ski boot system of claim 1, wherein the upper cuff is selectable from a plurality of cuff lengths.

11. The ski boot system of claim 1, further comprising omni directional ladders to fit complex curvatures of lower shell and cuff.

12. The ski boot system of claim 11, wherein at least one pivot mounting location enables a free-pivoting cuff that does not contact the lower shell during forward flex.

13. The ski boot system of claim 1, wherein the boot board includes a multi-layer stack of removable layers configured to adjust boot board height.

14. The ski boot system of claim 13, wherein individual layers of the multi-layer stack are peel-away layers having a thickness between 2 mm and 3 mm.

15. The ski boot system of claim 1, wherein the upper cuff includes multiple selectable pivot mounting locations relative to the lower shell.

16. A method of customizing a ski boot, comprising: selecting a lower shell and an upper cuff; installing a boot board within the lower shell; temporarily mounting selected closure components to reinforced attachment locations on the lower shell and upper cuff; evaluating fit and performance; and permanently mounting selected closure components based on the evaluation.

17. A ski boot system configured for onsite assembly and user-specific customization, comprising: a lower shell defining a foot-receiving cavity; an upper cuff configured to surround a lower leg of a user and pivotally coupled to the lower shell; a boot board positioned within the lower shell beneath an inner boot; and a plurality of closure components including buckles and flexible bales, wherein the lower shell and the upper cuff each include a plurality of pre-defined, reinforced attachment locations that: are structurally reinforced relative to surrounding shell material, include interior recesses aligned with exterior mounting regions, and are visually marked to indicate allowable positions for mounting the closure components, wherein the closure components are selectively and re-positionably mountable at the reinforced attachment locations using removable fasteners to permit temporary installation and repositioning by a user, wherein at least one of the closure components is configured to be mounted in a cross-wrapping configuration across the lower shell using the flexible bales to distribute closure forces across the foot, and wherein the ski boot system enables independent customization of left and right ski boots based on anatomical differences of a user.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0022] The accompanying drawings, which are incorporated herein and form a part of this specification, illustrate exemplary embodiments of the present invention. Together with the detailed description, the drawings serve to explain the principles of the invention and to enable a person skilled in the relevant art to make and use the invention.

[0023] FIG. 1 is a cross-sectional view of a ski boot extending from a toe region to a heel region, according to an exemplary embodiment of the present invention.

[0024] FIG. 2 is a top perspective view of a boot board, according to an exemplary embodiment of the present invention.

[0025] FIG. 2A is a cross-sectional view of a multi-level stacked structure comprising three layers of high-density foam polymer, according to an exemplary embodiment of the present invention.

[0026] FIG. 2B illustrates an arch support element (arch cookie), according to an exemplary embodiment of the present invention.

[0027] FIG. 3 is a frontal view of a lower shell of a ski boot, according to an exemplary embodiment of the present invention.

[0028] FIG. 4 is a medial side view of the lower shell, according to an exemplary embodiment of the present invention.

[0029] FIG. 5 is a lateral side view of the lower shell, according to an exemplary embodiment of the present invention.

[0030] FIG. 6 is a top view of the lower shell, according to an exemplary embodiment of the present invention.

[0031] FIG. 7 illustrates an arrangement of mounting components in regions of the lower shell having compound curvature, according to an exemplary embodiment of the present invention.

[0032] FIG. 8 illustrates a cross-wrapping buckle configuration mounted on the lower shell, according to an exemplary embodiment of the present invention.

[0033] FIG. 9 illustrates an arrangement of buckle components, according to an exemplary embodiment of the present invention.

[0034] FIG. 10 illustrates a first closure arrangement, according to an exemplary embodiment of the present invention.

[0035] FIG. 11 illustrates a second closure arrangement, according to an exemplary embodiment of the present invention.

[0036] FIG. 12 illustrates a third closure arrangement, according to an exemplary embodiment of the present invention.

[0037] FIG. 13 illustrates a method for recessing mounting hardware into the shell or cuff, according to an exemplary embodiment of the present invention.

[0038] FIG. 14 is a cross-sectional view of a portion of the lower shell showing an internal tunnel and an external buckle mounting undercarriage bracket on the shell or cuff.

[0039] FIG. 15 is an alternate view of the configuration shown in FIG. 14, according to an exemplary embodiment of the present invention.

[0040] FIG. 16 illustrates a bale component, according to an exemplary embodiment of the present invention.

[0041] FIG. 17 illustrates a standard ladder component, according to an exemplary embodiment of the present invention.

[0042] FIG. 18 illustrates multiple perspectives of a standard short-lever metal buckle, according to an exemplary embodiment of the present invention.

[0043] FIG. 19 illustrates a snow seal component, according to an exemplary embodiment of the present invention.

[0044] FIGS. 20A-20D illustrate various closure system components, according to exemplary embodiments of the present invention.

[0045] FIG. 21 illustrates a speed buckle, according to an exemplary embodiment of the present invention.

[0046] FIG. 22 illustrates a detailed view of a standard all-metal buckle including a metal bracket configured to attach to a ladder via an expanded rod, according to an exemplary embodiment of the present invention.

[0047] FIG. 23 illustrates a front view of a configuration representative of conventional ski boots, shown for comparative purposes.

[0048] FIG. 24: shows typical loads measured at medial side of a foot during skiing.

[0049] FIG. 25 shows typical loads measured at lateral sides of foot during skiing.

[0050] FIG. 26 shows the locations on the foot where measurements were taken.

[0051] FIG. 27 shows a typical plot of time versus force measured at peak value.

DETAILED DESCRIPTION

[0052] The subject matter of the present invention will now be described more fully with reference to the accompanying drawings, which form a part of this disclosure and illustrate specific exemplary embodiments. However, it should be understood that the subject matter may be embodied in various forms and is not limited to the specific embodiments set forth herein. Rather, these embodiments are provided by way of example to convey the scope of the invention. It is intended that the claims encompass a broad range of subject matter, including methods, devices, components, and systems. Accordingly, the following detailed description is not intended to be taken in a limiting sense.

[0053] As used herein, the term exemplary is intended to mean serving as an example, instance, or illustration. Any embodiment described as exemplary should not be construed as preferred or more advantageous over other embodiments. Similarly, the expression embodiments of the present invention does not imply that all embodiments must include all features, advantages, or modes of operation described.

[0054] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms a, an, and the include plural references unless the context clearly dictates otherwise. Furthermore, the terms comprises, comprising, includes, and/or including specify the presence of stated features, integers, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

[0055] The following detailed description sets forth the best currently contemplated modes for carrying out exemplary embodiments of the invention. This description is not intended to be limiting, but rather to illustrate the general principles of the invention. The claims of any issued patent will define the scope of the invention.

REFERENCE NUMERALS

[0056] 10Boot board base [0057] 12Inner boot/liner [0058] 15Multi-level stack (boot board layers), [0059] 16Arch region of boot board [0060] 17Arch cookie (arch support element) [0061] 18Multi-layer structure of arch cookie [0062] 19Lower shell [0063] 20Buckle mounting platform/undercarriage mounting bracket [0064] 21Buckle [0065] 22Ladder (rack element) [0066] 23aWitness line (medial allowable mounting boundary) [0067] 23bWitness line (lateral allowable mounting boundary) [0068] 24Exclusion zone (non-mountable area to avoid ski interference) [0069] 25Bale (flexible closure element) [0070] 26Power strap [0071] 27Cuff pivot location [0072] 28Upper cuff [0073] 31Cuff witness line (vertical repositioning boundary) [0074] 32Tunnel (internal recess for mounting hardware) [0075] 33Shell or cuff adaptation layer/molded structural reinforcement [0076] 34Buckle attachment rod [0077] 100Ski boot assembly/ski boot system

[0078] The invention described herein pertains to a ski boot system configured to enable onsite assembly of customized ski boots according to individual user requirements. The disclosed ski boot system provides a substantially greater degree of customization than conventional ski boots, allowing precise accommodation of anatomical differences between users and between a user's left and right feet. The system further enables customization and adjustment under actual use conditions, including during fitting, training, or skiing.

[0079] The ski boot system includes a shell system comprising a lower foot-shaped component (lower shell) and an upper leg-shaped component (cuff). The system further includes a plurality of closure components for coupling the cuff to the lower shell and for securing the shell around the foot. Both the lower shell and the cuff include a plurality of variable attachment points configured for selective assembly of closure componentry, thereby providing a wide scope of customization. The attachment points are reinforced for structural integrity and are visibly marked to facilitate accurate, secure installation. The markings assist users in identifying compatible closure components without reliance on complex manuals. In certain implementations, a single attachment point may accept two or more types of closure components, or multiple closely spaced attachment points may be provided to serve similar functional objectives with different closure componentry.

[0080] In certain implementations, the lower shell and cuff are designed with a maximum number of reinforced and properly contoured areas configured to accept closure componentry of various types, thereby enabling secure retention of the user's natural athletic stance. An enhanced boot board is incorporated within the shell to improve comfort and performance, as determined by user feedback. The optimal stance may be determined externally for each leg independently prior to final assembly.

[0081] During assembly, the ski boot system allows selection of an appropriate lower shell size, cuff size, and closure componentry from a range of options, with iterative trials. This process enables the user to achieve a natural stance with maximum comfort and performance. The user may test multiple configurations and select those best suited to individual requirements. The reinforced and marked attachment points further ensure durability and repeatability of the customized configuration.

[0082] The disclosed ski boot system allows closure components to be temporarily mounted to the lower shell and cuff, enabling the user to build and adjust customized ski boots for each foot in real time. Temporary attachment is achieved using fasteners such as tee nuts and screws rather than permanent rivets. This enables adjustments during fitting, training, or skiing, allowing users to evaluate different closure configurations before committing to permanent installation.

[0083] In one aspect, the ski boot system includes buckles of varying sizes and leverage characteristics, selected based on pressure requirements at different regions of the shell. For example, relatively narrow, low-profile buckles may be used near the toe box region, while higher-leverage, longer-arm buckles may be used around the instep or ankle circumference. In certain implementations, one or more buckles are mounted to the shell or cuff using a pivoting or rotatable interface. This interface allows the buckle body or undercarriage to rotate about at least one axis relative to the shell surface. As a result, the buckle self-aligns with ladders or bales and adapts to compound shell curvatures, reducing localized pressure points, improving load distribution, and maintaining consistent closure force across irregular or angled surfaces.

[0084] In certain implementations, the ski boot system includes a manual, also referred to herein as an Astro Fit Menu. The manual provides selectable options including, but not limited to, cuff heights, closure types, pivot locations, colors, and power strap designs. Each component may be offered in multiple sizes, types, and colors. An exemplary selection schema may include: [0085] COLORS: shell ______ cuff ______ [0086] CUFF LENGTH: short ______ medium ______ long ______ [0087] ARCH SUPPORT: yes ______ no ______ [0088] CUFF PIVOT POSITION: low ______ medium ______ high ______ [0089] LIFT: none ______ 2 mm ______ 4 mm ______ 6 mm ______ [0090] BUCKLES: latch ______ cross-wrap ______ both ______ micro/speed ______

[0091] The Astro Fit Menu may also be provided in digital form. The digital interface may guide users through compatible selections, automatically disabling incompatible options. Photographic or graphical representations of components may be included, and a virtual ski boot may be generated based on selected components. The system may further display specifications and predicted performance characteristics of the assembled ski boot, along with explanations of how individual components affect fit, comfort, and performance.

[0092] In use, a customer may first provide basic information such as name and intended skiing discipline. The system may then map the left and right feet independently, using Mondo point sizing or other known measurement systems. The plantar surface of each foot may be mapped using measurement devices or manual techniques. Each foot may be visually inspected for asymmetries, flexibility, and pressure-sensitive areas.

[0093] Based on the measurements, appropriate shells for the left and right feet are selected. If both feet are the same size, mirror-image shells may be used. Otherwise, different shell sizes may be selected for each foot.

[0094] Boot boards are then customized for each foot and installed into the respective shells. With the user wearing ski socks, each foot is inserted into the shell, and forward flex is evaluated. The process may be repeated using boot board lift shims of approximately 2 mm, 4 mm, or 6 mm until an optimal response is achieved.

[0095] Once boot board height is established, arch support elements (arch cookies) of selected stiffness and height may be installed on the boot board based on user feedback. This procedure may be performed independently for each foot.

[0096] Liners (inner boots) are then placed into the shells, and fit is evaluated again. Insoles may be added if required.

[0097] After liner fitting, the user selects instep buckles and other closure components. Various closure configurations may be previewed using images and temporarily installed onto the shell and cuff.

[0098] Cuff pivot locations and additional closure options are then selected and installed, either temporarily or permanently. Finally, a power strap may be installed and adjusted.

[0099] The system may include multiple cuff sizes, such as short, medium, and long lengths. Each cuff length may include different buckle configurations and multiple selectable pivot mounting positions.

[0100] Markings on the shell, cuff, and closure components, in combination with the manual, enable users to assemble the ski boots without professional assistance. The system includes separable buckle mounting components and optional gaskets that may be used to adapt closure components to compound shell curvatures as needed.

[0101] In certain implementations, the user may reconfigure the ski boots if requirements change, with upgrade costs substantially lower than replacement of an entire ski boot.

[0102] In certain implementations, the shell and cuff include markings indicating a recommended sequence for closing and tightening the closure components, thereby promoting optimal comfort, efficiency, and performance.

[0103] FIG. 1 illustrates a sectional view of a ski boot 100 extending from a toe region to a heel region. As shown, a boot board 10 is positioned within a lower shell 19 and beneath an inner boot (liner) 12.

[0104] FIG. 2 illustrates a top perspective view of the boot board 10, with an edge cutaway showing a multilayer structure. The boot board 10 may be formed from a multi-level stack 15 comprising, for example, three layers of high-density foam polymer, each having a thickness of approximately 2-3 mm. One or more layers of the multi-level stack 15 may be selectively peeled away to customize height. The boot board 10 further includes an arch region 16 configured to receive an arch support element (arch cookie). An exemplary arch cookie 17 is illustrated in FIG. 2B. The arch cookie 17 may also be formed from multiple layers of suitable material, such as foam polymer. FIG. 2A illustrates a cross-sectional view of a multilayer structure 18 forming the arch cookie 17.

[0105] The arch cookie 17 may be secured to the boot board 10 using suitable fastening means, including adhesive, snap-fit structures, hook-and-loop fasteners, or combinations thereof. In the illustrated embodiment, the boot board 10 includes apertures and the arch cookie 17 includes corresponding plugs configured to engage the apertures, thereby securing the arch cookie to the boot board.

[0106] FIG. 3 illustrates a frontal view of the lower shell 19. Dotted lines illustrate witness lines 23a and 23b, which identify regions on the interior of the shell that are recessed to receive hardware mounted on the exterior of the shell. A shaded region 24 indicates an exclusion zone in which hardware is not mounted to avoid interference with an opposing ski. FIG. 4 illustrates a medial view of the lower shell 19, again showing the shaded exclusion zone 24.

[0107] FIG. 5 illustrates a lateral view of the lower shell 19 showing buckle-reinforced mounting platforms 20 applied to allowable locations defined by the witness lines 23a and 23b. The platforms 20 may be adhesively attached post-manufacture or integrally molded into the lower shell 19 during factory production.

[0108] FIG. 6 illustrates a top view of the lower shell 19 with three buckles 21 mounted using separately applied buckle platforms 20. Alternatively, such platforms may be molded into the shell. As shown, the buckles 21 and ladders 22 are located entirely within the allowable regions defined in FIG. 3.

[0109] FIG. 7 illustrates an arrangement in which uppermost closure components are positioned in regions of the lower shell 19 having compound curvature. In this configuration, both the mounting platforms 20 (see FIG. 5) and adaptation layers 33 (see FIG. 15) are required within the witness line areas 23a and 23b. Flexible bales 25, shown in FIGS. 8 and 9, may also be employed.

[0110] FIG. 8 illustrates a top view of the lower shell 19 showing a cross-wrapping arrangement of buckles 21 mounted within regions of compound curvature defined by the witness lines 23a and 23b of FIG. 3. Both molded-in and separately attached mounting platforms, including those shown in FIG. 15, are utilized to achieve this configuration. Flexible bales 25 are employed, requiring a redesign of conventional buckles to replace rigid metal brackets with bale attachments. Angle (a) illustrates a representative cross-wrap angle of approximately 65 degrees. Dimensions (b) and (c) illustrate representative distances of approximately 1 inches and 2 inches, respectively.

[0111] FIG. 9 illustrates a closure arrangement in which all components require customized mounting platforms 20 and adaptation layers 33 as shown in FIG. 15. The buckles are redesigned to utilize bales 25. All components are positioned within the witness line regions 23a and 23b of FIG. 3. An uppermost buckle and ladder are positioned at the instep region to restrain upward heel lift, a configuration unique to the lower shell.

[0112] FIGS. 10, 11, and 12 illustrate three different closure arrangements mounted on upper cuffs 28 of a fully assembled shell kit system. The cuffs are provided in three different lengths. Each cuff length illustrates one exemplary buckle arrangement, although additional configurations are possible. A power strap 26 is shown in each figure. A standard two-buckle lower shell configuration is also illustrated for comparison, representing an industry-standard arrangement offering no alternative closure configurations to the user.

[0113] FIG. 12 further illustrates two pivot locations 27 on the cuffs 28, separated by a dotted witness line 31 present on all cuff lengths. This line indicates a mounting boundary that allows vertical repositioning of the cuff relative to the lower shell. Such repositioning enables a free-pivoting cuff that does not contact the lower shell 19 during forward flex. This configuration prevents distortion of the lower shell, particularly at the metatarsal heads of the forefoot, thereby preserving ski edge control during flexion. The configuration further provides three additional flex options in addition to the flex characteristics inherent to the different cuff lengths.

[0114] FIG. 13 illustrates a representative method for recessing mounting hardware, including components shown in FIGS. 16-20, into the cuff or, in some cases, the lower shell 19. The lower shell 19 utilizes internal tunnels 32 (see FIG. 15) positioned according to the witness lines shown in FIG. 3. All recesses are formed on interior surfaces of the shell and cuff as molded structural features. Section 33 represents a molded structural adaptation allowing standard buckles to be mounted to the shell or cuff.

[0115] FIG. 14 illustrates a cross-sectional view of a portion of the lower shell 19 showing an internal tunnel 32 and an external buckle mounting undercarriage bracket 20.

[0116] FIG. 15 illustrates a similar cross-sectional view as FIG. 14, further including a shell or cuff undercarriage mounting platform 20. A shell adaptation layer 33 is shown to achieve conformity with compound curvature of the lower shell 19.

[0117] FIG. 16 illustrates a flexible bale 25 usable in cross-wrapping closure arrangements. Attachment of the bale 25 to a buckle requires modification of a metal flange of a conventional buckle, whereby an existing metal bracket is removed and replaced by the bale to enable the cross-wrap configuration.

[0118] FIG. 17 illustrates a standard ladder 22 used in conjunction with buckles 21 to complete a closure. FIG. 18 illustrates multiple views of standard short-lever metal buckles. FIG. 19 illustrates a snow seal component positioned at a front portion of the lower shell 19 to form a snow-blocking dam between medial and lateral shell portions.

[0119] FIGS. 20A-20D illustrate various closure system components. FIG. 20A illustrates a ladder side view. FIG. 20B illustrates a short-lever buckle. FIG. 20C illustrates a tee nut having a circular base, enabling temporary attachment of closure components to the shell or cuff in place of permanent rivets. FIG. 20D illustrates an Allen wrench used for installing and removing temporarily mounted components, including buckles 21, ladders 22, and pivots.

[0120] FIG. 21 illustrates a speed buckle. In this configuration, only the tee-nut or rivet attachment hole requires a recessed area beneath the shell, although multiple recesses may be provided in some implementations. Clearance for buckle operation is accommodated by the mounting structure design.

[0121] FIG. 22 illustrates a detailed view of a standard all-metal buckle having a metal bracket attached to a ladder by an expanded rod. The illustration demonstrates removal of the expanded rod to detach the metal bracket, allowing replacement with a soft bale attachment. This represents a structural modification of the buckle. FIG. 22 shows a buckle attachment rod 34 which allows the currently used metal bracket to fit the ladder rungs. This rod can also be used in order to attach soft variable lengths of cable bales.

[0122] FIG. 23 illustrates a front view of conventional ski boots in which metal-to-metal closure components complete the lower shell structure. Such configurations are known to cause discomfort on the top of the foot. Loosening the buckle may reduce discomfort but degrades lateral foot control and skiing performance. In contrast, the disclosed cross-wrapping configuration using individually adjustable soft bales eliminates concentrated pressure points while maintaining performance. The bales may be provided in different lengths.