Shin protector
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-05-17
- Publication Date
- 2026-04-08
AI Technical Summary
Existing shin guards are not optimally adapted to individual users, particularly in alpine skiing, where they must overlap with ski boots and absorb significant height differences, making it difficult to achieve effective protection with current adjustment methods.
A method using thermoformable materials and insert shapes that adapt to the user's shin and footwear, allowing for precise fitting by heating the hard shell and insert molds to conform to the leg and shoe contours, reducing production time and material usage.
This method significantly reduces the time and effort required for individual adaptation, enabling shin guards to effectively absorb large height differences and provide optimal support, especially when worn with ski boots, thereby enhancing protection and comfort.
Smart Images
Figure EP2024063645_05122024_PF_FP_ABST
Abstract
Description
[0001] TITLE
[0002] SHIN GUARDS
[0003] TECHNICAL FIELD
[0004] The present invention relates to methods for producing a shin guard and to a shin guard obtained accordingly and to uses of such a shin guard, in particular in alpine skiing.
[0005] STATE OF THE ART
[0006] Shin guards are used to protect the user from blows to the shin and knee.
[0007] In order for the protection to be as effective as possible, the shin guard must be optimally adjusted to the user and to any footwear worn by the user.
[0008] A shin guard typically has a hard outer shell with an exposed convex outer surface facing outward and a concave inner surface with padding. These shin guards are typically secured with clips or fastening straps that wrap around the wearer's calf.
[0009] Especially in alpine skiing, the poles are hit hard in slalom racing, and shin guards and their optimal fit are extremely important in this area. The challenges are particularly great in this area because the shin guards must at least partially overlap with the ski boot, and correspondingly large differences in level must be absorbed by the appropriate padding.
[0010] WO2023066429 discloses a method for producing a device for protecting a body part, in particular a shin guard, and such a device. To enable cost-effective and reliable protection of the body part, a curable but not yet cured molded part is applied to the body part to be protected, and the molded part is cured in place on the body part to be protected.
[0011] DE202023001648U1 describes an individually adjustable body protector, particularly for athletes, comprising a composite of a hard shell, an adhesive layer, and a cushioning layer. The hard shell is made of a biodegradable polymer compound, the adhesive layer is acrylate-based, and the cushioning layer comprises ethylene vinyl acetate. US Pat. No. 5,890,224 discloses a protector for protecting a person's extremity from impacts during sporting activities, comprising an elongated, tubular element made of stretchable fabric material that is concentrically attached over the person's extremity. The fabric is tensioned so that the tubular element conforms tightly to the person's extremities.A rigid shell is molded to fit the shape of the individual's limb. The rigid shell is placed over one end portion of the elongated tubular member, such that the end portion of the tubular member is positioned between the individual's limb and the rigid shell. The second end of the tubular member is retracted over the rigid shell to cover the entire rigid shell and hold the rigid shell firmly in place on the individual's limb, even during strenuous physical activity involving the individual's limbs.
[0012] PRESENTATION OF THE INVENTION
[0013] The object of the present invention is to provide a method for providing shin guards that are optimally adapted to the user. In particular, it should be possible to produce individually adapted shin guards with as little effort as possible, using as little material as possible, especially different materials, and in a short amount of time.
[0014] As a solution, a method is proposed for producing a shin guard that is individually adapted to the user. It consists of an outer hard shell and an inner padding layer that is shaped to fit the user's shin and, if necessary, footwear. A thermoformable material is used as the padding, or appropriate insoles.
[0015] In principle, the use of such materials is known, for example to adapt shoes or shoe insoles and the like to the body.
[0016] However, the present invention is not limited to the use of such materials for the use of a custom-fit shin guard. It has been shown that efficient and rapid production tailored to individual needs is surprisingly only possible if the proposed procedure is followed, i.e., if specific insoles are used that have a special shape and allow the shin guard to be optimally adjusted, even when the user is wearing ski boots, for example, meaning that even large height differences in the padding can be accommodated.
[0017] The proposed method proceeds in such a way that, in a first step, the hard shell is provided with an elastic and thermoformable, substantially undeformed outer insert mold at least partially lying on its concave inner surface, which insert mold has a constriction on both sides between an upper knee region and a lower shoe region, forming a central tapered region (which runs virtually parallel to the shinbone), or an upper tapered region and an extension only in a lower shoe region, and with an elastic and thermoformable, substantially undeformed inner insert mold at least partially lying on this outer insert mold (which essentially covers the entire concave inner surface, iein particular in the central tapered area of the outer insert shape is wider) is heated to a forming temperature at which the insert shapes can be permanently deformed without losing their elasticity and at which the hard shell is not plastically deformed, in a second step the heated shin guard with insert shapes in the still malleable state is attached with its concave inner surface to the corresponding shin and, if applicable, the knee, if applicable, with footwear of the user with a contact pressure, so that the insert shapes permanently adapt in their inner shape to the surface contour of the shin and, if applicable, the knee, if applicable, with footwear, in a third step the adapted shin guard is removed and cooled.
[0018] According to the first embodiment, the outer insole has a constriction, i.e., it has an elongated shape that runs parallel to the shinbone, with a laterally widened section at the top and bottom, and a central tapered area between them, i.e., a central area with a smaller extension transverse to the direction of the shinbone than the two areas at the top and bottom. The width of the upper and lower areas is therefore greater than the width in the central area. This design ensures optimal support conditions in the area of the knee and at the transition to the shoe.
[0019] According to the second embodiment, the outer insole shape does not have a widening at the upper end, i.e., in the knee area, but only in the shoe area. In other words, according to this second embodiment, the outer insole shape has a narrow upper area that essentially reaches the knee or immediately below it and extends downwards to the shoe area. In the shoe area, the outer insole shape widens laterally, i.e., the width of the shoe area is greater than in the narrow upper area.
[0020] Particularly preferred in the second embodiment, there can be a further insert between the outer insert mold and the hard shell, which is then preferably arranged in the narrow upper region and has a smaller width than the narrow upper region of the outer insert mold. This further insert insert can be made of the same material and with the same thickness as the other two insert molds, and it has a smaller surface area than the outer insert mold, so that the outer insert mold still comes into contact with the hard shell, at least in some areas. Further preferably, this insert insert can have a layer of an adhesion promoter (e.g. double-sided adhesive tape) on the surface facing the hard shell in order to attach the entirety of the insert molds to the inside of the hard shell for thermal deformation.The adhesion promoter or adhesive tape should preferably be heat-stable for the forming steps, ie it should withstand treatment in the oven at a temperature in the range of 70-150°C, preferably in the range of 100-125°C, preferably for a period of 5-20 minutes, without any significant loss of adhesive strength.
[0021] According to a preferred embodiment, the edges of this insert, in particular an upper edge facing the knee, can be bevelled, i.e. in this region the thickness of the material of this insert successively decreases. Preferably, this additional insert is essentially rectangular with a width in the range of 2-5, preferably 3-4.5 cm, and a length in the range of 10-25, preferably in the range of 15-20 cm. The longitudinal axis of such an insert preferably runs essentially parallel to the longitudinal axis of the narrow upper region or the central tapered region of the outer insert shape. In the case of the second embodiment, the upper edge of the insert is preferably flush with or slightly offset downwards from the upper edge of the insert (the upper edge facing the knee).
[0022] According to this first variant, the hard shell is heated together with the insert molds in the first step. Alternatively, it is also possible to heat the insert molds separately and not heat the hard shell, for example, by placing it in the oven. Once the insert molds are sufficiently warmed, these insert molds can be placed into the hard shell for the second step.
[0023] By designing the padding before molding in the form of two different insert shapes, and the specific constriction of the outer insert shape and the large-area design of the inner insert shape, whose outer contour of preferred masses essentially corresponds to the outer contour of the concave inner surface of the hard shell, apart from possibly minor recesses for fastening means of the shin guard, it is possible to essentially provide only these two insert shapes for each size of hard shell and to insert them directly without prior adjustment.
[0024] The advantages are on different levels:
[0025] 1. Construction: The design of the insoles is crucial for a simple fitting process: for a precise fit of the protector, the cavities in the foot area, ski boot area, and knee area must be filled, as well as allowing a direct fit to the shin. Finding this special construction is important for the success of the quick, simple, but very precise fitting.
[0026] 2. Process: Thermoformable inserts already exist in other areas, but not in this context with these two different insert forms of special shaping.
[0027] The fitting and padding process itself can be significantly reduced. The time required to create a custom-padded shin guard was reduced by more than tenfold using the proposed approach.
[0028] According to a first preferred embodiment, the method is characterized in that an additional knee insert covering at most the knee area is arranged in the upper knee area between the concave inner surface of the hard shell and the outer insert shape.
[0029] Alternatively, it is possible to place an additional shoe insole in the lower shoe area between the concave inner surface of the hard shell and the outer insole shape, covering at most the shoe area.
[0030] The parts of the insole molds that come into contact with the concave inner surface are advantageously attached to the concave inner surface before the first step. This can be either a permanent attachment, but is preferably a removable attachment, particularly preferably a hook-and-loop attachment, so that, for example, if the hard shell is damaged, it can be replaced without having to remake the customized padding.
[0031] Further preferably, the contact surfaces between the insert molds are fastened to one another before the first step, preferably in a material-locking connection, particularly preferably by an adhesive layer or at least one double-sided adhesive element, which preferably has the heat stability described above.
[0032] The first step is carried out, for example, in a (hot-air) oven at a temperature in the range of 70-150°C, preferably in the range of 100-125°C, preferably for a period of 5-20 minutes, particularly preferably for a period of 5-15 minutes. These temperatures arise because the padding typically uses material with a thermoforming temperature in the range of 70-90°C, for example, PE-EVA foam layers with a thickness in the range of 2-15 mm or 2-10 mm. The material used can also have microperforations.
[0033] Typically, in the second step, the protector is pressed against the user's leg at room temperature for a period of time in the range of 5-20 minutes, particularly preferably for a period of time of 5-15 minutes, wherein the material of the insole molds is still plastically deformable, preferably using at least two, preferably at least three additional fastening straps encircling the leg and the protector and, if appropriate, with the fastening straps already attached to the hard shell.
[0034] Advantageously, after the third step, areas of the insert molds that protrude beyond the peripheral outer edge of the hard shell are removed, preferably using a cutting device and / or a grinding device.
[0035] The material of the hard shell is typically a thermoplastic or a thermosetting plastic material, preferably a material selected from the group polyamide, in particular aramid, polycarbonate, polyurethane, polypropylene, polyethylene, polyvinyl chloride (PVC), polyethylene terephthalate, polystyrene, or mixtures or copolymers thereof, or preferably as a fiber composite material, which can be natural fibers (flax, hemp), glass fibers or carbon fibers, and wherein the hard shell has fastening straps attached thereto for temporary fastening around the lower leg of the user.
[0036] The inserts are typically expanded foam layers, preferably based on foamed elastic polymer materials, preferably selected from the group consisting of polyethylene, polypropylene, polyurethane, vinyl polymers, especially ethylene vinyl acetate, or mixtures thereof. The inserts are typically formed as layers with a thickness in the range of 0.3-20 mm, preferably in the range of 5-15 mm.
[0037] It is possible to choose different hardness and thicknesses for the different insole shapes, for example a different thickness for the knee insole and the shoe insole, which in turn is selected differently than the thickness of the inner and / or outer insole.
[0038] To ensure greater wearing comfort, it is possible to arrange a textile layer or a fleece layer on the inside of the innermost insert shape facing the user.
[0039] The present invention further relates to a shin guard manufactured or producible by a method as described above. The shin guard is particularly characterized in that the hard shell comprises an elastic and thermoformed outer insert at least partially adjacent to its concave inner surface, which has a constriction on both sides between an upper knee region and a lower shoe region, forming a central tapered area, and an elastic and thermoformed inner insert at least partially adjacent to and connected to this outer insert, as well as fastening means for attachment to the shin of a user.
[0040] Such a shin guard is preferably characterized in that the material of the hard shell is a thermoplastic or a thermosetting plastic material, preferably a material selected from the group polyamide, in particular aramid, polycarbonate, polyurethane, polypropylene, polyethylene, polyvinyl chloride (PVC), polyethylene terephthalate, polystyrene, or mixtures or copolymers thereof, particularly preferably in fiber-reinforced form, which can be glass fibers or carbon fibers or also natural fibers such as flax or hemp, and wherein the hard shell has fastening straps attached thereto for temporary fastening around the lower leg of the user.
[0041] The material mentioned above is preferably used for the insoles.
[0042] Last but not least, the present invention relates to the use of such a shin guard as a protector in ski racing.
[0043] Further embodiments are specified in the dependent claims.
[0044] BRIEF DESCRIPTION OF THE DRAWINGS
[0045] Preferred embodiments of the invention are described below with reference to the drawings, which are for illustrative purposes only and are not to be construed as limiting. In the drawings:
[0046] Fig. 1 is a view of a hard shell of a shin guard from the inside; Fig. 2 is a view of insole molds, where in a) the outer insole mold is attached to the inner insole mold, and b) a shoe insole (top) and a knee insole (bottom) are shown.
[0047] Fig. 3 a view of a shin guard with padding from the inside before adjustment;
[0048] Fig. 4 is a front view of a user having a shin guard fitted;
[0049] Fig. 5 a finished individually fitted shin guard with padding from the inside;
[0050] Fig. 6 the outer insert shape in a top view;
[0051] Fig. 7 the knee insert in a top view;
[0052] Fig. 8 the shoe insole in a top view;
[0053] Fig. 9 the inner insert shape in a top view;
[0054] Fig. 10 shows the outer insert shape according to a second embodiment of the invention in a view from the side of the hard shell;
[0055] Fig. 11 the inner insert shape of the second embodiment;
[0056] Fig. 12 a section through the insert molds before they are attached to the hard shell perpendicular to the plane of the insert molds of the second embodiment.
[0057] DESCRIPTION OF PREFERRED EMBODIMENTS
[0058] Fig. 1 shows a shin guard without padding 1, i.e., the hard shell 2 from the inside, i.e., looking at the concave inner surface 3. This concave inner surface 3 encloses half of a hollow space in which the user's shin rests. The hard shell is generally a single layer of an impact-resistant plastic material, for example, a thermoplastic, fiber-reinforced (glass, carbon, or natural fibers such as hemp, flax) plastic material such as polyamide, especially aramid.
[0059] For fastening, two fastening straps are provided on this hard shell, which are generally fastened in the area of the two longitudinal edges 6 and 7, for example, pulled through slots 8 or fastened at the corresponding points. Suitable fastening straps, for example, are textile fastening straps which have an eyelet side 9 to which an eyelet 11 made of a hard material, plastic or metal, is attached, and on the opposite side a Velcro side 10 which can be pulled through the eyelet 11 on the other side and then fastened to itself with the Velcro fastener. There are typically at least two such fastening options: an upper fastening strap 9 / 10 and a lower fastening strap 9710'. The hard shell has a lower edge 4, which lies in the area of the ski boot, and an upper edge 5, which lies in the area of the knee.
[0060] The proposed method utilizes the insert molds mentioned above. Fig. 2 shows these insert molds, where in a) the outer insert mold 12 is shown on the inner insert mold 13, as seen from the side of the hard shell 2, in the relative position in which it is inserted into the hard shell 2. Typically, the outer insert mold 12 is attached to the inner insert mold 13 using double-sided adhesive tape or a double-sided adhesive surface provided on the mold or the hard shell. However, it is also possible to apply a liquid adhesive or similar, although in any case, care must be taken to ensure that the adhesive material is compatible with both the material of the insert molds and the hard shell, as well as with the thermoforming temperatures.
[0061] The insert molds 12 and 13 are the essential components of the proposed method. Additionally, as shown in b), further smaller inserts can be provided, namely a knee insert 14 in the knee area and a shoe insert 15 in the shoe area. These inserts are additionally attached, with their rounded sides essentially flush with the contour, between the hard shell 2 and the outer insert mold 12, i.e., in the illustration according to a), they are, in a sense, additionally attached to it. Again, the attachment can be achieved using the same means as described above in connection with the inner and outer insert molds.
[0062] The material layers for these insoles typically consist of a foamed ethylene vinyl acetate material (PE-EVA, typically with a vinyl acetate content in the range of 45-50%), for example, with a hardness in the range of 40-50 Shore A. The thickness of the layers is typically in the range of 5-15 mm, and the density is in the range of 40-50 kg / m3. Possible materials include materials from Podiatech under the name Podiamic®.
[0063] The insert layers are attached to the concave inner surface 3 before heating, for example, in an oven for 10 minutes at a temperature of 110°C. This is preferably done in a removable manner, for example, by providing hook-and-loop fasteners on the padding and the concave inner surface 3. This allows the customized padding to be easily replaced if, for example, the hard shell is defective.
[0064] Fig. 3 shows the situation prior to the first process step, i.e., the shin guard 18 with the padding is shown before fitting. Particularly at the bottom, it is clear how the inner insert mold 13 is positioned entirely on the inside, followed by the next layer of the outer insert mold 12, then the shoe insert 15 only in the lowest area, and finally, the hard shell 2. This creates temporary cavities through which one can see the concave inner surface 3, and the padding protrudes (too) far. The individual side surfaces 16 of the inserts are visible all the way around.
[0065] This shin guard 18 is now placed in an oven, as mentioned, until the padding reaches a temperature slightly above the material temperature suitable for thermoforming; for the materials listed above, this is typically in the range of 70-80°C. Therefore, an oven with a temperature of approximately 110°C is used for 10 minutes.
[0066] Once the deformation temperature of the material of the insole molds has been reached, the heated shin guard, i.e. hard shell and insole molds, is attached to the user's leg, as shown schematically in Fig. 4. To ensure that the contact pressure is sufficiently great for the material to effectively adapt completely to the external shape of the user and the shoes 19 worn by them, additional circumferential fastening straps 20 are used in addition to the aforementioned fastening straps already attached to the shin guard. It is also possible to dispense with the use of the fastening straps 9 / 10 attached to the shin guard if, for example, it is to be prevented that the padding material for the crotch in the area of their attachment does not shift during thermoforming or deform in the wrong direction due to excessive fastening force.The additional fastening straps can simply be provided as circumferential fastening straps that run over the convex outer surface 17 and around the back of the user's lower leg 21.
[0067] Fig. 5 then shows the shin guard in the form adapted to the user, again in a similar representation to Figures 1 and 3, i.e. from the inside. The concave inner surface 24 of the padding now has a surface geometry corresponding to the negative imprint of the lower leg / knee / shoe, which is adapted to the individual specific conditions of the user. This is therefore a customized padding layer 42, and if this is attached to the hard shell 2, for example by a Velcro connection, as mentioned above, then this padding layer 42 can also be easily replaced, for example if differently colored hard shells are to be used in a competition, hard shells with a different front, or if a hard shell is defective and needs to be replaced.
[0068] It should be noted that a further processing step is usually required to achieve the state shown in this figure. Specifically, after adjusting the insole shapes to the user, the padding material in the edge area must be adjusted. This is preferably done using a grinding device, which machines the padding essentially flush with the outer contour 4-6 of the hard shell 2.
[0069] The individual insert shapes are shown in detail in Fig. 6-9.
[0070] Fig. 6 shows the outer insole shape 12. This has a bone shape, so to speak, i.e. there are two lateral constrictions 27 along the longitudinal direction, so that a relatively long tapered region 28 forms in the middle. Above this tapered region 28 lies the knee region 25, which has a rounded contour 29 towards the top, which essentially corresponds to the shape of the upper edge 5 of the hard shell 2 or deliberately protrudes slightly above it. On the underside below the tapered region 28 lies the wide shoe region 26, whose downward rounding 30 in turn essentially corresponds to the shape of the lower edge 4 of the hard shell 2.
[0071] Fig. 7 shows the knee insert 14. This knee insert 14 can also be inserted between the hard shell and the outer insert mold, specifically on the knee area 25, so that the rounded portion 29 of the outer insert mold 12 approximately coincides with the rounded portion 33 of the knee insert. The relative positioning of these two inserts can be facilitated by the two guide markers 43 that may be provided on the corresponding molds. The lower edge 34 is typically formed as a straight line.
[0072] Fig. 8 shows the shoe insert 15, which can be placed on the shoe area 26 of the outer insert mold 12 and fastened thereto, again in such a way that the rounding 30 of the shoe area 26 coincides with the rounding 31 of the shoe insert 15. The upper edge 32 is again typically formed as a straight line.
[0073] Fig. 9 shows the inner insert mold 13. The outer contour of this inner insert mold 13 essentially corresponds to the contour line of the hard shell, although it must of course be taken into account that this adaptation must be ensured for the curved, inserted inner insert mold 13. Here, too, there is a knee area 35 at the top and a shoe area 36 at the bottom. The outer insert mold is attached to this inner insert mold 13 such that the rounded portion 29 of the knee area of the outer insert mold 12 approximately coincides with the rounded portion 40 in the knee area 35 of the inner insert mold 13. This can again be facilitated by appropriate guide markers 43.
[0074] At the bottom, the outer insole form 12 is aligned so that its lower rounding 30 coincides with the lower rounding 41 in the shoe area 36 of the inner insole form 13.
[0075] As already mentioned, the outer line of the inner insert shape 13 corresponds approximately to the contour line of the hard shell 2. However, if, as shown in the first figure, the fastening straps 9 / 10 are attached somewhat on the inside of the hard shell, i.e. in the area of the concave inner surface 3, offset inwards from the side edge 6 / 7, it can be advantageous, as shown in this figure, if there are constrictions 37 / 38 for the straps 9 / 10, so that an expanded area 39 is formed between them. This prevents too much padding material from being arranged in the area of the fastening straps 9 / 10, so that an optimal contour can no longer be guaranteed there, even during thermoforming.
[0076] Figs. 10-11 show how the insert shapes can be designed in a second embodiment, in which the outer insert shape 12 has no extension 25 in the knee area, and in which a further insert insert is provided partially between the outer insert shape 12 and the hard shell 2.
[0077] Fig. 10 shows the outer insert shape 12 of this second embodiment. It has a somewhat partial bone shape, i.e., there are two lateral tapers 27 along the top longitudinal direction, forming a relatively long tapered region 28' in the upper area facing the knee, which ends at the upper edge 47. Above this tapered region 28', there is therefore no extended knee area as in the previous embodiment. On the underside, below the tapered region 28', lies the wide shoe area 26, whose downward rounding 30 essentially corresponds to the shape of the lower edge 4 of the hard shell 2.
[0078] In this embodiment, there is another insert 44 between the hard shell 2 and the outer insert mold 12, which is provided exclusively in the tapered area 28'. It has a width in the range of 3-5 cm, i.e., the width of this insert is significantly less than the width of the tapered area 28'. The width in the tapered area 28' is approximately 7-9 cm. The length of the tapered area 28' above the shoe area 26 is approximately 20-28 cm. The length of the insert element 44 is either the same length or slightly shorter, typically in the range of 17-20 cm.
[0079] The insert 44 is preferably arranged slightly offset laterally outward and arranged with its longitudinal axis parallel to the narrow region 28'. A bevel is preferably provided at the upper edge 45, i.e., the material of the insert 44 becomes successively thinner there, providing a smooth transition to the surface of the outer insert mold 12 facing the hard shell. This upper edge 45 is approximately at the level of the upper edge 47 of the outer insert mold, or is slightly offset downward, typically in the range of 2-10 mm.
[0080] Fig. 11 shows the knee insert 14. This knee insert 14 is additionally inserted between the hard shell 2 and the outer insert form 12.
[0081] Fig. 12 shows the second embodiment in a section perpendicular to the plane of the insole molds along the main axis (vertically along the dashed line that extends across Figs. 10 and 11 when the insole molds 12 and 13 are placed on top of one another). Here, it can be seen how, preferably, the two lower edges 41 and 30 of the insole molds 12 and 13, respectively, are arranged substantially flush, and how the additional insole insert 44 is arranged opposite the inner surface 48 of the inner insole mold 13 above the shoe region 36 of the outer insole mold 12 such that the beveled upper edge 45 is arranged approximately flush with or slightly below the upper edge 47 of the outer insole mold 12.
[0082] LIST OF REFERENCE SYMBOLS
[0083] 1 Shin guards without 22 Overhang of the inserts padding 23 Shin guards with
[0084] 2 hard shell of 1 padding after the
[0085] 3 concave inner surface of 2 adjustment
[0086] 4 Lower edge of 2 24 concave inner surface of the
[0087] 5 Top edge of 2 padding
[0088] 6 inside leg long edge 25 knee area of 12 of 2 26 shoe area of 12
[0089] 7 outer leg long edge 27 lateral of 2 constriction / taper
[0090] 8 slot in 2 or of 12 mounting area at 2 for 28 central tapered area 9 / 10 of 12
[0091] 9 fastening straps, 28' tapered area of 12 eyelet side 29 rounding in the knee area
[0092] 10 fastening straps, of 12 Velcro side 30 rounding in the shoe area
[0093] 11 hard material eyelet out of 9 of 12
[0094] 12 outer insert shape 31 rounding of 15
[0095] 13 inner insert form 32 upper straight edge of 15
[0096] 14 Knee insert 33 Rounding of 14
[0097] 15 shoe insole 34 lower straight edge of 14
[0098] 16 Side surface of the insert 35 Knee area of 13
[0099] 17 convex outer surface of 2 36 shoe area of 13
[0100] 18 shin guards with 37 upper constriction for padding in front of the upper fastening strap adjustment 38 lower constriction for
[0101] 19 Ski boot lower fastening strap
[0102] 20 Mounting straps 39 Expansion area
[0103] 21 Lower leg between 37 and 38 Rounding in the knee area 44 Insole insert of 13 45 Bevelled edge of 44 Rounding in the shoe area 46 Contact side / contact surface of 13 of 44 adapted 47 Top edge of 12 at
[0104] Padding layer of the second embodiment guide marker / positioning marker 48 facing the shin inner surface of 13
Claims
PATENT CLAIMS 1. A method for producing a shin guard (23) individually adapted to the user, comprising an outer hard shell (2) and an inner padding layer (42) adapted in its shape to rest on the shin and optionally on the footwear of the user, characterized in that in a first step, either the hard shell (2) is provided with at least one elastic and thermoformable, substantially undeformed outer insert form (12) at least partially abutting against the concave inner surface (3) of the hard shell (2) and having a constriction (27) on both sides between an upper knee region (25) and a lower shoe region (26) to form a central tapered region (28), or a tapered region (28') and an extension only in a lower shoe region (26), and with at least one,on this outer insert form (12) at least partially resting elastic and thermoformable, substantially undeformed inner insert form (13), and / or the at least one undeformed outer insert form (12) and / or the at least one undeformed inner insert form (12) alone, is heated to a forming temperature at which the insert forms (12, 13) can be permanently deformed without losing their elasticity, and at which the hard shell (2) is not plastically deformed, in a second step, the heated shin guard with insert forms (12, 13) in the still malleable state is fastened with its concave inner surface to the corresponding shin and optionally to the knee, optionally with footwear of the user, with a contact pressure, so that the insert forms (12, 13) permanently adapt in their inner shape to the surface contour of the shin and optionally of the knee, optionally with footwear, and in the process from the insert forms (12,13) the adapted padding layer (42) is formed, wherein in the case where the at least one outer insert mold (12) and / or at least one inner insert mold (12) has been heated alone, the heated insert molds (12, 13) are previously inserted into the hard shell (2) so that the heated outer insert mold (12) at its concave, inner surface (3) at least partially rests and / or the warmed inner insert form (13) rests at least partially on this outer insert form (12), in a third step the adapted shin guard (23) is removed and cooled.
2. Method according to claim 2, characterized in that in the upper knee region (25) between the concave inner surface (3) and the outer insert shape (12) an additional knee insert (14) covering at most the knee region (25) is arranged, and / or in that in the lower shoe region (26) between the concave inner surface (3) and the outer insert shape (12) an additional shoe insert (15) covering at most the shoe region (26) is arranged and or in that there is a further insert insert (44) between the concave inner surface (3) and the outer insert shape (12), which is preferably arranged in the tapered region (28') and has a smaller width than the tapered region (28') of the outer insert shape.
3. Method according to one of the preceding claims, characterized in that the parts of the insert molds (12-15, 44) coming into contact with the concave inner surface (3) are fastened to the concave inner surface before the first step, preferably a detachable fastening being provided, particularly preferably a Velcro fastening.
4. Method according to one of the preceding claims, characterized in that the contact surfaces between the insert molds (12-15, 44) are fastened to one another before the first step, preferably in a material-locking connection, particularly preferably by an adhesive layer or at least one double-sided adhesive element.
5. Method according to one of the preceding claims, characterized in that the first step is carried out in an oven with a temperature in the range of 70-150°, preferably in the range of 100-125°, preferably for a period of 5-20 minutes, particularly preferably for a period of 5-15 minutes.
6. Method according to one of the preceding claims, characterized in that in the second step the protector is pressed against the leg of the user at room temperature for a period in the range of 5-20 minutes, in particular preferably for a period of 5-15 minutes, preferably using at least two, preferably at least three fastening straps (20) encircling the leg and the protector.
7. Method according to one of the preceding claims, characterized in that after the third step, areas of the insert molds projecting beyond the circumferential outer edge (4-7) of the hard shell are removed, preferably using a cutting device and / or a grinding device.
8. Method according to one of the preceding claims, characterized in that the material of the hard shell is a thermoplastic or a thermosetting plastic material, preferably a material selected from the group polyamide, in particular aramid, polycarbonate, polyurethane, polypropylene, polyethylene, polyvinyl chloride, polyethylene terephthalate, polystyrene, or mixtures or copolymers thereof, particularly preferably in fiber-reinforced form, which can be natural fibers including hemp or flax, glass fibers or carbon fibers, or mixtures thereof, and wherein the hard shell has fastening straps (9, 10) attached thereto for temporary fastening around the lower leg of the user.
9. Method according to one of the preceding claims, characterized in that the insert molds (12-15, 44) are expanded foam layers, preferably based on foamed elastic polymer materials, preferably selected from the group: polyethylene, polypropylene, polyurethane, vinyl polymers, in particular ethylene vinyl acetate, or mixtures thereof.
10. Method according to one of the preceding claims, characterized in that the insert molds (12-15, 44) are layers with a thickness in the range of 0.3-20 mm, preferably in the range of 5-15 mm.
11. Method according to one of the preceding claims, characterized in that a textile layer or a nonwoven layer is arranged on the inner side of the innermost insert form facing the user.
12. Shin guards manufactured or producible by a method according to one of the preceding claims, characterized in that the hard shell (2) of the shin guard has an elastic and thermoformed outer insert (12) at least partially resting on its concave inner surface (3), which has a constriction (27) on both sides between an upper knee region (25) and a lower shoe region (26) to form a central tapered region (28), or a tapered region (28') and an extension only in a lower shoe region (26), and has an elastic and thermoformed inner insert (13) at least partially resting on and connected to this outer insert (12), as well as fastening means (9, 10) for fastening to the shin of a user.
13. Shin guards according to claim 12, characterized in that the material of the hard shell is a thermoplastic or a thermosetting plastic material, preferably a material selected from the group polyamide, in particular aramid, polycarbonate, polyurethane, polypropylene, polyethylene, polyvinyl chloride, polyethylene terephthalate, polystyrene, or mixtures or copolymers thereof, particularly preferably in fiber-reinforced form, which can be natural fibers including hemp or flax, glass fibers or carbon fibers, or mixtures thereof, and wherein the hard shell has fastening straps (9, 10) attached thereto for temporary fastening around the lower leg of the user.
14. Shin guards according to one of the preceding claims 12 or 13, characterized in that the insert shapes (12-15, 44) are expanded foam layers, preferably based on foamed elastic polymer materials, preferably selected from the group: polyethylene, polypropylene, polyurethane, vinyl polymers, in particular ethylene vinyl acetate, or mixtures thereof, wherein the insert shapes (12-15, 44) are preferably layers with a thickness in the range of 0.3-20 mm, preferably in the range of 5-15 mm.
15. Use of a shin guard according to any one of the preceding claims 12-14 as a protector in ski racing.