Ski Boot Shell With Inserted Slipper For Size Variation
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Solution Overview
Problem
The existing solutions for ski boot manufacturing require multiple expensive molds for each boot size, leading to high investment costs and cumbersome adjustment processes for ski equipment hire stores, as they need to manage multiple sizes and adjust bindings frequently.
Innovation Solution
The integration of a slipper with a sole and side walls into a conventional rigid shell allows for reducing the boot size defined by the shell, enabling a single shell to accommodate multiple sizes without the need for multiple molds, using a semi-rigid component made from expanded polyurethane or rubber with a hardness of around 25 Shore D, which can be produced using a simple and inexpensive process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple different shells are used for each boot size, then the boot size accuracy is improved, but the manufacturing cost increases due to requiring multiple expensive molds
Solution Approach 1:
The invention divides the boot sizing system into two independent segments: a single standardized shell and interchangeable insoles of different thicknesses. The shell remains uniform across all sizes, while the insole thickness varies to achieve different boot sizes. This segmentation eliminates the need for multiple shell molds, reducing manufacturing costs while maintaining size accuracy through the standardized shell design combined with variable insole thickness.
Solution Approach 2:
The shell is designed as a universal component that can serve multiple boot sizes through the combination with different insoles. A single shell design can accommodate various boot sizes (e.g., sizes 23-26) by simply changing the insole thickness, making the shell multi-functional across different size requirements. This universality eliminates the need for size-specific shell variations, reducing mold requirements while maintaining precise size control.
2Adaptability or versatility
If inner boots with thick walls are used to compensate for shell volumes, then different boot sizes can be achieved, but the force transmission performance deteriorates
Solution Approach 1:
The invention separates the functions of size adjustment and force transmission into different components. The thin-walled innerboot maintains optimal force transmission properties, while the insole thickness provides the size adjustment function. This segmentation allows each component to be optimized for its specific function without compromising the other.
Solution Approach 2:
The insole acts as an intermediary element between the foot and the innerboot, providing size adjustment through variable thickness without requiring thick-walled innerboots. This intermediary approach allows size variation while maintaining the structural integrity and force transmission capabilities of the thin-walled innerboot.
3Ease of operation
If multiple series of ski boots in all sizes are kept in stock, then customer size availability is improved, but the investment cost increases
Solution Approach 1:
The shell is designed as a universal base that can be configured for multiple sizes through interchangeable insoles. A single shell can serve as the basis for multiple boot sizes (e.g., one shell can produce sizes 23, 24, 25, or 26 depending on the insole used), allowing hire stores to maintain a smaller inventory of shells while still offering a complete size range to customers.
Solution Approach 2:
The boot sizing system becomes dynamic and adaptable through the interchangeable insole mechanism. Instead of maintaining static inventories of multiple shell sizes, the system allows a single shell to dynamically adapt to different size requirements by swapping insoles, reducing the total quantity of boots that need to be kept in stock.
4Manufacturing precision
If frequent adjustment operations are performed on ski bindings, then the fit accuracy is improved, but the time consumption and error risk increase
Solution Approach 1:
The correct insole thickness is selected and installed before the customer tries on the boot, preliminarily setting the correct size. This preliminary action eliminates the need for subsequent binding adjustments, as the boot size is already correctly configured through the insole selection, saving time and reducing error risk.
Solution Approach 2:
The sizing system becomes self-adjusting through the insole selection mechanism. The correct size is automatically achieved by selecting the appropriate insole thickness, eliminating the need for manual binding adjustments. The system serves itself by providing the correct fit through the insole-shell combination without requiring additional adjustment operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces manufacturing costs by allowing a single shell to produce multiple boot sizes, minimizing the need for different molds and adjustments, while maintaining performance and comfort by using a single injection-molded shell for various sizes, thus reducing the number of required shells and cuffs.
Implementation Method 1
a semi-rigid component made from expanded polyurethane or rubber with a hardness of around 25 Shore D
Data Source
AI summary
A series of ski boots comprising at least two ski boots whose rigid outer shell (2) is identical, and in which at least one of the boots of the series of boots has a rigid shell (2) comprising an internally inserted slipper (20; 20′), the slipper (20; 20′) comprising a bootboard (25; 25′) and side walls (21; 21′), so that the at least two ski boots comprising an identical rigid outer shell (2) are of different sizes.