SPORT BOOT LINER AND METHOD FOR MAKING SAME

摘要

A liner (20, 120) for a sport boot shell (25) and a method for making a custom fitted liner (20, 120) for a sport boot, are disclosed. Liner (20) is designed to be worn inside a boot shell (25). In a preferred embodiment liner (20) includes inner and outer flaps (34, 36) which wrap in opposite directions across a wearer's shin and form a compound curve in a region (80) in front of the wearer's ankle. The liner (20), including flaps (34, 36), may be made from a single piece of thermoplastic foam material (42) of uniform thickness. The design of the liner prevents the cuff (38) of the liner (20) from loosening around the wearer's shin and calf when the wearer's leg is flexed forward at the ankle. The shell (25) can therefore be worn more loosely than is necessary with a boot liner of conventional design. Liner (20) may be made by making an unfitted liner (60) from a sheet of thermoformable material (42). Unfitted liner (60) has a forwardly facing opening (63) and wings (64, 66) extending forwardly on either side of opening (63). Unfitted liner (60) is then heated to above the thermoforming temperature of material (42) and simultaneously fitted to sheell (25) and the wearer's foot and leg by the steps of: placing the wearer's foot into unfitted liner (60); forming flaps (34, 36) by wrapping wings (64, 66) across the wearer's shin; holding unfitted liner (60) in place with an elastic stocking (72); inserting the wearer's foot, unfitted liner (60) and elastic stocking (72) into shell (25) and allowing unfitted liner (60) to cool.