Abstract:
A system for creating at least one foot insert for an individual using a neutralizer  10 , a levelor  40 , and a sled  60 . The neutralizer has a housing, protractor, and an angularly adjustable plate capable of supporting the foot. The neutralizer is adapted to accommodate a single foot of the individual to determine the neutral angle for each foot individually. The levelor is positionable on the neutralizer and has a plurality of adjustable arms to transfer the neutral angle from the neutralizer to the levelor. The levelor is also mountable to the sled with the adjustable arms being adapted to engage an insert for transferring the neutral angle to the insert.

Description:
This application is a CIP of U.S. application Ser. No. 09/667,998 filed Sep. 22, 2000, now U.S. Pat. No. 6,564,465. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to a device and method for forming an athletic foot support that may be used in such equipment as, among other things, ski boots, skates, bike shoes and the like. More specifically, the present invention concerns a device and method that produces an insert or foot support that positions the ankle joint or sub taylor joint in a relaxed position by correcting the pronation of the foot. 
     SUMMARY OF THE INVENTION 
     This invention provides a device and method that measures and then corrects the pronation of the foot, a condition where the foot collapses to the medial or inside of the foot, and how this affects athletic ability. The degree of pronation is evaluated for each foot independently. The end result provides an equal amount of pronation to occur in each foot by building a corrective mold of the foot, or a “canted footbed”. Being that most individual&#39;s feet have individual needs, it is critical to evaluate each foot separately. This is important to many athletic activities that demand the athlete to move symmetrically—for instance, skiing, skating, and any other laterally-oriented sport. The term “canted footbed” like a house, provides a solid level object for the house to sit upon. The foot bed is the foundation for the muscular-skeletal system to sit upon and work most efficiently since the foot is a complex joint. Not only does it support enormous amounts of weight, but it is the primary joint for balancing. The present invention is a process and device that takes both of these factors into consideration. The foot must be able to support the weight of the body plus the added weight of G forces, especially in skiing. While supporting large loads, it must also be able to make fine-tuning movements while skiing. Understanding the demands of skiing specifically was the thrust behind the invention. The physics of the sport require that the skier balance on top of a frictionless surface while moving dynamically from one foot to the other. Symmetric movement is important in the creation of a seamless move from one side to the other with rhythmic flow. If the sub taylor joint is predisposed with nonfunctional tension, the ability to move freely will be jeopardized. The fine muscular movements of the foot and ankle dictate the degree of success in the rest of the biomechanical chain. This is, to a large extent, the cause of tension or an imbalanced interaction in the chain. 
     To achieve the proper pronation of the sub taylor joint, how the foot is designed to support weight, and walk must be understood, or what is commonly referred to as a dynamic gate. The phases of the dynamic gate are heel strike, mid range, and toe off. 
     In the heel strike, the calcaneus hits the ground usually to the lateral side of the foot. Then the hips move forward and the weight moves to the outer three metatarsals to support lateral balance. This is known as the midrange. Then, the foot naturally pronates to one degree or another to allow the weight to move to the medial side of the foot or the two strong toes. Then, as the hips pass in front of the foot, the large strong toes will push off. This is the understanding of the dynamics of the foot in a stride. 
     In skiing, biking, skating, etc . . . because the equipment limits the range of motion, there is no stride, there is only lateral movement—basically, stuck in the midrange mode. It is however a dynamic stance, because the foot moves laterally to create balance while the body is in motion. This is the difference between what the present invention achieves and what many others do in this field. All other alignment processes implement a two-footed stance to determine the position of neutrality. This is done by aligning the center of the knee in relation to the center of support. This is done while standing on two feet or in a static state. If a person is standing on two feet, you then have to look at the base of support as being a six piece balancing system. In this situation, the person may be maintaining balance equally in all six quadrants or in one of the six quadrants and using two others to maintain a steady or “static” balance. 
     If you reduce the base of support to only one foot, you have a three-sided base which needs to articulate to maintain balance or balance dynamically. The present invention achieves this state by first analyzing the ankle joint to determine correct foot alignment. The balance analyser and the foot level control quality and assure accuracy of the foot foundation used in the insert. Typically, the optimal outcome should be to limit the amount of pronation in the ankle to approximately two degrees. The application of this type of process to foot beds will increase the amount of relatedness in the foot and ankle joint. The subsequent outcome will be more athleticism in the user. The position of the foot will provide an ability for the user to move the foot laterally and with a great deal of agility. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The novel features which are characteristic of the present invention are set forth in the appended claims. The invention itself, however, together with further objects and attendant advantages, will be best understood by reference to the following description taken in connection with the accompanying drawings in which: 
         FIG. 1  shows a perspective view of one embodiment of a foot neutralizer used with the present invention; 
         FIG. 2  shows a perspective view of an alternate embodiment of a foot neutralizer which may be used with the present invention; 
         FIG. 3  illustrates how the foot neutralizer shown in  FIG. 1  is used to take a pronation measurement; 
         FIG. 4  is a perspective view of a leveler used with the present invention; 
         FIG. 5  is a perspective view of an insert used with the present invention; 
         FIG. 6  is a perspective view of a jig used with the present invention; 
         FIG. 7  is an exploded perspective view illustrating various manufacturing steps used with one embodiment of the invention; 
         FIG. 8  is a front view showing an insert located in a ski boot; and 
         FIG. 9  is a side view showing an insert in a ski boot. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Set forth below is a description of what is currently believed to be the preferred embodiment or best example of the invention claimed. Future and present alternatives and modifications to the preferred embodiment are contemplated. Any alternates or modifications in which insubstantial changes in function, purpose, structure or result are intended to be covered by the claims of this patent. 
     The present invention includes a number of components such as a foot neutralizer  10  as shown in  FIG. 1 , a leveler  40  as shown in  FIG. 4 , a foot bed  50  as shown in  FIG. 5 , a sled  60  as shown in  FIG. 6 , and a sander  70  as shown in FIG.  7 . Neutralizer  10  includes a housing  12 , protractor  14 , an angularly adjustable plate  16 , crank  18  with threaded rod  19  having threads  23  that coact with threads  21  on support  22 , and rod  24 . Bearings  11 A,  11 B,  11 C and  11 D may also be provided for ease of operation. 
       FIG. 2  shows an alternate embodiment of a foot neutralizer  100 . It includes a housing  102 , angularly adjustable plate  104 , foot rests  106  and  108 , upright support bar  110 , and a positionable horizontal bar  112  that adjustably slides along bar  114  of support  110 . Also included is protractor  116 . 
     Leveler  40  includes arm  42 , which may be made from a piece of angle iron, and arm  44 , which may be made from a unshaped channel. As shown in  FIG. 4 , arms  42  and  44  are generally disposed in a perpendicular relationship. Included on arm  42  are slanted notches  82  and  84  and extended groove  80 . A two-way bubble indicator  86  is located on one end of arm  42 . Indicator  86  may be comprised of tubing that encloses liquid and an air bubble. 
     Also provided on leveler  40  are a number of coacting fasteners  51 - 58 . Fastener  52  may be a wing nut which coacts with fastener  51  which is located inside groove  80 . This arrangement allows the overall length of the leveler to be adjusted to accommodate various foot sizes. Fasteners  53 - 56  are used to adjust the width of the leveler by being adjustable within groove  85 . These fasteners along with fasteners  57  and  58  are also used to level the leveler as will be described in further detail below. 
     Also included with the present invention is a composite foot bed  50 . It consists of a foot blank  51  which is molded to conform to the shape of the user&#39;s foot. A posting foam  53  is used as the base of the foot bed composite. 
     A sled  60  is also used with the present invention. It includes a base  62  defining a channel  64 . Also included is upright post  67  which is supported by bracket  66 . 
     Locking posts  68  and  69  are also provided. The locking posts function to connect the leveler to the sled. Locking posts  68  and  69  may be coacting fasteners or other clamping and locking devices. 
     A table  70  is also used which is adjacently located near a vertical sander. Table  70  includes a guide  72  which is sized to fit within channel  64  of sled  60 . Guide  72  and channel  64  are sized within a close tolerance so as to maintain a straight line as sled  60  moves along guide  72  as will be described in more detail below. 
     In use, a mold is first made for each foot of the individual. This may be done by a silicon bean bag on which a foot is placed. Air is then vacuumed out of the bag so that the shape of the impression is maintained. A plaster mold is made of the impression and then a plastic mold is made over the plaster mold to form foot blank  61  of composite foot bed  50 . This is done by trimming blank  61  and attaching it to posting foam  63  by adhesives. As shown in  FIG. 5 , when this process is finished, foot bed  60  should consist of a foot blank  61  that conforms to a user&#39;s foot which has been attached to a base  63  made of posting foam, which has a flat surface  67 . 
     Next, leveler  40  is positioned on the foot bed. This is done by placing fastener  57  near what would be the heel portion of the foot bed at the center line. Fasteners  56  and  53  are then placed at the outer edges of bed  50  near the toe line. For reference purposes, to relocate the leveler on bed  50  for use in later finishing steps, reference marks may be made on bed  50  by a common marker. With the leveler  40  at rest on bed  50 , the lengths of fasteners  53 ,  56  and  57  are adjusted to level leveler  40  on bed  50  through the use of bubble level  86 . 
     To determine an individual&#39;s neutral ankle position, foot neutralizer  10  or  100  is used. To determine a neutral position, one foot at a time is measured, while maintaining an individual in the same upright, relaxed stance. To do this, for an individual&#39;s left foot, the person stands on foot neutralizer  100 . The left foot is placed on plate  104  which is in a level position and the right foot is placed on rest  108 . The individual then stands upright in a relaxed position and may use bar  114  for support. Wand or bar  112  is located next to the person&#39;s hip which acts as reference point for maintaining this position. 
     The heel of the foot is placed on the center line which is defined by rod  24 . Crank  18  is then operated by rotation which causes threads  21  and  23  to coact thereby resulting in plate  16  being angularly adjusted. Protractor  14  indicates the amount of adjustment undertaken. The same type of adjustment system is also used with the neutralizer shown in FIG.  2 . 
     To achieve a neutral position, the operator visually examines the tendons by the ankle until they are in a relaxed state or are working equally. This commonly occurs with no more than two degrees of adjustment of pronation—with the big toe of the foot over the smaller toes as shown in FIG.  3 . However, supination, orientation with smaller toes over the big toe, may also occur. 
     Next the adjustment plate is left at the angular orientation selected and may be locked in place. Leveler  40  is then placed on plate  16  or  104  in approximately the same location as was the foot. The lengths of fasteners  53 ,  56  and  57  are then adjusted to level leveler  40  by observing bubble levels  86 . It should be noted that fasteners  54 ,  55  and  58  may be a double nut arrangement which assists in maintaining the desired location and length of the fasteners. 
     Next, leveler  40  is placed on foot bed  50  in the same position in which it was originally adjusted to level. Bed  50  and leveler  40  are then secured together by masking tape or other suitable means. Through this process, the angle of plate  16  or  104  as measured by the protractor will be transferred to bed  50 . 
     As shown in  FIG. 7 , leveler  40  is mounted to sled  60 . This is done by inserting grooves  82  and  84  onto locking knobs or posts  68  and  69  which are sized to fit inside of the grooves. Sander  90  is then activated and is used to remove the flat surface  67  of bed  50 . 
     To do this sled  60  is mounted on table  70  by placing guide  72  inside channel  64 . This allows surface  67  of bed  50  to be urged against sander  90  which removes the foam of bed  50  to reproduce the same angle as that of plate  16  or  104 . Once the sander has removed a sufficient amount of material along the entire length and width of bed  50 , the process is completed. To perform the process for the other foot, the exact some procedure is used. 
     As shown in  FIGS. 8 and 9 , bed  50  is placed inside a piece of sports equipment such as ski boot  130 . As shown, bed  50  holds foot  132  at the angle which is the neutral state for the ankle. Of course, as mentioned above, bed or insert  50  may be used in other sports equipment as well. 
     In addition, the inserts  50  may be pre-made with a range of predetermined angles. For example, insert  50  may have an angle that ranges from ½ a degree to 3 degrees and be pre-made in ½ degree increments. This reduces the turn-around time to complete the process. 
     It should be understood that various changes and modifications to the preferred embodiment described would be apparent to those skilled in the art. Changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its intended advantages. It is, therefore, intended that such changes and modifications be covered by the following claims.