Note: Descriptions are shown in the official language in which they were submitted.
CA 02515254 1999-12-21
ICE SKATE
Field of the invention
The invention relates to an ice skate comprising a structural inner shell for
supporting and enclosing the foot and an outer skin covering affixed to the
outer side of the inner shell. The outer skin covering is made of a skin cut
from a flat piece of synthetic fabric or textile material. An ice runner
holder and
ice runner assembly is mounted to the bottom of the inner shell.
Background of the invention
Traditionally, shoes, boots and skate boots are fabricated by stitching and
gluing various layers of fabric, textile or leather material together over a
last
which is a three-dimensional shape of the inside walls of the desired form of
boot or shoe. The rigidity and flexibility characteristics of the footwear are
achieved by interposing various layers of materials having suitable
mechanical properties in specific regions of the footwear. Often rigid plastic
components are added to the construction to increase the strength and
2o support of the footwear in specific areas. The footwear is usually
completed
with an outsole nailed, tacked or glued to the assembly of components and a
cushioning insole positioned inside. For skates, a ground engaging supporting
element such as an ice runner holder or an in-line roller chassis is mounted
to
the outsole to complete the product.
This type of construction is extensively used in the shoemaking industry. It
generates a good product but has many disadvantages. For instance, the
number of individual parts involved in high quality footwear can be
staggering;
a conventional ice skate for hockey may have some eighty parts to be to be
3o assembled and shaped over the last. The considerable number of elements to
be assembled entails an increased risk of errors during assembly, particularly
in the alignment of the various elements. Furthermore, the assembly of
1
CA 02515254 1999-12-21
various parts inevitably leads to undesirable variations of shape and volume
of the footwear. For instance, seemingly identical size #9 footwear may have
width variations which render many units uncomfortable to wear for some
people. A consumer should technically try on different pairs of the same size
to find a pair which best fits his or her feet. Also, in this type of
construction,
material is folded underneath the insole which necessarily implies an
accumulation of material between the insole and the outsole thereby creating
variations of the distance between the outsole and the pre-assembled upper.
1 o Footwear so constructed will sometime exhibit poor form fitting of the
foot
because of the variations of the internal volume of the footwear resulting
from
variation of assembly inherent in this manufacturing process. Furthermore,
because of those same variations of manufacturing, the rigid supporting
components added to the footwear structure may not be properly positioned
~ 5 or oriented inside the footwear. A small variation of the position or
orientation
of the rigid components may render a footwear uncomfortable and provide
inadequate support of the foot for the sporting activity it is designed for.
In an effort to reduce the number of components and to reduce variations of
2o shape, volume, and support in the footwear construction, sports footwear
have increasingly been made of a plastic molded shell and sometimes of a
combination of rigid plastic with softer fabric components.
U.S. Patent 4,777,741 discloses an article of footwear such as a shoe or
25 skate, which comprises a molded outer shell and a semi-rigid molded tongue
portion to close the footwear. This solution reduces the number of
components but does not provide localized support of the foot as is required
for optimal performance. The molded outer shell provides rigid support to the
foot and ankle, however does not take into account the variation of support
3o required for the specific sporting activity.
2
CA 02515254 1999-12-21
U.S. Patent 4,509,276 discloses a skate boot made of a lower exterior molded
rigid plastic portion and intermediate and upper portions made of pliable
material to allow forward flexure and torsional flexibility in the ankle area.
This
construction again offers a rigid outer shell, which provides rigid support to
the
foot only and a softer more flexible support for the ankle.
U.S. Patent 5,339,544 discloses a footwear comprising a first component
made of a single piece of molded synthetic material having a rear upper
portion which extend from an insole, and a second component made of soft
material having a front upper portion and a lining. The two components are
connected together with the lining of the second component inserted inside
the rear portion of the first component. This provides a two-piece rigid
plastic
outer shell construction having a limited amount of components. However, the
foot support provided is randomly applied and arbitrarily separated in the
middle of the foot.
Large plastic inserts have been designed to improve the general as well as
the localized foot support. U.S. Patent 3,807,062 discloses a boot having an
inner molded shell formed of a rigid material for providing rigidity at
selected
20 locations such as the sole and toe area of the foot; and the heel and ankle
portion of the foot; and an outer shell which is molded about the inner shell.
The outer shell is made of a dissimilar plastic material having generally
flexible and abrasion-resistant characteristics to provide flexibility at
selected
locations and also to provide an exterior surface capable of resisting surface
25 wear and abrasion. The boot is thus reinforced at selected area while other
areas are more flexible. Inserting a molded inner shell into a molded outer
shell thus reduces the number of components. The boot is reinforced but does
not provide adequate support of the foot. The boot is also left with an
appearance which may not be appealing to consumer.
These designs effectively reduce the number of components utilized in the
construction of footwear or skate. They also provide localized reinforcement
to
3
CA 02515254 2006-05-31
the footwear for increased performance. However, variations of the end shape
and of the inner volume of the footwear remain. The foot support provided is
often less than adequate for optimal performance. Finally, the appearance of
some of these designs is not appealing.
Thus there is a need in the industry for a footwear construction having
controlled end shape and volume of the footwear, which utilizes fewer
components, provides optimal foot support for increased performance and
has an exterior look which may be made more appealing to the consumer.
Statement of the invention
As embodied and broadly described herein, the invention provides an ice
skate comprising: (a) a structural one-piece molded inner shell for supporting
and enclosing a foot having a bottom area, a length, lateral and medial sides,
a back, an ankle with malleoli and a toe area, the inner shell having an inner
side, an outer side, a sole portion covering the bottom area of the foot,
lateral
and medial quarters extending along the length of the foot and projecting
upwardly from each side of the sole portion to cover the lateral and medial
2o sides of the foot, heel and ankle counters surrounding the back of the foot
and
the ankle and linking the lateral and medial quarters, and a toe box covering
the toe area of the foot; (b) an outer skin covering affixed to the outer side
of
the inner shell, the outer skin covering being made of a skin cut from a flat
piece of synthetic fabric or textile material or leather; (c) a tongue
covering an
upper frontal area of the boot; and (d) an ice runner holder and ice runner
assembly mounted to a bottom of the inner shell. The outer skin covering may
at least partially cover the heel counter and the lateral and medial quarters
of
the inner shell and extending at least partially under the sole portion of the
inner shell.
The skate may further comprise a footbed cushioning the sole portion and a
lower inner portion of each side of the inner shell. The skate may further
4
CA 02515254 2006-05-31
comprise a lining extending along an inside surface of the inner shell. The
skate may further comprise an outsole mounted to the bottom of the inner
shell. As a variant, the inner shell further comprises a tendon guard rising
4a
CA 02515254 1999-12-21
above the ankle counter and the lateral and medial quarters. The outer skin
covering may comprise left and right quarters for covering at least partially
the
respective lateral and medial quarters of the inner shell. The outer skin
covering may also comprise a decorative component.
The inner shell may be shaped to generally conform to the anatomical contour
of the foot. The ankle counter may be shaped to generally conform to the
malleoli. The shell may further comprise a stiffening member defining the
sole,
the ankle counter and a portion of the heel counter which links the ankle
counter and the sole together to form a continuous stiffening member.
Other objects and features of the invention will become apparent by reference
to the following description and the drawings.
~5 Brief description of the drawings
A detailed description of the embodiments of the present invention is provided
herein below, by way of example only, with reference to the accompanying
drawings, in which:
Figure 1 is a perspective view of a first embodiment of a molded shell in a
sport footwear according to the invention;
Figure 2 is a side elevational view of the molded shell shown in Figure 1;
Figure 2a is a sectional view of the molded shell taken along line a-a of
Figure
2;
Figure 3a is a perspective view of a second embodiment of a molded shell in
3o a sport footwear according to the invention;
5
CA 02515254 1999-12-21
Figure 3b is a perspective view of a third embodiment of a molded shell in a
sport footwear according to the invention;
Figure 3c is a perspective view of a fourth embodiment of a molded shell in a
sport footwear according to the invention;
Figure 3d is a perspective view of the first embodiment of a molded shell in a
sport footwear according to the invention;
1o Figure 4 is an exploded view of a first embodiment of a sport footwear
construction according to the invention;
Figure 5a is a top plan view of a skin component for a sport footwear
according to the invention;
Figure 5b is a top plan view of the skin component shown in Figure 5a with
added decorative components;
Figure 5c is a top plan view of a second embodiment of a skin component for
2o a sport footwear according to the invention;
Figure 5d is a top plan view of the skin component shown in Figure 5c with
added decorative components;
Figure 6 is a perspective view of a first embodiment of the assembled upper
portion of a sport footwear according to the invention;
Figure 7 is a side elevational view of the assembled upper portion of sport
footwear illustrated in Figure 6 shown with an ice skate runner.
Figure 8 is a side elevational view of the assembled upper portion of a sport
footwear illustrated in Figure 6 shown with an in-line roller chassis.
6
CA 02515254 1999-12-21
Figure 9 is a side elevational view of the assembled upper portion of a sport
footwear illustrated in Figure 6 shown with a second type of ice skate runner.
Figure 10 is an exploded view of a second variant of a sport footwear
construction according to the invention;
Figure 11 is a perspective view of a second variant of an assembled sport
footwear according to the invention;
1o Figure 12 is an exploded view of a third variant of a sport footwear
construction according to the invention;
Figure 13 is a perspective view of a third variant of an assembled sport
footwear according to the invention;
Figure 14 is a perspective view of the assembled sport footwear illustrated in
Figure 13 shown with an in-line roller chassis.
Figure 15 is a perspective view of the assembled sport footwear illustrated in
Figure 13 shown made into a hiking boot.
In the drawings, embodiments of the invention are illustrated by way of
examples. It is to be expressly understood that the description and drawings
are only for the purpose of illustration and are an aid for understanding.
They
are not intended to be a definition of the limits of the invention.
7
CA 02515254 2006-05-31
Detailed description of the embodiments
Figure 1 illustrates a structural molded inner shell 20 having the general
outer
shape of a boot for skates. Shell 20 is a monocoque (one-piece component)
that may be made and manufactured by injection molding of suitable
thermoplastic material. It comprises a heel counter 22, an ankle counter 24,
which surrounds the foot's malleolis, a tendon guard 26, and a medial quarter
28 and a lateral quarter 30. Each quarter 28, 30 extends longitudinally from
heel and ankle counter 22 and 24, to the front of shell 20. A sole 32 extends
the entire length of shell 20 and joins together quarters 28 and 30. Quarters
28 and 30 have edges 34 and 36,which together define the opening of the
skate boot for insertion and removal of the foot. Each edge 34 and 36 has a
upper leading segment 33 curving outwardly away from each other so as not
to create a pressure zone in the frontal area of the wearer's ankle. Sole 32
~5 further comprises a receptacle groove 31 adapted to receive a toe box. In
the
illustrated embodiment of Figure 1, the frontal portion of shell 20 in the toe
area is open. It allows the installation of a toe-box/tongue assembly 65 as
shown in Figure 4. As a variation, shell 20 could easily be closed at the toe
area in such a manner that a toe box 21 shown in stippled lines would be
2o integral with shell 20.
Shell 20 is the central structural component of a footwear according to this
technique. It is molded to generally conform to the shape of the foot and
ankle. The shape given to shell 20 dictates the general shape of the footwear.
25 Shell 20 is designed with variable wall thickness to provide flexible areas
and
more or less rigid areas. Sole 32 is a portion where rigidity is required.
Sole
32 may have a thickness of 4 to 5 mm to provide the necessary rigid platform
for a skate. Quarters 28 and 30 have a thickness ranging from 1.5 mm in
hatched portions 38 and 39, to about 3 mm for the remaining portions of
3o quarters 28 and 30. The thinned walled portions 38 and 39 correspond to the
bone pressure zones at the front and back of the foot and are shaped to
substantially enclose these bony areas. Portions 38 and 39 provide more
s
CA 02515254 1999-12-21
flexibility in these areas so that shell 20 will more easily conform to the
bone
structure of the foot in these particularly sensitive areas. Portions 39 are
elongated and cover a substantial portion of the font of each quarter 28 and
30 while portions 38 are more constrained to the lower heel area. No ridges
are noticeable between thinned portions 38, 39 and the remaining portions of
quarters 28 and 30. Tendon guard 26 is also about 3 mm thick. By
strategically varying the wall thickness of various areas of shell 20, it is
possible to alter and control the behavior and physical properties of shell 20
for the specific requirement of the footwear being made.
As shown in Figure 1, shell 20 is preferably, although not necessarily, made
with two distinct thermoplastic materials. A first, more rigid thermoplastic,
makes up sole 32 and ankle counter 24 to form a stiffening member 40 while
the rest of shell 20 which includes tendon guard 26, and both lateral and
medial quarters 28 and 30, is made of a second softer thermoplastic. Ankle
counter 24 is a curvilinear segment surrounding the malleolis and enclosing
the lower portion of the Achilles tendon. The area located between stiffening
member 40 and the rest of shell 20 and outlined by dotted line 44 represent
the portion where the two thermoplastics overlap and are chemically bonded
2o together. Compatible materials may be manufactured into the same mold. For
example, the technique of successive injection molding results in a shell
having a single layer as opposed to superimposing two materials thereby
obtaining two layers. Stiffening member 40 encompasses the entire sole 32,
ankle counter 24 and the rear portion of heel counter 22 which links together
sole 32 and ankle counter 24. Stiffening member 40 provides added rigidity to
sole 32 and provides lateral support to the ankle of the foot.
As shown in Figures 1 and 2, ankle counter 24 which is part of stiffening
member 40 is separated from the heel portion of sole 32 on each side of shell
3o by the softer thermoplastic. This configuration allows greater flexibility
of the
ankle relative to the foot in the forward direction as well as in torsion,
while
providing the necessary lateral support of the ankle. Variation of the
thickness
9
CA 02515254 1999-12-21
of stiffening member 40 also provided a means of controlling its rigidity. For
instance, ankle counter 24 is preferably about 2.5 mm whereas sole 32 is
about 4 or 5 mm in thickness.
Edges 34 and 36 of shell 20 may also be slightly thicker than the rest of
quarters 28 and 30 as these areas will later be provided with lace eyelets
where tension will be applied during tightening of the skate boot. Increasing
the thickness of these areas reinforces these locally solicited areas so that
quarter 28 and 30 will be better suited to resist the tension of laces. A more
1o resilient material may also be used to reinforce these areas.
As shown specifically in Figure 2a which is a sectional view of shell 20 taken
at line a--a, the profile of each side of shell 20 is such that it follows the
general curves of the ankle and heel. This results in an increased lateral
support to the wearer's foot while also providing increased comfort, as no
pressure points are created. As a further refinement, the upper edges 33 are
curved outwardly thereby avoiding pressure points along the sides of the
lower leg, which could result from lateral motion of the wearer's leg. Ankle
counter 24 moulds the outward curves of each malleoli of the foot. Shell 20
extends downwardly from ankle counter 24 into depression areas 35 which
follows the contours of the lower ankle leading to the heel counter 22
enclosing and supporting the heel of the foot. Shell 20 is ergonomically
designed to generally follow the anatomical contour of a human foot and ankle
thereby providing uniform support and avoiding the creation of pressure points
which often results from plastic reinforcement used in footwear.
Figures 3a to 3d illustrate variations of the shape of shell 20 to accommodate
various types of footwear. A shell 200 is designed for a walking boot, a
hiking
boot or an in-line roller skate. Shell 200 does not feature a tendon guard and
3o therefore provides less support in the back portion of the lower leg. Shell
200
is less restrictive as is required for hiking boot and in-line roller skate.
Shell
110 is designed for a shoe of a lesser height such as a running shoe, a soccer
CA 02515254 1999-12-21
shoe, a football shoe, baseball shoe, a golf shoe or a regular walking shoe.
Both shells 200 and 110 have variable wall thickness to provide more or less
flexibility to specific areas of the footwear as dictated by the activity it
is
designed for. Both shells 200 and 110 also feature stiffening members 215
and 122, respectively, which are similar to stiffening member 40 of shell 20
previously described with reference to Figure 1. It should be noted that a
stiffening member is not essential for footwear requiring minimal support and
added flexibility. For instance, a regular walking shoe may require very
little
lateral support and a very flexible sole. This type of footwear could have a
1o shell 110 made of a single thermoplastic of variable thickness.
A shell 300 similar to shell 20 on Figure 1 is also illustrated in Figure 3c
which
features a row of lace eyelets 54 along each edge 34 and 36. Lace eyelets
are normally made later on in the process of making the footwear but can be
previously perforated if needed.
With reference to Figures 4 to 6, a skate boot 55 will now be described.
Figure
4 is an exploded view of the various elements which constitute skate boot 55.
The shell 20 is the central structural element of the skate boot 55. A skin
2o assembly 60 preferably made of synthetic fabric or technical textile
material
such as nylon, aramid textile used with or without a thermoplastic sheet
backing. Skin assembly 60 is cut and assembled to conform to the outer wall
of shell 20, is positioned over shell 20 and affixed or glued in place. Skin
assembly 60 is essentially non-structural and is provided to enhance the
aesthetics of the skate boot.
A lining 62 made of a foam material shaped to precisely conform to the inside
of the rear portion of shell 20, extends from tendon guard 26 down to sole 32
and covers both sides of the ankle area. Lining 62 is glued inside shell 20. A
3o footbed 58 also made of a foam material and having an inner surface
conforming to the exact contour of a human foot is positioned on sole 32,
inside shell 20. Footbed 58 comprises a sole 59 and a sidewall 61 extending
11
CA 02515254 1999-12-21
along each side and around the heel portion of footbed 58. While lining 62 is
glued to the inside of shell 20, footbed 58 is removable from inside shell 20.
The bottom surface of footbed 58 which is in contact with sole 32 when
inserted into shell 20, can be made of a non-skid material such as a material
having a high friction coefficient or a partially adhesive material which
ensures
that footbed 58 will not move inside shell 20 during use. A section 64 on both
sides of footbed 58 partially overlaps lining 62 when footbed 58 is inserted
into shell 200.
1o A tongue/toe box assembly 65 comprising a tongue 68 and a rigid toe
protector 67 affixed to tongue 68 is installed over the front portion of shell
20.
Toe protector 67 is inserted into receptacle groove 31 and between quarters
28 and 30 and affixed or fastened to shell 20 thereby connecting the entire
tongue/toe box assembly 65 to shell 20. Tongue 68 extend all the way down
15 to the bottom of toe protector 67 to cover and cushion the toe area of the
skate boot and ensure that the wearer's toes will not touch the plastic toe
protector 67.
The assembly usually follows this general sequence: The skin assembly 60 is
2o first affixed to shell 20. Lining 62 is then glued inside shell 20. Lace
eyelets 54
are punched into each edge 34/71 and 36/72 of the pre-assembly as is shown
in Figures 6, 7, 8 and 9 and tongue/toe box assembly 65 is installed onto
shell
20. A ground engaging implement such as an ice runner holder 84 or 86 or an
in-line wheel chassis 85, or an outsole is mounted to sole 32 of shell 20.
25 Finally, footbed 58 is inserted into shell 20 to complete the skate. Of
course,
variations of this sequence are possible and depend on the manner in which
the ground engaging implement is mounted to the boot and also on the
manufacturing equipment available.
3o Figure 5a illustrates a skin 70, which has been cut from a flat piece of
synthetic fabric or textile material. The cutting operation of skin 70 is
adapted
to be fully automated since it is performed on a flat surface. Skin 70
12
CA 02515254 1999-12-21
comprises a right quarter 74 and a left quarter 76 linked together by a bridge
portion 78. Each quarter 74 and 76 further comprises half-tendon guards 79
and 80 respectively. The heel portions 81 and 82 of each quarter 74 and 76 is
given a slightly curvilinear profile to enable the formation of a rounded heel
counter which conforms to the heel counter 22 profile of shell 20 shown in
Figures 1 and 2.
Figure 5b illustrates a skin 70 to which decorative components 89 and 90
were added. Decorative components 89 and 90 are assembled to skin 70 by
1o automated process such as automatic stitching or welding. The automation of
this process is again simplified because it is done on a flat surface.
Components 90 may be stitched, welded or glued to components 89 in a first
step then the assembly of components 89 and 90 may be assemble to skin 70
in a final step. Of course, the assembly of the various decorative components
may be performed in any order to adapt to the specific physical requirements
of available manufacturing equipment. It can also be done all at once. The
flexibility of fabrication of the skin assembly 60 is due primarily to the
fact that
all the assembly operations, including the cutting of skin 70, are performed
while the fabric material is laying down flat. Figure 5b illustrates the
decorative
2o components 89 and 90 stitched to skin 70 as shown by the stitching lines by
way of example only. Decorative components 89 and 90 could be welded or
glued or otherwise affixed to skin 70 in any known fashion without departing
from the principle of assembling as many if not all skin components while the
various pieces are flat and therefore easy to work. The process is thereby
simplified and can readily be automated.
Skin 70 is folded around bridge portion 78 and sewn along half-tendon guard
79 and 80 to form skin assembly 60. Extensions 45 and 46 are also sewn
together at the front of skin assembly 60.
Figures 5c and 5d illustrate a variation of a skin 70. The right quarter 74
and
the left quarter 76 are, in this case, are linked together at tendon guard 92,
13
CA 02515254 1999-12-21
which is the equivalent of the assembly of half-tendon guard 79 and 80 of
Figures 5a and 5b. Half-bridge portions 78A and 78B are provided at the
lower part of each quarter 74 and 76, to be sewn together later on to form
skin
assembly 60 shown in Figure 4. In this variation the heel portions 81 and 82
are separated by a cut-out portion 93 which has curvilinear walls to enable
the
formation of a rounded heel counter as previously mentioned when referring
to the curvilinear profile of heel portions 81 and 82 shown in Figures 5a and
5b.
Figures 5c and 5d illustrate each quarter 74 and 76 having a similar profile
to
quarters 74 and 76 of skin 70 shown in Figures 5a and 5b. Figure 5c
illustrates a skin 70 made from a single flat piece of fabric or textile
material
whereas Figure 5d illustrates a skin 70 with decorative components 89 and 90
added in the same fashion as previously described in Figure 5b.
Skin 70 is cut, as its profile indicates, to conform to the general shape of
shell
20. The profile and shape of skin 70 may vary according to the shell 20 it is
intended for. It must be understood that the skin 70 may or may not conform
to the shell 20. As a variant, the skin may cover only partially the external
2o surface of the shell 20 leaving portions of the shell 20 exposed, giving
the
skate boot 55 a different look. As a further variation of skin 70, quarters 74
and 76 may be two single pieces joined together by a third piece covering
bridge portion 78.
The flat skin 70 is folded at the bridge portion 78 and sewn at the rear edges
of cuff portions 79 and 80, at heel portions 81 and 82, and at the extensions
45 and 46 to form a skin assembly 60 as shown in Figure 4, which can be
positioned over and affixed to shell 20. Similarly, if the variant shown in
Figures 5c and 5d is used, flat skin 70 is folded at tendon guard 92, the two
3o half-bridges 78A and 78B and the two extensions 45 and 46 are sewn
together to form a skin assembly 60 as shown in Figure 4, which can be
positioned over and affixed to shell 20.
14
CA 02515254 1999-12-21
Skin assembly 60, once formed, preferably has openings in its bottom portion
to provide direct access to shell 20 when fastening an ice runner holder 84 or
86, or an in-line wheel chassis 85 to the skate boot. Skin assembly 60 is
positioned over shell 20 and conforms to the shape of shell 20. The general
shape of skin assembly 60 ensures a reasonably good alignment between the
two components however positioning pins (not shown) may be added to shell
20, which are inserted into corresponding apertures of skin assembly 20 so as
to precisely align the two parts, ensuring consistent assembly.
Figure 6 illustrates the completed skate boot 55 without its ground-engaging
implement. Skin assembly 60 is affixed to shell 20 and conforms exactly to the
shape given by shell 20. Lace eyelets 54 were perforated or punched along
the edges 34/71 and 36/72 using a automatic punch which guides itself along
the edge and rapidly perforates a series of eyelets 54 equally spaced apart.
Lining 62 is affixed inside shell 20 and cushions the wearer's heel, ankle and
lower leg. Tongue/toe box assembly 65 is installed to the front portion of
shell
to cover and cushion the entire frontal area of the wearer's foot and ankle.
The resulting boot is light, comfortable and provides the required support for
skating.
Figure 7 illustrates skate boot 55 to which a standard ice runner holder 84
having a front pedestal 97 and a rear pedestal 98, is mounted. An outer sole
95 may be glued or nailed to the bottom of the shell to provide added
thickness enabling ice runner holder 84 to be riveted to skate boot 55 with
rivets 99. Outer sole 95 and front and rear pedestal 97 and 98 are provided
with corresponding apertures to insert rivets 99 and fasten ice runner holder
84 to skate boot 55.
Similarly, Figure 8 illustrates skate boot 55 to which an in-line wheel
chassis
85 is mounted. An outer sole 95 may be glued or nailed to the bottom of the
shell to provide added thickness and the in-line wheel chassis 85 is riveted
to
skate boot 55 using rivets 99.
CA 02515254 1999-12-21
Figure 9 illustrates an ice runner holder 86 having a front pedestal 100 and a
rear pedestal 101 that are shaped to conform more specifically to the contours
of skate boot 55. A front spacer 103 and a rear spacer 104 are positioned in
between ice runner holder 86 and skate boot 55. Ice runner holder 86 is
mounted to skate boot 55 by internal fasteners, which connect ice runner
holder 86 directly to the bottom of shell 20. Since skin assembly 60 extends
underneath shell 20, the space between front and rear pedestals 100 and 101
is cover by the textile material giving the skate an aesthetic look.
1 o Figures 10 and 11 illustrate the various components necessary to make a
low-
cut footwear according to the invention. A molded shell 110 preferably made
of injected thermoplastic, having a low-cut profile corresponding to the
general
outer shape of a shoe is shown. Shell 110 comprises a heel counter 112, a
medial quarter 114 and a lateral quarter 116, both of variable thickness
extending longitudinally from heel counter 112 to the front portion of shell
110.
Quarters 114 and 116 have edges 118 defining the main opening for insertion
and removal of the foot. A sole 120 extends the entire length of shell 110.
Shell 110 as shown comprises a stiffening member 122 which encompasses
sole 120 and the upper portion of heel counter 112. Stiffening member 122 is
2o made of a more rigid thermoplastic to provide added support to the wearer's
foot. As previously mentioned, depending on the sporting activity the footwear
is designed for, a supporting member 122 made of a more rigid material may
not be required. For instance, a simple walking shoe does not require added
support as a soccer or football shoe does.
As previously described, variations of shell 110's wall thickness, variations
of
materials, or combination of two or more materials are methods of changing
and adapting the physical properties of shell 110 and of the footwear so
constructed for its intended use. Shell 110 is shown with thinned wall regions
124 and 126 that provides added flexibility in areas corresponding to bone
pressure points. Shell 110 is the central component of the shoe to be
constructed. It is molded to conform to the shape of the foot and its shape
16
CA 02515254 1999-12-21
dictates the general shape of the footwear. Shell 110 further provides the
supporting structural element of the footwear.
An outer cover 125 made of a single layer or multiple layers of fabric,
textile or
leather material, which may or may not be decorated with various other
components, is used to cover shell 110. Outer cover 125 encloses the entire
shell 110 and only requires minor shaping of the toe box 126 which may
easily be achieved with a more or less rigid toe protector sewn or affixed
inside toe box 126. Preferably, the toe protector is shaped to fit within the
1o receptacle groove 128 of shell 110. A softer, more flexible toe protector
is
used for walking or golfing shoe for instance as these types of shoes do not
require solid frontal protection. On the other hand, a soccer or football
shoe,
and to a lesser extent, a baseball shoe will be fitted with a more rigid
plastic
toe protector similar to toe protector 67 used for skate boot 55. Outer cover
125 further comprises a tongue 130, which cushions and covers the frontal
portion of the wearer's foot. Tongue 130 is sewn or otherwise affixed to the
front portion of outer cover 125. Outer cover 125 is glued to shell 110 so
that it
will conform to the shape defined by shell 110.
2o An outer sole 132 of a specific configuration dictated by the sport the
footwear
is intended for is glued or nailed to the assembly of shell 110 and outer
cover
125. For illustrative purposes, a simple walking shoe sole is show. However
the footwear is adapted to accommodate a variety of outer soles 132 featuring
various types of spikes for football, baseball or soccer shoes or studs for
golf
or track and field shoes.
Finally, a footbed 135, which is adapted to conform to the interior space of
shell 110, is inserted into the assembly of shell 110, outer cover 125 and
outer
sole 132 to provide the necessary level of comfort and the necessary level of
3o support for the arch of the foot. Footbed 135 is made of a foam material.
It
has an inner surface conforming to the contour of a foot. Footbed 135
comprises a sole 136 and a sidewall 137 extending along each side and
17
CA 02515254 1999-12-21
around the heel portion of footbed 135. The bottom surface of footbed 135
which is in contact with sole 120 when inserted into shell 110, can be made of
a non-skid material or partially adhesive material which ensures that footbed
135 will not move inside shell 110 during use. Footbed 135 may further
comprise a frontal enclosing portion that covers the entire toe area of shoe
140. Preferably, sidewall 137 and tongue 130 abut one another when shoe
140 is laced up or fastened. Lace eyelets 141 are perforated into each side of
shoe 140 using an automatic punch which guides itself along the edge and
rapidly perforate a series of eyelets 141 equally spaced apart.
Figures 12 to 15 illustrate another embodiment of a footwear construction
according to the invention. The various components necessary to make a
short boot are shown in an exploded view. A molded shell 200 is the central
component of the boot to be constructed. It is molded to conform to the shape
of the foot and its shape dictates the general shape of the final boot 250.
Shell
200 provides the supporting structural element of the footwear. Shell 200 may
be made of injected thermoplastic material. Shell 200 comprises a heel
counter 202, an ankle counter 204, a medial quarter 206 and a lateral quarter
208, both of variable thickness extending longitudinally along each side of
2o shell 200, from the back of shell 200 to the front portion of shell 200.
Quarters
206 and 208 have edges 210 defining the main opening for insertion and
removal of the foot. A sole 212 extends the entire length of shell 200. Shell
200 as shown, comprises a stiffening member 215, which forms sole 212 and
ankle counter 204. Stiffening member 215 is made of a more rigid
thermoplastic than the rest of shell 200 to provide added support to the
wearer's foot. As previously mention, depending on the sporting activity the
boot is designed for, a supporting member 215 made of more rigid material
may or may not be required. For instance, a boot designed for an in-line
roller
skate as shown in Figure 16 requires added support to provide a boot having
3o good performance. As previously described, variations of shell 200's wall
thickness, variations of materials, or combination of two or more materials
are
methods of changing and adapting the physical properties of shell 200 and of
18
CA 02515254 1999-12-21
the boot so constructed for its intended use. Shell 200 is shown with thinned
wall regions 216 located between ankle counter 204 and the heel portion of
sole 212 to provide more flexibility in this area of bone pressure point.
Another
thinned wall area 218 is provided to increase flexibility of shell 200 around
the
widening portion of the foot corresponding to another bone pressure point.
At the opposite end of the spectrum, a walking boot or hiking boot as shown in
Figure 16 does not require the added support of stiffening member 215. Shell
200 can be made of a single thermoplastic material having various
1o thicknesses in selected areas such as 216 and 218. Shell 200 so constructed
provides the necessary support while also providing overall flexibility.
Shell 200 is inserted into an outer cover 225 made of a single layer or
multiple
layers of fabric, textile or leather material, which may or may not be
decorated
with various other components. Outer cover 225 has been previously
assembled and shaped and further comprises a reinforced toe box 226
provided which by a more or less rigid toe protector sewn or glued inside toe
box 226. Preferably, the toe protector is shaped to fit within the receptacle
groove 228 of shell 200. Outer cover 225 further comprises a tongue 230,
2o which cushions and covers the frontal portion of the wearer's foot. Tongue
230 is sewn or otherwise affixed to the front portion of outer cover 225.
Outer
cover 225 is glued to shell 200 so that it will conform to the shape defined
by
shell 200.
An outer sole 232 of the specific configuration required for the final
footwear is
glued or nailed to the assembly of shell 200 and outer cover 225. For
illustrative purposes, a thin sole 232 for in-line roller skates is shown.
However, the footwear is adapted to accommodate a variety of outer soles.
3o A lining 240 made of a foam material is shaped to precisely conform to the
inside of the rear portion of shell 200 and extends from the upper edge 237 of
19
CA 02515254 1999-12-21
shell 200 down to the sole 212. Lining 240 cushions both sides of the ankle
area and is glued inside shell 20.
A footbed 235 is inserted inside shell 200. Footbed 235 is made of a foamy
material and comprises an inner surface conforming to the exact contours of a
foot thereby providing comfort to boot 250. Footbed 235 comprises a sole 236
and a sidewall 238 extending along each side and around the heel portion of
footbed 235. The bottom surface of footbed 235 which is in contact with sole
212 when inserted into shell 200, can be made of a non-skid material or
~o partially adhesive material which ensures that footbed 235 will not move
inside shell 200 during use. A section 241 of footbed 235 overlaps lining 240
when positioned inside shell 200.
Figure 13 illustrates a boot 250 resulting from the assembly of the various
~5 parts described above. As previously described, lace eyelets 227 may be
perforated before or after assembly of outer cover 225 to shell 200.
Figure 14 illustrates an in-line roller skate 260 constructed by assembling an
in-line roller chassis 252 to boot 250. Figure 16 illustrates a walking boot
or
2o hiking boot 270 constructed by assembling a specific sole 254 to boot 250.
As can be seen from the description of various embodiments a footwear
constructed according to the invention, shell 20/110/200 is the central
component. With its use, the manufacturing process is no longer a series of
2s consecutive assembly steps which occur over a form or last of the footwear
but is a joining together of a limited number of prefabricated items
manufactured separately. This manufacturing process increases the
possibilities of automation, as each item is fabricated separately and brought
together at the end of the production cycle. Furthermore, the molding of shell
30 20/110/200 reduces the possibilities of errors. Once the mold is optimal,
each
part being produced from the mold is unlikely to substantially vary. The
joining
CA 02515254 1999-12-21
of the outer cover or skin components only requires minimal control of the
alignment of the two pre-fabricated parts.
For skate boot 55 shown in Figure 5, toe-box/tongue assembly 65 is also
manufactured separately and brought to the production line at the end of the
production cycle only. Tongue 68 is sewn or glued to toe protector 67. Toe
protector 67 is glued or otherwise affixed to the front of shell 20 to
complete
the skate boot.
1o This modular approach of the manufacturing process leads to a decrease in
rejected items during production, a better control of the end shape and
volume of the footwear and of course to a decrease in overall cost as
production is rationalized.
The above description of embodiments should not be interpreted in a limiting
manner since other variations, modifications and refinements are possible
within the spirit and scope of the present invention. The scope of the
invention
is defined in the appended claims and their equivalents.
21
