Note: Descriptions are shown in the official language in which they were submitted.
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SKATE BOOT
Field of the invention
The invention relates to a lasted skate boot comprising a thermoformed outer
shell having
a rear portion following the profile of the Achilles tendon.
Background of the invention
1 o Typical skate boots are fabricated by assembling together previously die-
cut pieces of
textile material and shaping them over a last. Various pieces of textiles or
fabrics are cut
to specific patterns, which are then pre-assembled by stitching or gluing or
both into a
multi-layer construction. The rigidity and flexibility characteristics of the
skate boot are
defined by the various layers of materials being positioned and layered in
specific regions
of the pre-assembled component of the skate boot. The accumulation of pieces
of
material into layers and the mechanical properties of each piece of textile or
fabric
material define the overall dynamic behavior of the skate boot. Usually, the
pre-
assembled component further includes rigid components generally made of
plastic to
increase the rigidity of specific area of the skate boot. The pre-assembled
boot generally
2o consists of the back and sides of the skate boot and a toe cap and tongue
assembly. The
pre-assembled boot has the general configuration of the finished product but
has not yet
been shaped to the final form of the skate boot.
The pre-assembled component is positioned over a last and formed to obtain the
shape
of the desired finished product. A last is a three-dimensional shape of the
inside cavity
of a boot. The pre-assembled boot may be mounted upside down onto the last for
ease
of manipulation and assembly of the remaining components making up the skate
boot.
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An insole is placed on the top part of the upside down last and the pre-
assembled boot
is stretched over the last and over the insole in order for the pre-assembled
boot to
conform to the specific shape of the last. The stretched material is then
glued and nailed
or tacked to the insole to maintain the desired shape.
Once the upper part of the skate boot is completed, a rigid outsole is secured
to the insole
of the boot to complete the skate boot. An ice skate blade holder or an in-
line roller
chassis is finally mounted to the bottom of the boot to complete the skate.
1 o This type of process is extensively used in the shoemaking industry. It
generates a good
product but has some disadvantages. For instance, the number of parts involved
in the
multi-layer construction can be staggering; a conventional ice skate for
hockey may have
up to eighty parts to be assembled and shaped over the last. As a consequence,
the
manufacturing process is lengthy and complex.
There is a need in the industry for a skate boot made of fewer components than
the
traditionally made skate boot and which is lighter than the traditionally made
skate boot.
There is also a need for a skate boot, which provides flexibility and
durability as well as
optimal performance.
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Summary of the invention
As embodied and broadly described herein, the invention provides a lasted
skate boot
comprising an upper for enclosing a human foot, the foot having a heel, an
Achilles tendon
having a rear upper part and a rear lower part that projects outwardly with
relation to the
rear upper part, the rear lower part merging with the heel, the foot also
comprising an ankle
with a medial malleolus and a lateral malleolus, a plantar surface, medial and
lateral sides
and toes; (a) the upper comprising an outer shell and an inner lining mounted
inside the
outer shell; (b) the inner lining comprising a surface for facing the heel,
the ankle and the
1 o medial and lateral sides of the foot, the inner lining being affixed to an
inner surface of the
outer shell; and (c) the outer shell being made of a thermoformable synthetic
material and
comprising a heel counter for receiving the heel of the foot, an ankle portion
for receiving
the ankle and medial and lateral quarters for receiving the medial and lateral
sides of the
foot respectively, the medial and lateral quarters extending forwardly from
the heel counter
and the ankle portion, wherein the ankle portion comprises a rear upper part
and a rear
lower part that projects outwardly with relation to the rear upper part, the
rear lower part
merging with the heel counter, the rear upper part following the rear upper
part of the
Achilles tendon and the rear lower part following the rear lower part of the
Achilles
tendon.
As embodied and broadly described herein, the invention further provides A
lasted skate
boot for enclosing a human foot, the foot having a heel, an Achilles tendon
having a rear
upper part and a rear lower part that projects outwardly with relation to the
rear upper part,
the rear lower part merging with the heel, the foot also comprising an ankle
with a medial
mallealus and a lateral malleolus, a plantar surface, medial and lateral sides
and toes; the
skate boot comprising an outer shell that is thermoformed in a three
dimensional shape
such that the outer shell comprises: (a) a heel counter for receiving the heel
of the foot; (b)
medial and lateral quarters for receiving the medial and lateral sides of the
foot
respectively, the medial and lateral quarters extending forwardly from the
heel counter and
3o the ankle portion; and (c) an ankle portion for receiving the ankle, the
ankle portion
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comprising a rear upper part shaped for following the rear upper part of the
Achilles tendon
and a rear lower part shaped for following the rear lower part of the Achilles
tendon, the
rear lower part projecting outwardly with relation to the rear upper part and
merging with
the heel counter.
As embodied and broadly described herein, the invention also provides A method
of
making a lasted skate boot for enclosing a human foot, the foot having a heel,
an Achilles
tendon having a rear upper part and a rear lower part that projects outwardly
with relation
to the rear upper part, the rear lower part merging with the heel, the foot
also comprising
1 o an ankle with a medial malleolus and a lateral malleolus, a plantar
surface, medial and
lateral sides and toes, the method comprising: (a) providing a pre-cut sheet
of
thermoformable synthetic material; and (b) thermoforming the sheet of
synthetic
thermoformable material to form an outer shell comprising (i) a heel counter
for receiving
the heel of the foot; (ii) an ankle portion for receiving the ankle; and (iii)
medial and lateral
quarters for receiving the medial and lateral sides of the foot respectively,
the medial and
lateral quarters extending forwardly from the heel counter and the ankle
portion; wherein
the ankle portion is thermoformed such that it comprises a rear upper part and
a rear lower
part that projects outwardly with relation to the rear upper part, the rear
lower part merging
with the heel counter, the rear upper part following the rear upper part of
the Achilles
2o tendon and the rear lower part following the rear lower part of the
Achilles tendon.
Other objects and features of the invention will become apparent by reference
to the
following description and the drawings.
2s 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:
3o Figure 1 is a perspective view illustrating a male-female mold for forming
an outer shell
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according to the invention;
Figure 2 is a perspective view illustrating a second male-female mold for
forming the
outer shell;
Figure 3 is a perspective view illustrating a third male-female mold for
forming the outer
shell;
Figure 4 is a perspective view illustrating a fourth male-female mold for
forming the
outer shell;
Figure 5 is a rear elevational view of the outer shell shown in an unfolded
position;
Figure 6 is a cross-sectional view of the outer shell taken at line 6-6 of
Figure 5;
Figure 7 is a perspective view of the outer shell shown in a folded position;
Figure 8 is a cross-sectional view of the outer shell taken at line 8-8 of
Figure 7;
Figure 9 is a rear elevational view of the outer shell shown in a folded
position;
Figure 10 is a perspective view of the outer shell shown in a folded position;
Figure 11 is an exploded perspective view illustrating an ice skate
incorporating the outer
shell constructed in accordance with the invention;
Figure 12 is a perspective view illustrating the upper constructed in
accordance with the
invention with a last and an insole;
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Figure 13 is a perspective view of an ice skate incorporating the skate boot
constructed
in accordance with the invention;
Figure 14 is a perspective view of a human foot with the contour of the foot
in stippled
lines and the bones in plain lines; and
Figure 15 is a front elevational view of the foot of Figure 14.
In the drawings, embodiments of the invention are illustrated by way of
examples. It is
1 o 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.
Detailed description of embodiments
A skate boot manufactured in accordance with the present invention is
illustrated
generally by reference numeral 10 in Figure 13.
Referring to Figure 11, skate boot 10 comprises an upper 12 for enclosing a
human foot.
2o Upper 12 comprises an outer shell 14 and an inner lining 16 mounted inside
outer shell
14. Outer shell 14 illustrated in Figures 5 to 11 is for use in a skate boot
for a right foot.
Outer shell 14 made of a thermoformable synthetic material. More particularly,
outer
shell 14 is made by thermo-pressured molding of a suitable thermoforming
material
initially in uniform thickness sheet form such as a pre-cut sheet having a
desired contour,
the sheet being made of thermoforming materials such as those sold under the
trade-mark
MEGABIX~ (a core of extruded SURLYN°, a backing of SONTARA~ and a
hot melt
coating; thickness of 0.95 mm), FORMO500~ (non woven polyester with a core of
extruded polyolefinic, stiffening layers of synthetic latex on each side and
an ethylene
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vinyl acetate hot melt adhesive on one side; thickness of 1.50 mm), BYLON~ (a
nylon
multifilament with a backing of black saturated needle punched polyester
nonwoven and
a face coating of non-fray urethane) and MOSOCA~ (NYLON~ 66 with a core of
SURLYN~ and a PU coating).
Outer shell 14 can be made of a homogenous thermoforming synthetic material or
can be
made of layers of different thermoforming synthetic materials. For example,
outer shell
14 may comprise two layers, the material of the outer layer of shell 14 being
more rigid,
or more resistant to abrasion, than the material of the inner layer of shell
14. More
1o specifically, outer layer of shell 14 can be made of a pre-cut sheet of
MOSOCA~ and
inner layer of shell 14 can be made of a pre-cut sheet of polystyrene, both
sheets being
thermoformed together. A pre-cut sheet of polyethylene or polyurethane may
also be used
for inner layer of shell 14. The outer and inner layers may be stitched
together before or
after the thermoforming operation if desired.
Inner lining 16 is made of a soft material and has an inner surface 38 and an
outer surface
40. Inner lining can be a fabric made of 100% nylon fibers. Inner surface 38
is intended
to contact the skin of the foot in use. Outer surface 40 of inner lining 16 is
secured to
outer shell 14 by affixing means such as glue, stitches, nails, adhesives or
tacks. It is
2o understood that inner lining 16, being made of a soft material, is less
rigid than outer shell
14 that is thermoformed of synthetic material being sufficiently rigid for
supporting the
foot.
Skate boot 10 also includes a footbed 20, an insole 22 facing the plantar
surface of the
foot and an outsole 24 secured to insole 22. Insole 22 is secured to outer
shell 14 with a
fastener such as stitches, glue, nails, adhesives or tacks. An ice skate blade
holder 26 is
secured to outsole 24. It is understood that an in-line roller chassis may
also be secured
to outsole 24. Insole 22 and outsole 24 have apertures for allowing access to
a locking
mechanism of the ice skate blade with ice skate blade holder 26 (not
illustrated).
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Skate boot 10 also comprises a tongue 28 and a toe box 30 facing the toes of
the foot.
Tongue 28 extends upwardly and rearwardly from toe box 30 and covers the upper
front
portions of the foot and the ankle. Preferably, toe box 30 and tongue 28 are
pre-
assembled prior to installing into outer shell 14. The frontal edge of tongue
28 is sewn
s directly to toe box 30, and then both sides of toe box 30 are secured to
outer shell 14 with
a fastener such as stitches, glue, nails, adhesives or tacks. Toe box 30 may
also be glued,
nailed or tacked to outer shell 14.
Skate boot 10 also comprises a band 32 secured to an upper portion of outer
shell 14,
to band 32 being made of fabric, textile or leather and comprising apertures
34. Eyelets 36
are punched into band 32, outer shell 14 and inner lining 16 vis-a-vis
apertures 34. It is
understood that the skate boot may comprise lacing loops and/or eyelets 36.
Skate boot
may comprise a rigid insert 37 that provides more rigidity in the ankle and
heel
portions of skate boot 10 and which is sandwiched between outer shell 14 and
inner
lining 16. Skate boot 10 may also comprise a protective overlay recovering a
portion of
upper 12 or a rear cover 39 secured to a rear portion of outer shell 14 (see
Figure 12).
Protective overlay and rear cover 39 may be made of fabric, textile or
leather.
A typical human foot is shown in Figures 14 and 15. The human foot has a heel
H, an
2o Achilles tendon AT having a rear upper part UP and a rear lower part LP
that projects
outwardly with relation to the rear upper part UP, the rear lower part LP
merging with the
heel H.
The foot also comprises a plantar surface PS, a medial side MS, a lateral side
LS, toes T,
2s and an ankle A with a medial malleolus MM and a lateral malleolus LM,
lateral
malleolus LM being below than medial malleolus MM.
Referring to Figures 5 to 10, outer shell 14 is formed of a heel counter 42
receiving heel
H, an ankle portion 44 receiving ankle A and medial and lateral quarters 58,
60 receiving
3o medial and lateral sides MS, LS of the foot respectively. Medial and
lateral quarters 58,
s
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60 extend forwardly from heel counter 42 and ankle portion 44. Medial quarter
58
comprises inner and outer surfaces 58IS and 5805 and lateral quarter 60
comprises inner
and outer surfaces 60IS and 6005.
Ankle portion 44 comprises a rear upper part 46 and a rear lower part 48 that
projects
outwardly with relation to rear upper part 46, the rear lower part 48 merging
with the heel
counter 42. Ankle portion 44 is formed for following the rear profile of
Achilles tendon
AT. More specifically, the rear upper part 46 of ankle portion 44 follows the
rear upper
part UP of Achilles tendon AT and the rear lower part 48 of ankle portion 44
follows the
rear lower part LP of Achilles tendon AT. Heel counter 42 is substantially cup
shaped
for following the contour of heel H.
Ankle portion 44 also comprises medial and lateral sides 50, 52. Medial side
50
comprises inner and outer surfaces SOIS, SOOS and lateral side 52 comprises
inner and
outer surfaces 52IS, 5205. Medial and lateral sides 50, 52 also comprise
medial and
lateral depressions 54, 56 respectively. Medial depression 54 receives medial
malleolus
MM and lateral depression 56 receives lateral malleolus LM, lateral depression
56 is
located slightly below medial depression 54 for conforming to the morphology
of the
foot.
As shown more particularly in Figures 8 and 9, medial and lateral sides 50, 52
of ankle
portion 44 and medial and lateral quarters 58, 60 are adapted to conform to
the general
morphology of the foot. In fact, inner surfaces SOIS, 52IS of ankle portion 44
an inner
surfaces 58IS and 60IS of medial and lateral quarters 58, 60 follow the sides
of heel H
and ankle A, and medial and lateral sides MS, LS of the foot while accounting
for
statistical variations of the relative position of medial malleolus MM and the
lateral
malleolus LM.
Medial and lateral quarters 58, 60 comprise quarter reinforcing elements 62
and medial
3o and lateral sides S0, 52 of ankle portion 44 comprise ankle reinforcing
elements 68.
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Referring to Figure 6, quarter reinforcing element 62 comprises a ridge 64
formed on
outer surface 6005 of lateral quarter 60 and a groove 66 registering with
ridge 64, groove
being formed on inner surface 60IS of lateral quarter 60. Referring to Figure
8, ankle
reinforcing element 68 comprises a ridge 70 formed on outer surface 5205 of
lateral side
52 of ankle portion 44 and a groove 72 registering with ridge 70, groove 66
being formed
on inner surface 52IS of lateral side 52 of ankle portion.
Outer shell 14 illustrated in Figures 5 to 13 comprises quarter reinforcing
elements 62
that continue with ankle reinforcing elements 68 for forming continuous
elongated
to reinforcing elements on outer shell 14, these continuous elongated
reinforcing elements
being also formed on the rear portion of ankle portion 44. Outer shell 14 also
comprises
heel reinforcing elements 74 that are formed on heel counter 42, heel
reinforcing
elements 74 being continuous with quarter reinforcing elements 62 for forming
continuous elongated reinforcing elements on the sides of outer shell 14.
~5
As reinforcing elements 62 and 68, heel reinforcing elements 74 comprise a
ridge formed
on the outer surface of heel counter 42 and a groove registering with the
ridge, the groove
being formed on the interior surface of heel counter 42.
2o It is understood that quarter and ankle reinforcing elements 62, 68 and
quarter and heel
reinforcing elements 62, 74 may be separate or formed together and their
design may be
selected for obtaining the desired rigidity, stability and flexibility of
skate boot 10.
Reinforcing elements 62, 68 and 74 may or may not have the same width and
height (or
depth) but their pattern is identical for the following aspect: a ridge (or
projection) formed
25 on the outer or inner surface of outer shell 14 corresponds to a groove (or
depression) that
registers with the ridge, the groove being formed on the outer or inner
surface of outer
shell 14 (naturally, a ridge formed on the outer surface of outer shell 14
corresponds to
a registered groove formed on the inner surface of outer shell 14).
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It is also understood that the ridge of reinforcing elements 62, 68 and 74 may
be formed
on the interior surfaces of medial and lateral quarters 58, 60, ankle portion
44 and heel
counter 42 respectively while the registered groove of reinforcing elements
62, 68 and
74 may be formed on the outer surfaces.
Reinforcing elements 62, 68 and 74 also protect the foot from impacts due to a
puck, a
ball or a stick since these elements tend to dissipate the impact energy.
In order to manufacture outer shell 14, a pre-cut sheet of thermoformable
synthetic
1 o material is inserted into the cavity of one of the male-female mold shown
in Figures 1 to
4.
The male and female portions of the molds define the inner and outer surfaces
of outer
shell 14 respectively. For instance, the male portion of the molds defines
inner surfaces
~ 5 SOIS, 52IS of ankle portion 44 and inner surfaces 58IS, 60IS of medial and
lateral
quarters 58, 60 whereas the female portion of the molds defines outer surfaces
SOOS,
520S of ankle portion 44 an outer surfaces 5805, 6005 of medial and lateral
quarters
58, 60.
2o As seen in Figures 2 and 4, grooves and ridges are provided in the female
and male
portions of the molds while only grooves are provided in the female portion of
the mold
illustrated in Figure 1 and only ridges are provided on the male portion of
the mold
illustrated in Figure 3. Due to the presence of ridges in the male portions
and grooves in
the female portion, the deformation of the synthetic material is more
important in the
25 region of the reinforcing elements when using the molds illustrated in
Figures 2 and 4.
Moreover, the deformation of the synthetic material is less important when
using the
molds illustrated in Figures 1 and 2 than the molds illustrated in Figures 3
and 4 since the
three-dimensional shape of the latter molds is more prominent than the one of
the molds
illustrated in Figures 1 and 2.
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The pre-cut sheet is aligned and temporarily secured to one of the mold
portions using
any suitable means to accurately position the pre-cut sheet within the mold
and maintain
same in position when the mold is closed. Once the mold is closed over the pre-
cut sheet,
the mold is heated up to the thermoforming temperature of the pre-cut sheet
and male and
female portions are pressed against the pre-cut sheet.
As indicated above, the pre-cut sheet of outer shell 14 may be formed of
layers of
different thermoforming synthetic materials. It is understood that the pre-cut
sheet of
outer shell 14 can be thermoformed and the pre-cut sheet of inner lining 16
can be affixed
1o to outer shell 14 during a subsequent shaping operation. Naturally, the
material of inner
lining 16 must be selected from materials that may be shaped with the outer
shell 14.
In an embodiment of the invention, heat and pressure are applied
simultaneously for a
period of 15 seconds to 2 minutes after which the mold is allowed to cool down
so that
the pre-cut sheet will set to the three-dimensional shape defined by the male
and female
portions of the mold. Preferably, heat and pressure are applied simultaneously
for a
period of 45 seconds to 1 minute. The applied heat is generally between
250°F and
350°F. The applied pressure is generally between 75 psi and 150 psi. It
is understood that
the amount of time, temperature and pressure may be different if a cooled mold
is used.
By utilizing different grades of thermoformable synthetic material, different
thermoformable synthetic materials or the same material with different
density, the
designers are able to vary the mechanical properties of outer shell 14.
Similarly, by
utilizing different patterns for reinforcing elements 62, 68 and 74 (i.e.
location, number,
width, height (or depth) and orientation), the designers are able to vary the
mechanical
properties of outer shell 14. In that sense, using different thermoformable
synthetic
materials and patterns of reinforcing elements 62, 68 and 74, the designers
are thus able
to vary the flexibility, rigidity and stability of skate boot 10.
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Referring now to Figure 12, outer shell 14 also comprises a lower skirt
portion 76 that
is foldable to overlap a portion of insole 22. A last 78 is inserted into the
inside cavity of
upper 12. Last 78 enables upper 12 to maintain its shape when skirt portion 76
is folded
to give upper 12 its final shape. Last 78 is inserted into upper 12 and insole
22 is
positioned underneath last 78 inside skirt portion 76.
Once the assembly is completed, upper 12 is placed upside down into a lasting
machine.
Glue is first applied to the bottom surface of insole 22 along its periphery.
Skirt portion
76 is then folded over last 78 onto the bottom surface of insole 22, using the
lasting
1 o machine wipers. Once folded, skirt portion 76 is bonded to insole 22 by
the glue that was
previously laid on the bottom surface of insole 22. Skirt portion 76 is
further nailed,
stitched, or tacked all around insole 22 to provide the necessary mechanical
grip to
remove the pulling forces and allow the glue to properly set between skirt
portion 76 and
insole 22. Once skirt portion 76 is firmly attached to insole 22 and upper 12
has acquired
~ 5 its final shape, a light sanding of the folded skirt portion 76 is
performed to partially even
the lower surface of upper 12 and provide a flat surface on which outsole 24
can be glued
or nailed.
The above description of embodiments should not be interpreted in a limiting
manner
2o 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.
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