Note: Descriptions are shown in the official language in which they were submitted.
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SKATE
FIELD OF THE INVENTION
[0002] The present invention relates to skates, and particularly
(although not
exclusively) to ice skates.
BACKGROUND OF THE INVENTION
[0003] Skates are a type of footwear commonly used in many athletic
activities such
as ice skating, ice hockey, inline roller skating, inline roller hockey, etc.
A skate typically has
a skate boot and a ground-engaging skate element such as a blade or a set of
inline rollers
attached to the underside of the boot permitting movement of the skate (and
its wearer) across
an appropriate surface. The skate boot typically covers all of the foot and
part of the leg of a
wearer.
[0004] Skates have been around for some time and are well known in the
art. While in
some ways similar to other footwear, they have their own unique design
characteristics owing
to the use to which they are put. Skating is not the same as walking, hiking,
skiing, etc. Thus,
for example, skates should be comfortable to wear while skating (especially
during hockey
play in the case of hockey skates), provide good control while skating
(especially during
hockey play in the case of hockey skates), and have a relatively long lifetime
(as compared
with some other types of footwear). The comfort and control provided by a
skate depend on
many factors including the hardness of the skate boot, the flexibility in the
ankle in the area of
the skate boot, the overall flexibility of the skate, the conformity of the
skate boot to the foot
of a wearer, and the weight of the skate. A skate boot's resistance to cuts,
ruptures and
impacts is also
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important because it contributes to the safety of the user and the useful
lifetime of the
skate. A skate's useful lifetime also depends on resistance to cyclic stresses
and forces
applied to the skate while skating.
[0005] Conventionally there are two different kinds of skates, which
are separated
according to the manner in which their skate boots are constructed. The more
traditional
of these is the "lasted" skate boot, while the other is the "non-lasted" skate
boot
(sometimes referred to as "molded" skate boots ¨ although lasted skate boots
may have
components that were molded ¨ and although there are other non-lasted methods
of
manufacturing besides molding). Each of these types of boots will be discussed
in turn.
[0006] The "lasted" skate boot is made in a manner similar to traditional
shoe
making techniques. As the name would suggest, a last (i.e. a, traditionally
wooden,
model of a foot used for making shoes or boots) or other similar form is used
in the
manufacture of this type of boot. The process of making a lasted boot starts
with
preparing the various materials from which the boot is to be made. This
traditionally
involves cutting out various shapes and forms from various layers of material
(which
might be leathers, synthetic fabrics, natural fabrics, foams, plastics, etc.)
necessary to
form the completed boot. These various shapes and forms are then superimposed
on the
last (usually one by one), worked to form the appropriate foot shape and
secured together
via any appropriate method (e.g. stitching, gluing, tacking, etc.).
[0007] While this traditional method has been employed for some time, and
is
still in wide use today, lasted skate boots have their disadvantages, most of
which are
well known in the art. Among them are the following: Given the number of
actions and
manipulations that are required, the manufacture of a lasted skate boot tends
to be very
labour intensive, and therefore more costly than non-lasted manufacturing
techniques,
meaning that lasted boots can be expensive to manufacture. Further, lasted
skate boots
tend to conform less well to the foot of a wearer given that a last merely
approximates the
three dimensional shape of a human foot, and that, in any event, the boots
tend not to be
of the exact shape of the last. Also, as the skate boot is made generally from
layers of flat
materials that are bent on the last to form the three-dimensional shape of the
boot, after
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bending, these materials can in some instances contain stresses within them
that may lead
to the skate boot being more easily damaged. Further, lasted skate boots have
a relatively
long "break in time", i.e. a period of time for which a wearer must wear the
skates to
break them in to get the skate boots to more comfortably conform to and fit
the wearer's
foot. Finally, lasted skate boots produced in this manner are not identical to
one another
(despite the use of the same last) since they are each individually made by
hand. Their
quality depends (at least in part) on the skill and craftsmanship of the
person who put
them together.
[0008] For these reasons, skate manufacturers have made attempts over
the years
at improving lasted skate boots. For instance, some have attempted to simplify
the
manufacturing process by reducing the number of layers of materials of which
the boot is
made, by adding in various molded plastic shells (usually in place of other
materials), by
making a flat "sandwich" of the layers of material of which the boot is to be
made before
putting the materials on the last and then bending the entire sandwich around
the last.
Some of these have been more successful than others.
[0009] The other predominant type of boot is the "non-lasted" skate
boot. As
mentioned above, this type of boot has conventionally also been known
sometimes as the
"molded" skate boot. Boots of this construction usually have a (relatively)
rigid shell
usually molded from a plastic or composite by any one of a number of
conventional
molding techniques. The shell provides the structure to the boot as it is
(usually directly)
molded into a three-dimensional shape during its manufacture, it is (usually)
the mold
that gives the shell its three-dimensional shape, and it is the shell's three-
dimensional
shape that will define the three-dimensional shape of the boot itself. The
shell also
carries most of the forces and stresses exerted on the boot while skating. The
remainder
of the skate boot components are affixed, either directly or indirectly, to
the shell.
[0010] As is the case with lasted skate boots, non-lasted skate boots
also have
their disadvantages, which are themselves generally well known in the art.
Specifically,
non-lasted skate boots tend to be made out of relatively rigid plastics or
composites that
do not offer much flexibility (particularly in the ankle area), and are
considered to be
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overly rigid in many cases by wearers. Moreover, given the amount of material
required
to make the shell have sufficient structural strength, non-lasted skate boots
tend to be
(relatively) much heavier than lasted skate boots (which is a significant
disadvantage).
Finally because of the rigidity of the skate boot, it is more difficult for
the boots to break
in and conform better to the foot of a wearer over time. Skate manufacturers
have tried to
ameliorate some of these disadvantages, again with more or less success over
time.
[0011] In summary though, notwithstanding the advances in skate boot
technology that have been made over time, no conventional skate boot, be it
lasted nor
non-lasted, is "perfect" nor its without drawbacks, and there is currently
room for
improvement in skate boot manufacturing technology.
SUMMARY OF THE INVENTION
[0012] Thus, it is an object of the present invention to ameliorate
at least some of
the inconveniences present in the prior art.
[0013] It is also an object of the present invention to provide an
improved non-
lasted skate boot as compared with at least some of the prior art.
[0014] Therefore, in one aspect, as embodied and broadly described
herein, the
present invention provides a skate boot comprising a non-lasted boot shell.
The shell has
a first non-lasted three-dimensional sub-shell and a second non-lasted three-
dimensional
sub-shell. The second sub-shell is interior to and adjoins the first sub-
shell. The first
sub-shell comprises a first material having a first density and the second sub-
shell
comprises a second material having a second density. The second density is
less than the
first density. The shell is shaped so as to have a heel portion, an ankle
portion, a lateral
portion, a medial portion, and a sole portion. A ground-engaging assembly is
disposed on
an underside of the skate boot.
[0015] The first material has a first stiffness and the second
material has a second
stiffness. In some embodiments the first stiffness is less than the second
stiffness, while
in other embodiments the first stiffness is greater than the second stiffness.
The choice
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of the actual stiffness of each of the materials and of the stifthess
difference between
them depends on the desired final characteristics of the skate including the
desired overall
stiffness of the skate.
[0016] In the context of the present application the term "shell" means a
boot
structure that carries all or a major portion of the torsional and bending
stresses applied to
the boot. However. "shell" does not require that that outer sub-shell be the
outermost
structure of the skate boot (although this is the case in some embodiments),
as additional
elements or structures may be disposed on or outward of that outer sub-shell.
The term
"non-lasted" means that the shell or sub-shell (as the case may be) is
directly formed into
a three-dimensional shape at the time of initial formation (as opposed to
being formed flat
and being later bent into a three dimensional shape, around a last for
example). The term
"non-lasted" does not exclude, however, any kind of operation or working being
performed on non-lasted shell or sub-shell after it has been initially formed
to change or
alter the shape into which it was initially formed. In addition, the term "non-
lasted shell"
does not require that the entire shell be non-lasted, for the purposes of the
present
specification, a shell is non-lasted if the various sub-shells of which it is
formed are all
non-lasted (other add-on components may be formed in other manners).
[0017] The present inventors have realized that by using a shell of the
present
invention, it is possible to manufacture skate boot shells wherein the
component sub-
shells thereof synergistically interact with one another to produce a shell
having enhanced
characteristics over both (i) any of the sub-shells taken separately and (ii)
a single-
material shell made from one of the materials of which one of the sub-shells
is made.
Thus, in certain embodiments for example, it is possible to create boot shells
that have
sufficient structural strength to serve their intended function, yet that are
lighter than
conventional non-lasted skate boots. Further, without wishing to be bound by
any
particular theory, it appears that in some embodiments by locating a
relatively dense one
of the sub-shells away from the foot of the wear and by placing a lower
density material
in between that dense sub-shell and foot, a skate boot with good
characteristics
(including, in some embodiments, characteristics approaching those of good
lasted skate
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boots) can be obtained. Also, again without wishing to be bound by any
particular
theory, in some embodiments shells of the present invention, by having an
integral sole
portion, appear to offer better fit with the ground-engaging element assembly
and to
provide for better energy transfer to the skating surface.
[0018] Further, some embodiments of the present invention can have
certain
advantages over prior art lasted-skate boots. Because the sub-shells are non-
lastedly
formed having a predetermined three-dimensional shape (i.e. are generally
directly
formed into that predetermined three-dimensional shape ¨ with or without minor
working
after formation), the final shape of the boot shell (and thus the boot itself)
can be
determined and reproduced with accuracy. This can improve the quality and
consistency
of the production process, as (but for errors in the production process) each
of the skate
boots made by this process can be the same. This can also allow for a more
precise
design and determination of the final shape of the boot shell in order to
ensure that the
skate boot has desired characteristics and shape (for example, to better
anatomically
conform to the shape of the foot and ankle). Such design at a micro level is
generally not
possible with lasted skate boots. Furthermore, the process by which the
present skate
boots are manufactured has less room for error and does not require craftsmen
with the
high degree of skill level required with lasted booted manufacturing
processes, and
therefore may be simpler, more efficient and less expensive.
[0019] In addition some embodiments of the present invention have
certain
advantages over prior art non-lasted skate boots. Having a shell construction
of the
present invention, in certain embodiments the present skate boots can be much
lighter
than prior art non-lasted skate boots and therefore can be unlikely to suffer
the drawback
of being found to be too heavy by their wearers. Further, by having a inner
sub-shell
being less dense than the first outer sub-shell in some embodiments, the
present skate
boots can provide better fit and comfort to a wearer than conventional non-
lasted skate
boots. They also can be more flexible and can have a reduced break-in time.
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[0020] Preferably, in the context of the present invention, the second
(and in a dual
sub-shell - the inner) material is a foam, and more preferably it is a
thermoplastic foam.
Foams are highly preferred as they are relatively inexpensive, relatively easy
to work with, are
lightweight, have sufficient strength, provide good impact absorption, and are
generally heat
formable. Thermoplastic foams provide the additional benefit that they may be
reheated after
initial formation and reshaped to better conform to the foot of a person who
will use the skate,
reducing the "break-in" time. (This thermoforming may be accomplished using
any one of a
number of conventional techniques.) Other possible second materials are non-
foam materials
having void spaces therein. A non-limiting list of suitable second materials
includes:
expanded polypropylene (EPP), expanded polystyrene (EPS), a latex foam, a
vinyl foam,
cork, 3D thermoplastic or composite meshes having a honeycomb structure, and
balsa wood,
etc., and combinations thereof.
[0021] Preferably, the first (and in a dual sub-shell - the outer)
material is a plastic.
Plastics are preferred as they are relatively inexpensive, relatively easy to
work with, and have
sufficient strength and rigidity. Thermoplastics are preferred. A non-limiting
list of suitable
first materials includes: high density polyethylene (1-1DPE), polypropylene
(PP), ionomers
such as Surlyn , polyearbonates (PC) such as Lexan , polyethylene
terephthalate (PET),
acrylonitrile butadiene styrene (ABS), thermoplastic elastomers (TPE's) such
as polyether
block amide (for example, Peba.x , composites (including fibreglass), resin
impregnated
textiles, textiles, etc., and combinations thereof (Surlyn thermoplastic
resins (E.I. DuPont
de Nemours and Company; Wilmington, Delaware, U.S.A.) are ionomer resins
created from
acid copolymers wherein acid neutralization results in the formation of ion
clusters.
Copolymers used in the formation of Surlyn resin can include ethylene acid
copolymers
such as ethylene/methacrylic acid.)
[0022] For ornamental or other reasons, in some embodiments, the first
material may
also be or include a graphical element laminate.
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For example, such a graphical element laminate may include: a base layer
having inner and
outer sides; a first thermoplastic layer laminated on the base layer outer
side, the first
thermoplastic layer having inner and outer sides; and a graphical element
printed on the inner
side of the first thermoplastic layer, at least a portion of the first
thermoplastic layer overlying
the graphical element being transparent or translucent such that when the
laminate forms part
of the skate boot, the graphical element being visible through the first
thermoplastic layer
from an exterior of the skate boot. The base layer may also include a design
element also
visible from the exterior of the skate boot. Optionally, a second
thermoplastic layer may
interposed between the first thermoplastic layer and the base layer. In such
cases, the
graphical element may be, or may also be, printed on the second thermoplastic
layer.
[0023] Further, in some embodiments of the present invention, and
particularly in
those where the outermost sub-shell of the boot shell forms the outside
surface of the skate
boot, the outer surface of the outermost sub-shell (in addition to or in place
of being or having
a graphical element laminate as described above) may be textured, colored or
otherwise
decorated to provide ornamentation to the skate.
[0024] It is also possible in some embodiments to add additional material
to the
interior of the shell, be it for structural, reinforcement, ornamental or
other purposes. Such
materials can be similar to any one of the sub-shells or different from all of
them, depending
on their purpose. As an example, Surlyng strips may be added to the inner
surface of the
inner sub-shell to provide for additional reinforcement.
[0025] Further, with the combination of a plastic first material and a
foam second
material, some embodiments of the invention can provide better protection from
impacts to
wearers of the skate in that, without wishing to be bound by any particular
theory, it appears
that the plastic first sub-shell will distribute energy of the impact and that
the foam second
sub-shell will absorb the distributed energy of the impact.
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[0026] Preferably, the first sub-shell and the second sub-shell are
fastenerlessly
bonded to one another. I.e. they are bonded together as the materials of which
they are
made are directly bonded to one another without the intermediary of a
fastener. Whether
or not this is the case can depend on the materials of which the sub-shells
are constructed
and the method of manufacture chosen. Alternatively they may be fastenerlessly
bonded
together via bonding techniques such as heat fusion or high-frequency bonding.
Where
the first sub-shell and the second sub-shell are not fastenerlessly bonded
together, they
may be joined to one another via at least one of a chemical fastener and a
mechanical
fastener. Suitable chemical fasteners include any adhesive, glues, etc.
(whether, for
example, light-activated, heat-activated, solvent-based, water-based, etc.)
that are
compatible with both the materials being fastened and the manufacturing
process.
Suitable mechanical fasteners include: stitching, clips, rivets, staples,
tacks, surface
textures, interlocking elements (whether part of the sub-shells themselves or
added
thereto), etc.
[0027] Preferably the first sub-shell has a contoured inner surface
and the second
sub-shell has a contoured outer surface complimentary with the inner surface
of the first
sub-shell. In this manner, the two sub-shells will register very well together
leaving little
or no undesired space between them. In addition, the contoured surfaces may be
constructed so as to reduce (or prevent) undesired movement of the two shells
with
respect to one another during the manufacturing process to assist in improving
quality
and consistency of the process. Further, in addition to or in place of being
complimentary, the registering surfaces of the sub-shells may have
interlocking elements
(e.g ribs, grooves, etc.) that mate with one another when the sub-shells are
properly
placed together. These interlocking elements may serve, for example, as
alignment
elements (to ensure that the sub-shells are properly placed together) and/or
fasteners (to
prevent the sub-shells from coming apart).
[0028] Preferably, the first sub-shell has an inner surface and the
second sub-shell
has an outer surface, the inner surface covering an entirety of the outer
surface. In other
embodiments, the inner surface covers less than an entirety of the outer
surface.
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[0029] In some embodiments at least one of the first sub-shell and
the second sub-
shell is of variable thickness. In other embodiments more than one, or even
all of the
sub-shells are of variable thickness. By varying the thickness of the sub-
shells the
physical properties of the shell may be varied. For example, if reinforcement
of a
particular area is desired (as may be the case, for instance, when that area
of the boot will
undergo repeated cyclical stresses), the first sub-shell may be locally
thickened in that
area. As another example, if additional impact protection is desired in a
particular area,
the second sub-shell may be locally thickened in that area. The converse is
also true, L e.
that the thickness in particular areas may be reduced as is required as well,
where, for
example, more flexibility and/or less protection is required. Variable
thickness of any of
the sub-shells is not required however, and embodiments of the invention have
sub-shells
that are all of constant thickness.
[0030] Reinforcement of certain areas of the shell (or sub-shells thereof)
may also
be accomplished by designing those areas to have a shape that has this effect.
Examples
include shaping structures such as ribs, grooves, or dimples (such as on a
golf ball) or
others that have that effect of locally altering the structure (such as by
adding a
honeycomb structure) so as to result in a reinforcing effect. These may be in
addition to
or in place of altering the thickness in that area.
[0031] Additionally, a reinforcing element or elements may be
associated with the
skate boot for reinforcement. Such elements are not limited to being
associated only with
the shell. They include, but are not limited to, heel counters, ankle
supports, shanks,
plates or rods in the sole or elsewhere, and are well known in the art. These
elements
may, for example, thus be additional pieces of (relatively) rigid plastics,
composites,
metals, woods, foams, textiles, etc. associated with the area that needs
reinforcement.
They may be in one of the sub-shells of the shell, in between the various sub-
shells of the
shell, on the outside or inside of the shell, or located elsewhere on the
boot.
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[0032] In certain embodiments the boot shell or any one or all of the
sub-shells
(depending on the exact construction of the embodiment in question) have a
left portion
and a right portion that have been non-lastedly formed separately from one
another in
three-dimensions and then have been later joined together to form the desired
sub-shell
structure. Thus, for example, where the shell has two sub-shells, each of the
sub-shells
may be split down the longitudinal centerline of the sub-shell forming two
halves. The
halves can then be joined via any suitable conventional technique (e.g.
bonding, fusing,
gluing, stitching, etc.) during the manufacturing process. Alternatively, in
some
embodiments only one of the sub-shells is manufactured in halves (or portions)
and is
later joined together, while the other(s) are manufactured whole. All such
possible
combinations are within the scope of the present invention. Various ones of
embodiments of the invention of this type may be desirable in certain
instances, as, for
example, they can be easier to manufacture in certain circumstances (e.g. when
one or
more the sub-shells has an integrated toe cap portion).
[0033] An important aspect of some embodiments of the present
invention is that
they allow for the creation of a skate boot shell (and thus a skate itself)
that is highly
customizable. Thus, taking a dual sub-shell shell for example, it is possible
to design a
set of various interchangeable outer sub-shells, each one having its own
distinct
characteristics (as at least one of the properties thereof (for example one of
those
described hereinabove) varies between members of the set), and also a set of
various
interchangeable inner sub-shells, each one having its own distinct
characteristics (as at
least one of the properties thereof (for example one of those described
hereinabove)
varies between members of the set), and allowing a person (be it a consumer or
a retailer
for example) to choose the particular ones of the sets that they wish to have
in their skate
(or skates), allowing them to customize a skate (or skates) to their desired
specification
and having their desired characteristics. Further, owing to the synergistic
effect between
the various sub-shells when combined to form a shell of the present invention,
in this
manner, in some embodiments, this allows for the creation of a set of skates
having a
relatively wide range of characteristics in a relatively simple and efficient
manner that
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can be accessible to consumers at a relatively inexpensive price. In this
respect, having
shells of more than two sub-shells may increase these benefits.
[0034] It should be understood that although many of the examples and
terminology used in the present specification explicitly or implicitly refer
to a shell
having a simple dual sub-shell structure, the present invention is not so
limited. Shells
having more than two sub-shell structures are within the scope of the present
invention.
Thus for example, it is possible to add a third sub-shell interior to and
adjoining the
second sub-shell. The characteristics of the third sub-shell can depend on the
overall
desired characteristics of the skate. Depending on the manufacturing process
and design
characteristics, the third sub-shell can be different from the other two sub-
shells or can be
the same (as the first sub-shell for example). As an example, it is possible
to have an
injection molded EPP second sub-shell that is completely coated by SurlynO
through a
dipping process. Thus, the resulting shell would have a first and a third
Surlyno sub-
shell that are very similar if not identical to one another and that would be
connected to
one another. Alternatively, in a modified example, the Surlyn sub-shells
could be
created through a vacuum molding process, yielding a shell wherein the first
and third
sub-shells would not necessarily be connected to one another.
[0035] Preferably the skate boot further comprises: a boot toe cap
connected to
the boot shell for protecting the toes of a wearer of the skate boot; a boot
tongue
connected to the toe cap; a boot facing connected to the lateral and material
portions of
the boot shell; a boot liner disposed within the boot shell. Examples of these
components
are conventional skate components whose manufacture is readily within one
skilled in the
art of skate boot construction.
[0036] In some embodiments, the facing is more flexible than the
skate boot shell,
as this can provide the skate boot with the required overall flexibility while
having a
relatively rigid boot shell. The facing may be given the desired flexibility,
for example,
through its materials, construction, or method of attachment to the skate (or
some
combination thereof). A suitable example of such a facing is one made of an
expanse of
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ethyl-vinyl acetate (EVA) that is stitched to the shell only near to one edge
thereof,
leaving the majority of the facing (including the eyelets) neither overlying
nor underlying
shell and thus free to stretch, move, etc.
[0037] In some embodiments, at least one of the sub-shells includes a toe
cap
portion (in addition to its other portions). In some embodiments, all of the
sub-shells
include a toe cap portion. In either manner, in some embodiments of the
present
invention, the boot shell includes a toe cap portion.
[0038] Preferably the skate boot is an ice skate boot and the ground-
engaging
assembly includes a blade adapted for skating on ice.
[0039] In
another aspect, as embodied and broadly described herein, the present
invention provides, a method of manufacturing a non-lasted skate boot shell,
the shell
having a first non-lasted three-dimensional sub-shell and a second non-lasted
three-
dimensional sub-shell, the shell being shaped so as to have a heel portion, an
ankle
portion, a lateral portion, a medial portion, and a sole portion, the method
comprising:
(i) forming the first non-lasted thee-dimensional sub-shell, the first
sub-shell
having an inner surface;
(ii) forming the
second non-lasted three-dimensional sub-shell, separately
from the first shell sub-shell, the second sub-shell having an outer surface
registerable with the inner surface of the first sub-shell;
(iii) placing the second sub-shell within an interior of the first sub-
shell such
that the outer surface of the second sub-shell registers with the inner
surface of the first sub-shell; and
(iv) securing the second sub-shell to the first sub-shell.
[0040] In
still another aspect, as embodied and broadly described herein, the
present invention provides a method of manufacturing a non-lasted skate boot
shell, the
shell having a first non-lasted three-dimensional sub-shell and a second non-
lasted three-
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dimensional sub-shell, the shell being shaped so as to have a heel portion, an
ankle
portion, a lateral portion, a medial portion, and a sole portion, the method
comprising:
(i) non-lastedly forming the first three-dimensional sub-shell, the
first sub-
shell having an inner surface; and
(ii) non-lastedly
forming the second three-dimensional sub-shell within and
secured to the first sub-shell, the second sub-shell having an outer surface
registering with the inner surface of the first sub-shell.
[0041] In
yet another aspect, as embodied and broadly described herein, the
present invention provides a method of manufacturing a non-lasted skate boot
shell, the
shell having a first non-lasted three-dimensional sub-shell and a second non-
lasted three-
dimensional sub-shell, the shell being shaped so as to have a heel portion, an
ankle
portion, a lateral portion, a medial portion, and a sole portion, the method
comprising:
(i) non-lastedly forming the second three-dimensional sub-shell, the second
sub-shell having an outer surface; and
(ii) non-lastedly forming the first three-dimensional sub-shell around and
secured to the second sub-shell, the first sub-shell having an inner surface
registering with the outer surface of the second sub-shell.
[0042] Sub-shells of the present invention may be non-lastedly formed in
three
dimensions by one or more of any number of conventional molding methods
appropriate
for the materials of which the sub-shells are made and to the final assembly
process. For
example, some possible methods include vacuum molding (single or multiple
layer),
injection molding and over molding. It should be understood, however, that the
present
invention is not limited to molding (nor molded sub-shells). Other non-lasted
methods of
forming include, for example, spray build-up, dipping, brushing, and wet lay-
up (of resins
or composites for example). The actual particular methods used will vary from
embodiment to embodiment depending on any number of conventional factors and
considerations.
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[0043] As
an example, where it is desired to have a dual sub-shell shell with the
inner sub-shell being EPP and the outer sub-shell being Surlyn , the inner EPP
sub-shell
can be formed first in three dimensions through a conventional injection
molding
technique, and the outer Surlyn sub-shell can then be formed and secured
thereto by
being conventionally vacuum formed around the EPP sub-shell. Alternatively,
in
another example, both the inner EPP sub-shell and the outer Surlyn sub-shell
can be
separately formed (the order of forming of which is unimportant) and then
later secured
together with a suitable adhesive.
[0044] In still yet another aspect, as embodied and broadly described
herein, the
present invention provides a skate boot having a skate boot shell manufactured
according
to any one of the methods set forth hereinabove.
[0045] In a
further aspect, as embodied and broadly described herein, the present
invention provides a method of assembling a non-lasted skate boot shell, the
shell having
a first non-lasted three-dimensional sub-shell and a second non-lasted thee-
dimensional
sub-shell, the shell being shaped so as to have a heel portion, an ankle
portion, a lateral
portion, a medial portion, and a sole portion, the method comprising:
(i) providing the first non-lasted three-dimensional sub-shell, the first
sub-
shell having an inner surface;
(ii) providing the second non-lasted three-dimensional sub-shell, the
second
sub-shell having an outer surface registering with the inner surface of the
first sub-shell; and
(iii) positioning the second sub-shell within the first sub-shell such that
the
outer surface of the second sub-shell registers with the inner surface of the
first sub-shell.
[0046]
Optionally, in a separate and later step, the first sub-shell and the second
sub-shell can be secured to one another.
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[0047] Embodiments of the present invention each have at least one
of the above-
mentioned objects and/or aspects, but do not necessarily have all of them. It
should be
understood that some aspects of the present invention that have resulted from
attempting
to attain the above-mentioned objects may not satisfy these objects and/or may
satisfy
other objects not specifically recited herein.
[0048] It should be understood that examples used throughout the
present
specification are for illustrative purposes and as an aid to understanding.
They are not
intended to be limiting nor to define the present invention.
[0049] Additional and/or alternative features, aspects, and
advantages of
embodiments of the present invention will become apparent from the following
description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] For a better understanding of the present invention, as well
as other
aspects and further features thereof, reference is made to the following
description which
is to be used in conjunction with the accompanying drawings, where:
[0051] Figure 1 is a right front perspective view of a right skate
having a first
embodiment of the present invention;
[0052] Figure 2 is a right front perspective exploded view of the
skate of Figure
1;
[0053] Figure 3 is a right front perspective exploded view of the skate
boot shell
of the embodiment of the present invention incorporated into the skate of
Figure 1;
[0054] Figure 4 is a right front perspective view of the shell of
the embodiment of
the present invention incorporated into the skate of Figure 1;
[0055] Figure 5 is a cross-sectional view of the outer sub-shell of
the shell of the
embodiment of the present invention incorporated into the skate of Figure 1
taken along
= the line 5 ¨ 5 of Figure 3 and a right side elevational view of the inner
sub-shell of the
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shell of the embodiment of the present invention incorporated into the skate
of Figure 1,
when the two are assembled into a shell;
[0056] Figure 6 is a front elevation view of the outer sub-shell of
the shell of the
embodiment of the present invention incorporated into the skate of Figure 1;
[0057] Figure 7 is a front elevation view of the shell of the embodiment of
the
present invention incorporated into the skate of Figure 1;
[0058] Figure 8 is a top plan view of the outer sub-shell shown in
Figure 6;
[0059] Figure 9 is a top plan view of the shell shown in Figure 7;
[0060] Figure 10 is a right front perspective view of a shell being a
second
embodiment of the present invention;
[0061] Figure 11 is a cross-sectional exploded view of the shell of
Figure 10
taken along the line 11 ¨ 11 in Figure 10; and
[0062] Figure 12 is a cross-sectional view of the shell of Figure 10
taken along
the line 11 ¨ 11 in Figure 10 when the shell has been assembled.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0063] An embodiment of the invention, being an ice skate 100 (for
the right
foot), is shown in Fig. 1. (Other embodiments of the invention include., but
are not
limited to, left ice skates, and inline roller skates.) Skate 100 has a skate
boot 102 and a
skate blade assembly 104. Skate has a skate boot shell 106, which is shown
with a cut-
away to reveal the sub-shells 120, 122 thereof described in further detail
below. Skate
boot 102 also has a skate boot toe cap 108, a skate boot tongue 110, a skate
boot liner
118, and skate boot facing 112. Skate blade assembly 104 has a skate blade 114
and a
skate blade holder 116. The skate boot toe cap 108, skate boot tongue 110,
skate boot
liner 118, and skate blade assembly 104 and their various components are
conventional,
and their manufacture, assembly, and use are within the knowledge of one
skilled in the
art of skate design, and will not be described further herein.
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[0064] Fig. 2 shows an exploded view of the ice skate 100 of Fig. 1,
to allow for a
better understanding of the various components thereof. Referring particularly
to skate
boot shell 106, it will be seen that in this embodiment, skate boat shell 106
has two sub-
shells, an outer sub-shell 120 and an inner sub-shell 122. Skate 100 also has
an
associated reinforcing element 124 (being a conventional molded plastic ankle
protector),
a conventional lace bite protector 128, and a conventional mid-sole 123 (for
securing the
skate blade assembly 104 to the skate boot 102). Skate liner 118 also has
conventional
foam ankle padding 126.
[0065] Fig. 3 shows an exploded view of the boot shell 106, showing
the two sub-
shells, outer sub-shell 120 and inner sub-shell 122. Each of outer sub-shell
120 and inner
sub-shell 122 have a three-dimensional shape having a heel portion 120h and
122h
(respectively), an ankle portion 120a and 122a (respectively), a lateral
portion 1201 and
1221 (respectively), a medial portion 120m and 122m (respectively), and a sole
portion
120s and 122s (respectively). Thus, referring to Fig. 4, the boot shell 106
itself, when
assembled, has a three-dimensional shape having a heel portion 106h, an ankle
portion
106a, a lateral portion 1061, a medial portion 106m, and a sole portion 106s.
[0066] Outer sub-shell 120 is a vacuum-molded three-dimensional
structure made
of SURLYN , made via a conventional vacuum molding technique. Outer sub-shell
120
is three-dimensionally shaped (when molded) so as to (when incorporated into
boot shell
106 and when boot shell 106 is incorporated into skate 100) conform well to
the foot of a
wearer during use of the skate 100. Various views of the three-dimensional
shape of
outer sub-shell 120 can be seen in Figs. 6 and 8.
[0067] Referring to Fig. 5, which shows outer sub-shell 120 in cross-
section, the
thickness 120t of the outer sub-shell 120 can vary from between about 0.1 mm
to about 5
nun. Preferably, the thickness 120t is between about 0.5 mm to about 5 mm, and
more
preferably between about 1 mm to about 3 mm. The density of outer sub-shell
120 can
vary between about 0.75 gicrn3 and about 1.1 g/cm3. Preferably, the density is
between
about 0.85 g/cm3 and about 1.0 g/cm3. More preferably, the density is between
about 0.9
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g/crn3 to about 1.0 g/cm3. Most preferably, the density is between about 0.95
g/cm3 to
about 0.98 g/cm3.
[0068] Inner sub-shell 122 is an injection molded three-dimensional
structure
made of EPP, made via a conventional injection technique (with resin being
injected into
and then being allowed to expand in the mold). Inner sub-shell 122 is shaped
so as to
(when incorporated into boot shell 106 and when boot shell 106 is incorporated
into skate
100) conform well to the foot of a wearer during use of the skate 100. Various
views of
the three-dimensional shape of the inner sub-shell 122 can be seen in Figs. 7
and 9,
showing the assembled boot shell 106.
[0069] Although not shown, the thickness of the inner sub-shell 122 is
generally
constant in this embodiment (although it may vary in others). Preferably, the
thickness
of the inner sub-shell 122 is between about 1 mm to about 15 mm. More
preferably, the
thickness of the inner sub-shell 122 is between about 2 mm to about 10 mm.
Still more
preferably, the thickness of the inner sub-shell 122 is between about 4 mm to
about 8
mm. Yet more preferably, the thickness of the inner sub-shell 122 is between
about 5
ruin to about 6 mm. Most preferably, the thickness of the inner sub-shell 122
is about 5.4
mm. The density of inner sub-shell 122 can vary between about 0.016 g/cm3 (1
lb/113)
and about 0.32 g/cm3 (20 lb/ft3). Preferably, the density is between about
0.032 g/cm3 (2
lb/ft3) and about 0.16 g/cm3 (10 lb/ft3). More preferably, the density is
between about
0.80 g/cm3 (5 lb/113) and about 0.96 g/cm3 (6 lb/ft3). Most preferably, the
density is about
0.83 g/cm3 (5.2 lb/f13).
[0070] Referring to Fig. 3, inner sub-shell 122 has an outer surface
122o having a
contoured three dimensional shape. Outer sub-shell 120 has an inner surface
I20i having
a contoured three dimensional shape. The contoured shapes of the outer surface
122o
and the inner surface 120i are complimentary such that when the inner sub-
shell 122 is
placed within the outer sub-shell 120, the surfaces 122o, 120i register well
in forming the
boot shell 106. Further, as can be seen in the figures, both the outer sub-
shell 120 and the
inner sub-shell 122 are shaped so as to have ridges 120r, 122r (respectively)
on their
outer surfaces 120o, 1.22o (respectively) to provide reinforcement. The ridge
122r on the
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outer surface 122o of the inner sub-shell 122 is complimentary with a ridge-
receiving
shape 125 on the inner surface 120i of the outer-shell 120, such that they
register when
the boot shell is formed; and, together with the ridge 120r of the outer sub-
shell, form
boot shell reinforcement ridge 106r.
[0071] Referring to Figs. 4, 7 and 9, when the inner sub-shell 122 is
placed
within the outer sub-shell 120 to form boot shell 106, in this embodiment, the
entirety of
the outer surface 122o of the inner sub-shell 122 is covered by the inner
surface 120i of
the outer sub-shell 120.
[0072] Boot shell 106 is assembled by first coating the outer surface
122o of inner
sub-shell 122 with a conventional adhesive and then placing inner sub-shell
122 within
outer sub-shell 120.
[0073] Once boot shell 106 is assembled, skate 100 is assembled in a
conventional manner with the exception of facing 112 (which is made of EVA).
In skate
100, (in contrast with conventional facings) facing 112 is secured to boot
shell 106 via
stitching 113 only along the bottom portion of the facing. Thus, the majority
of the body
117 of facing 112 (including the eyelets 115) neither underlies nor overlies
the boot shell
106 and it is not secured to the boot shell. This leaves the majority of the
body 117 of
facing 112 free to stretch, move, contract, etc. during use of the skate 100,
adding to the
skate's flexibility.
[0074] Referring now to Figs. 10 and 11, there is shown a second embodiment
of
the present invention, being skate boot shell 206 (for a right skate ¨ the
full skate has
been omitted for ease of illustration since it is otherwise conventional),
which is similar
to the skate boot shell 206 with some exceptions. In this embodiment each of
the outer
sub-shell 220 and inner sub-shell 222 are formed as two halves. Thus, outer
sub-shell
220 has a right half 236 and a left half 234. Similarly inner sub-shell 222
has a right half
232 and a left half 230.
[0075] Outer sub-shell 220 has a heel portion 220h, a part of which
is located on
right half 236 and a part of which is located on left half 234. Outer sub-
shell 220 also has
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an ankle portion 220a, a part of which is located on right half 236 and a part
of which is
located on left half 234. Outer sub-shell 220 also has a medial portion 220m
located on
the left half 234 and a lateral portion 2201 located on the right half 236.
Outer sub-shell
220 also has a sole portion 220s, a part of which is located on right half 236
and a part of
which is located on left half 234.
[0076] Inner sub-shell 222 has a heel portion 222h, a part of which
is located on
right half 232 and a part of which is located on left half 230. Inner sub-
shell 222 also has
an ankle portion 222a, a part of which is located on right half 232 and a part
of which is
located on left half 230. Inner sub-shell 222 also has a medial portion 222m
located on
the left half 230 and a lateral portion 2221 located on the right half 232.
Inner sub-shell
222 also has a sole portion 222s, a part of which is located on right half 232
and a part of
which is located on left half 230.
[0077] Inner sub-shell 222 has an outer surface 222o (split across
its left half 230
and its right half 232). Outer sub-shell 220 has an inner surface 220i (split
across its left
half 234 and its right half 236). The outer surface 222o of the inner sub-
shell 220 is
complimentary with the inner surface 220i of the outer sub-shell 220 such that
the two
register well when the sub-shell halves 230, 232 and 234, 236 are formed into
a whole
sub-shell 222 and 220 (respectively) and the resultant sub-shells 220, 220 are
assembled
into boot shell 206.
[0078] Outer sub-shell halves 234, 236 are each a vacuum-molded three-
dimensional structure made of SURLYNe, made via a conventional vacuum molding
technique. Once manufactured, outer sub-shell halves 234, 236 are secured
together at
surfaces 243 via any suitable conventional technique (e.g. bonding, fastening,
stitching
etc.) to form joint 244 (in Fig. 12) and thus outer sub-shell 220 (which is
otherwise
similar to outer sub-shell 120 of the first embodiment, skate 100). Once
manufactured,
inner sub-shell halves 230, 232 are secured together at surfaces 242 via any
suitable
conventional technique (e.g. bonding, fastening, stitching, etc.) to form
joint 245 (in Fig.
12) and thus inner sub-shell 222 (which is otherwise similar to inner sub-
shell 220 of the
first embodiment, skate 100).
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10079] Boot. shell 206 is then assembled as is described above in
relation to the
first embodiment, skate too.
100801 Modifications and improvements to the above-described
embodiments of
the present invention may become apparent Co those skilled in the art. The
foregoing
description is intended to be exemplary rather than limiting,
