Note: Descriptions are shown in the official language in which they were submitted.
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1 IMPROVED SKATE SHELL
2 BACKGROUND OF THE INVENTION
3 1. Field of the Invention
4 [00011 The
present invention relates to a method for manufacturing a
skate shell, and more particularly to a method for manufacturing a non-lasted
6 skate shell for ice-skates, in-line skates and the like and having a
three
7 dimensional sheet arrangement.
8 2. Description of Related Art
9 [0002] A conventional
skate shell for an ice-skate or an in-line skate is
made of plastic material with injection molding processes and substantially
11 comprises a toe cap, two lateral vamps, a quarter and a sole.
12 [0003] US Patent
No. 7,712,173, entitled "Method of Manufacturing
13 an Ice Skate" discloses another outer shell having two skirt portions
folded
14 inwardly and affixed to each other by stitching or a snap assembly to
form a sole.
Therefore, the skate shell of the '173 Patent has to proceed with combining
and
16 lasting/brushing steps after the fanning process, so the method of the
'173 Patent
17 is complicated and time-consuming.
18 [0004] US Patent
Publication No. 2010/0275393, entitled "Method of
19 Making a Lasted Skate Boot" discloses an outer shell having two side
skirt
portions partially extending over and affixed to the insole to form the bottom
21 sole of the body. Therefore, the skate shell of the '393 Patent also has
to proceed
22 with combining insole, lasting, brushing and outsole assembling steps of
the
23 conventional skate lasting processes after the injection molding
process, so the
24 method of the '393 Patent is also complicated and time-consuming.
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[0005] In addition, an outsole is necessary with the sole of the shell of
the '173 Patent and the '393 Patent. The shell binds to the outsole through
glue
and nail tacking. Then a skate blade holder with a skate blade is securely
connected to the outsole to form a skate. However, gaps easily forms between
the
outsole and sole of the shell of the '173 Patent and the '393 Patent, so the
force
transmission between the outsole and the skate blade holder is insufficient.
Consequently, a user who wears the shells has to push the skates with large
force,
which makes the conventional skate laborious to use.
[0006] In addition, to enhance the structural strength of one part of the
conventional skate shell, a fabric sheet is embedded in the part of the
conventional
skate shell, such as the sole. However, the fabric sheet is mounted in a
single part
of the conventional skate shell, is arranged substantially in a single surface
and
cannot be arranged in a three dimensional form on the conventional skate
shell.
Therefore, to mount a fabric sheet in the conventional skate shell is limited
and is
not versatile.
[0007] To overcome the shortcomings, the present invention intends to
provide a method for manufacturing a skate shell to mitigate or obviate the
aforementioned problems.
SUMMARY OF THE INVENTION
[0008] One aspect of the invention is to provide a method for
manufacturing a non-lasted skate shell that has a three dimensional sheet
arrangement, is easily fabricated and has a good durability.
According to a further aspect of the invention, there is provided a method
for manufacturing a skate, comprising: providing an expandable sheet having an
expansibility of 0.1 to 10%, the sheet having a peripheral rim defined along
an
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edge of the sheet; providing a mold assembly having a combinative outer mold
and an inner mold to form a mold cavity between the outer mold and the inner
mold, and the inner mold having a mold block including a base and a shaping
block with a shape corresponding to that of the skate shell; forming the sheet
into
a three dimensional shape approximating the shape of the shaping block;
mounting
the shaped sheet around the shaping block and positioned on the base of the
mold
block on the inner mold; closing the mold assembly to form the mold cavity
between the inner mold and the outer mold and squeezing the peripheral rim of
the
shaped sheet between the inner mold and the outer mold so that at least a
portion
of the peripheral rim is not within the mold cavity; forcing molten plastic
material
into the mold cavity to make the plastic material combined with the shaped
sheet
and form a skate shell with the shaped sheet smoothly bonded to one surface of
a
plastic body of the skate shell in a three dimensional arrangement; and
opening the
mold assembly and removing the skate shell with the sheet from the mold
assembly.
According to another aspect of the invention, there is provided a method for
manufacturing a skate, comprising: providing a flat expandable sheet; applying
graphics to a first side of the sheet; forming the sheet into a three
dimensional
shaped sheet approximating the shape of a foot; providing a mold assembly
having
an outer mold and an inner mold, the outer and inner molds movable between an
open an a closed position, a mold cavity being defined between the molds when
in
the closed position; placing the shaped sheet over the inner mold; closing the
mold; and injecting plastic into the mold cavity so that plastic fills a space
between a first mold surface and one of the first or
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second sides of the shaped sheet, and the other of the first and second sides
of the
shaped sheet is urged against a second mold surface to form a skate shell.
10009] The
method for manufacturing a skate shell comprises acts of
providing an expandable sheet having an expansibility of 0.1 to 10%, providing
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1 a mold assembly, forming the sheet into a three dimensional shape,
mounting the
2 shaped sheet around an inner mold, closing the mold assembly, forcing
molten
3 plastic material into the mold assembly and opening the mold assembly.
The
4 sheet is provided with a peripheral rim. In the act of providing a mold
assembly,
the mold assembly has a combinative outer mold and an inner mold to form a
6 mold cavity between the outer mold and the inner mold, The inner mold has
a
7 mold block including a base and a shaping block. The shaping block has a
shape
8 corresponding to that of the skate shell. In the act of mounting the
shaped sheet
9 around an inner mold, the shaped sheet is mounted around the shaping
block and
positioned on the base of the mold block on the inner mold with a positioning
11 assembly. In the act of closing the mold assembly, the mold cavity is
formed
12 between the inner mold and the outer mold and the peripheral rim of the
shaped
13 sheet is squeezed by the inner mold and the outer mold. In the act of
forcing
14 molten plastic material into the mold cavity, the plastic material is
bonded with
the shaped sheet to form a skate shell with the shaped sheet smoothly attached
to
16 one surface of a plastic body of the skate shell in a three dimensional
17 arrangement. After the act of opening the mold assembly, the skate shell
with the
18 sheet is taken out of the mold assembly.
19 100101 Additionally, a skate shell for a skate in accordance with the
present invention is kept free from a toecap and/or a tongue and has a plastic
21 body and a shaped sheet. The plastic body has an inner surface, an outer
surface,
22 a vamp and a sole panel. The shaped sheet is three dimensional and
expandable,
23 is bonded on either the inner surface or the outer surface of the
plastic body and
24 covers the vamp and the sole panel.
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[0011] With such an arrangement, because the skate shell is formed as
2 a single part including the sole panel integrally formed with the skate
shell, no
3 lasting steps following the injection process are needed and a durable
itructure
4 of the skate shell is provided.
[0012] In addition, because the sole panel is made of rigid
6 thermoplastic or thermosetting plastic material, the durability of the
skate shell is
7 increased without mounting an additional outsole. The skate shell
produced in
8 accordance with the present invention is sturdier than that of the
conventional
9 skate boot that is lasted by providing an outsole attached on the skate
boot. The
skate shell made under this invention can better transfer power to the blade
to get
11 to a player's desired speed than the conventional skate boot does.
12 [0013] Furthermore, with the arrangement of the three dimensional
13 shaped sheet bonded onto the body of the skate shell, the appearance of
the skate
14 shell can be improved and versatile and the shaped sheet with no
stitching line in
ankle/tendon area to make the shaped sheet durable in structural strength.
16 [0014] In accordance with one embodiment, the present invention
17 provides a method for manufacturing a skate. The method comprising
providing
18 an expandable sheet having an expansibility of 0.1 to 10%, with the
sheet having
19 a peripheral rim defined along an edge of the sheet. The method further
comprises providing a mold assembly having a combinative outer mold and an
21 inner mold to form a mold cavity between the outer mold and the inner
mold, and
22 the inner mold has a mold block including a base and a shaping block
with a
23 shape corresponding to that of the skate shell. The method further
comprises
24 forming the sheet into a three-dimensional shape approximating the shape
of the
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1 shaping block, and mounting the shaped sheet around the shaping block and
2 positioned on the base of the mold block on the inner mold. The method
further
3 comprises closing the mold assembly to form the mold cavity between the
inner
4 mold and the outer mold and squeezing the peripheral rim of the shaped
sheet
5 between the inner mold and the outer mold so that at least a portion of
the
6 peripheral rim is not within the mold cavity, and forcing molten plastic
material
7 into the mold cavity to make the plastic material combined with the
shaped sheet
8 and form a skate shell with the shaped sheet smoothly bonded to one
surface of a
9 plastic body of the skate shell in a three dimensional arrangement.
Further, the
method comprises opening the mold assembly and removing the skate shell with
11 the sheet from the mold assembly.
12 100151 In some such embodiments, in the act of mounting the shaped
13 sheet around and positioned on the mold block of the inner mold, the
mold block
14 of the inner mold is provided with multiple hanging stubs mounted on the
base of
the mold block and around the mold cavity; the sheet is provided with multiple
16 hanging holes separately defined through the peripheral rim of the
sheet; and the
17 shaped sheet is positioned onto the hanging stubs on the inner mold by
the
18 hanging holes in the sheet.
19 [00161 In additional embodiments, the expandable sheet has an
expansibility of 0.1 to 5%. In further embodiments, the expandable sheet has
an
21 expansibility of 0.1 to 3%. In yet further embodiments, the expandable
sheet has
22 an expansibility of 0.1 to 2%.
23 100171 In yet additional embodiments, the sheet is selected from one
24 or more of fabric, textile, natural or artificial leather, synthetic
material and
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1 composite material. Some such embodiments additionally comprise trimming
at
2 least a part of the peripheral rim after removing the skate shell from
the mold
3 assembly, and attaching padding elements to the inside of the skate
shell. In
4 some embodiments padding elements are attached to a portion of the
peripheral
rim that was not within the mold cavity during plastic injection.
6 10018] In some embodiments the peripheral rim is formed as an
7 integral part of the sheet. In other embodiments the peripheral rim is
formed as a
8 separate element and is securely mounted on a periphery of the sheet.
9 [0019] In yet additional embodiments, in the act of forming the sheet,
a heel element is further attached to a heel segment of the sheet.
11 [0020] In further embodiments, in the act of forcing molten plastic
12 material into the mold cavity, the molten plastic material is injected
to urge the
13 shaped sheet to take on the contour of the shaping block of the mold
block on the
14 inner mold.
[0021] In some such embodiments the expanded sheet is further
16 provided with at least one auxiliary sheet on the expanded sheet to
increase the
17 thickness of the sheet on where the at least one auxiliary sheet is
mounted, and
18 the thickness of the plastic body corresponding to the at least one
auxiliary sheet
19 is correspondingly reduced.
[0022] In yet further embodiments, in the act of forcing molten plastic
21 material into the mold cavity, the molten plastic material is injected
into and is
22 filled in a gap between the mold block and the shaped sheet so that the
shaped
23 sheet is urged against an outer mold surface.
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[0023] In some such embodiments in the act of forcing molten plastic
material into the mold cavity, the shaped sheet is provided with at least one
injection hole defined through the shaped sheet, and at least one nozzle is
provided on the mold assembly and extends respectively through the at least
one
injection hole in the shaped sheet when the mold assembly is closed.
[0024] In still further embodiments the expanded sheet is further
provided with at least one auxiliary sheet on the expanded sheet to increase
the
thickness of the sheet on where the at least one auxiliary sheet is mounted,
and the
thickness of the plastic body corresponding to the at least one auxiliary
sheet is
corresponding reduced.
[0025] In some embodiments the peripheral rim is made of a material that
is different from the sheet.
100261 In accordance with another embodiment, the present invention
provides another method for manufacturing a skate, comprising providing a flat
expandable sheet; applying graphics to a first side of the sheet; and forming
the
sheet into a three dimensional shaped sheet approximating the shape of a foot.
The method further comprises providing a mold assembly having an outer mold
and an inner mold, the outer and inner molds movable between an open and a
closed position, a mold cavity being defined between the molds when in the
closed position; placing the shaped sheet over the inner mold; closing the
mold;
and injecting plastic into the mold cavity so that plastic fills a space
between a
first mold surface and one of the first or second sides of the shaped sheet,
and the
other of the first or second sides of the shaped sheet is urged against a
second
mold surface to form a skate shell.
. .
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1 [0027] Some such
embodiments additionally comprise providing a
2 positioning assembly, and placing the shaped sheet over the inner mold
3 comprises
expanding the sheet and engaging the expanded sheet with the
4 positioning
assembly so that the expanded sheet is held in tension over the inner
mold. In further embodiments the positioning assembly engages a peripheral of
6 the shaped sheet at a plurality of anchor portions.
7 [0028] In some
embodiments the expandable sheet has an
8 expansibility of
no more than 10%. In further embodiments the expandable sheet
9 has an
expansibility of no more than 5%. In yet further embodiments the
expandable sheet has an expansibility of no more than 3%.
11 [0029] In still further
embodiments the expandable sheet has an
12 expansibility of no more than 2%.
13 [0030]
Additional embodiments comprise providing a plurality of flat
14 expandable
sheets. In some such embodiments, forming a three-dimensional
shaped sheet comprises attaching the plurality of flat expandable sheets to
one
16 another.
17 [0031] In
another embodiment, when the expanded sheet is held in
18 tension over the
inner mold and the mold is closed, a peripheral rim of the shaped
19 sheet is engaged between mold elements and is not within the mold
cavity.
[0032] Yet further embodiments comprise removing the skate shell
21 from the mold and trimming off the entire peripheral rim.
22 [0033] Other
further embodiments comprise removing the skate shell
23 from the mold
and sewing a skate lining to the peripheral rim, which was not
24 within the mold
cavity and to which plastic is not bonded. In some such
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embodiments the shaped sheet engaged the positioning assembly at anchor
portions of the peripheral rim, and some embodiments additionally comprise
trimming the anchor portions off the peripheral rim after removing the skate
shell
from the mold.
[0034] In yet another embodiment, the plastic is injected adjacent the
second side of the shaped sheet, and the first side of the shaped sheet takes
on the
shape of the outer mold.
[0035] In still another embodiment, the plastic is injected adjacent the
first side of the shaped sheet, and the second side of the shaped sheet takes
on the
shape of the inner mold. In one such embodiment the plastic is configured so
that
the graphics on the first side of the shaped sheet are visible through the
plastic
after the plastic has cured.
[0036] Other advantages and novel features of the invention will become
more apparent from the following detailed description when taken in
conjunction
with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] Fig. 1 is a block diagram of a method for manufacturing a skate
shell in accordance with an embodiment of the present invention;
[0038] Fig. 2 is an exploded side view of a first embodiment of a sheet
for the method in accordance with the present invention;
[0039] Fig. 3 is an exploded side view of a second embodiment of a sheet
for the method in accordance with the present invention;
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1 [0040] Fig. 4 is an
operational cross sectional side view of a mold
2 assembly
embodiment for the method in accordance with the present invention
3 showing the mold assembly being closed;
4 [0041] Fig. 5 is
a perspective view showing the shaped sheet mounted
5 around the shaping block of the mold block of the inner mold;
6 [0042] Fig. 6 is
a cross sectional side view of the mold assembly in
7 Fig. 4 showing the mold assembly being closed;
8 [0043] Fig. 6A is
an enlarged cross sectional side view of the mold
9 assembly in Fig. 6;
10 [0044] Fig. 6B is
another enlarged cross sectional side view of the
11 mold assembly in Fig. 6;
12 [0045] Fig. 7 is
a perspective view of a first embodiment of a skate
13 shell with a
sheet shown in Fig. 2 bonded onto the inner surface of the skate shell =
14 manufactured by
the method in accordance with an embodiment of the present
invention;
16 [0046] Fig. 8 is
a cross sectional side view of the mold assembly in
17 Fig. 4 provided with a nozzle being mounted on the mold assembly;
18 [0047] Fig. 8A is
an enlarged cross sectional side view of the mold
19 assembly in Fig. 8;
[0048] Fig. 8B is another
enlarged cross sectional side view of the
21 mold assembly in Fig. 8;
22 [0049] Fig. 9 is
a perspective view of a second embodiment of a skate
23 shell with a
sheet shown in Fig. 2 bonded onto the outer surface of the skate shell
24 manufactured by the method in accordance with the present invention;
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1 [0050] Fig. 10 is a
perspective view of a third embodiment of a skate
2 shell with a
sheet shown in Fig. 3 bonded onto the outer surface of the skate shell
3 manufactured by the method in accordance with the present invention;
4 [00511 Fig. 11
is an exploded perspective view of an ice skate having a
skate shell manufactured by the method in accordance with the present
6 invention;
7 100521 Fig. 12
is a perspective view of a fourth embodiment of a skate
8 shell with a
sheet composed of multiple sheet pieces bonded onto the outer
9 surface of the
skate shell manufactured by the method in accordance with the
present invention;
11 100531 Fig. 13
is an operational cross sectional side view of another
12 embodiment of a
mold assembly for the method in accordance with the present
13 invention;
14 [00541 Fig. 13A
is an enlarged cross sectional side view of the mold
assembly in Fig. 13;
16 [0055] Fig. 14
is an exploded side view of a third embodiment of a
17 sheet for the method in accordance with the present invention;
18 [0056] Fig. 15 is an
enlarged cross sectional side view of the sheet
19 along line 15-15 in Fig. 14;
[0057] Fig. 16 is a perspective view of a fifth embodiment of a skate
21 shell with a
sheet shown in Fig. 14 bonded onto the inner surface of the skate
22 shell
manufactured by the method in accordance with the present invention; and
23 100581 Fig. 17 is an
enlarged cross sectional side view of the skate
24 shell along line 17-17 in Fig. 16.
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1 DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
2 [0059] With reference to Fig. 1 a method for manufacturing a skate
3 shell, especially a non-lasted skate shell with a three dimensional sheet
4 arrangement in accordance with the present invention comprises the
following
acts of providing an expandable sheet, providing a mold assembly, forming the
6 sheet into a three dimensional shaped sheet, mounting the shaped sheet
around
7 an inner mold of the mold assembly, closing the mold assembly, forcing
molten
8 plastic material into the mold assembly and opening the mold assembly.
9 100601 In the act of providing the expandable sheet, with further
reference to Fig. 2, the expandable sheet 10 is preferably a flat but flexible
sheet
11 made of a material having an expansibility of 0.1 to 10%. The
expansibility of
12 0.1 to 10% means that the sheet 10 may be expanded to 100.1 to 110% in
length
13 along a direction or in the whole area of the sheet when a force is
applied to the
14 sheet 10. Preferably, the expansibility of the sheet 10 may be 0.1 to
5%, with the
expansibility of 0.1 to 3% or 0.1 to 2% most preferred.
16 [0061] The sheet 10 may be fabric, textile, natural or artificial
leather,
17 synthetic material, such as Polyurethane (PO) and the like or composite
material,
18 such as carbon fiber or fiberglass and the like. The sheet 10 may be
composed of
19 one or multiple layers, and may include multiple pieces that are sewn,
bonded or
otherwise connected to form the sheet 10. In a preferred embodiment, desired
21 graphical features are printed or otherwise applied to the pieces that
make up the
22 sheet 10 when the sheet and/or pieces are flat This may occur before or
after the
23 pieces are assembled to form the sheet 10. In one embodiment, after
graphical
24 features are applied, and/or after desired visual or tactical treatments
have been
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3 embodiment, one or more of the pieces may have three-dimensional features
4 before being attached to other pieces. Further, different pieces may have
different material properties, such as expandability, thickness, color,
porosity or
6 the like.
7 100621 Preferably the sheet 10 has a peripheral rim 12 along an edge.
8 In the illustrated embodiment, the peripheral rim 12 is an integral part
of the
9 sheet 10 as shown in Fig. 2. Alternatively, the peripheral rim 12A can be
a
separately-manufactured element securely mounted on the periphery of the sheet
11 10A as. shown in Fig. 3, and the peripheral rim 12A is made of a
material that can
12 be the same or different from the sheet 10A. For example, in one
embodiment
13 the sheet 10A is fabric and the peripheral rim 12A is artificial
leather. In another
14 embodiment the sheet 10A and peripheral rim 12A are both fabric, but
fabric
having different properties such as expandability/elasticity, thickness,
color, etc.
16 Preferably a plurality of anchor tabs 13 are provided spaced apart along
the
17 peripheral rim 12,12A. In the illustrated embodiment, each anchor tab 13
has an
18 aperture 14.
19 100631 In the act of providing a mold assembly 20, with further
reference to Fig. 4, the mold assembly 20 in one embodiment comprises a
21 combinative outer mold 22 and an inner mold 24 configured to form a mold
22 cavity between the outer mold 22 and the inner mold 24 when the mold is
in a
23 closed position. The combinative outer mold 22 may comprise two side
mold
24 elements 222 and a top mold element 226.
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1 [0064] The inner
mold 24 is mounted between the side mold elements
2 222 and the top
mold element 226. The side mold elements 222 and the top mold
3 element 226 are
moveable to combine with the inner mold 24 to form a mold
4 cavity between
the inner mold 24 and the mold elements 222,226 of the outer
mold 22.
6 [0065] Fig. 4
includes arrows representing relative movement of
7 portions of the
mold embodiment. It is to be understood that these arrows
8 represent
relative movement between the elements of the mold, and various
9 specific
strategies can be employed for moving the mold portions relative to one
another. For example, in one embodiment the inner mold 24 is held stationary
11 and the top mold
element 226 moves into engagement with the inner mold 24. In
12 another
embodiment the top mold element 226 is stationary and the inner mold
13 24 moves upwardly
into engagement with the top mold element 226. In other
14 embodiments other
mold elements, or none of the mold elements, can be held
stationary while the other mold elements move relative thereto.
16 [0066] The inner
mold 24 has a mold block 242 comprising a base 244
17 and a shaping
block 246. The base 244 is formed on and protrudes from the top
18 of the inner mold
24. The shaping block 246 is formed on and protrudes from the
19 top of the base
244 and has a three dimensional shape corresponding to a desired
shape of a completed skate shell which, in a preferred embodiment, generally
21 follows the external anatomical three dimensional shape of a foot.
22 [0067] In some
embodiments the shaping block 246 will be contoured
23 to diverge from a
foot shape sufficiently to accommodate inserts such as
24 padding, stiffeners and/or vibration-dissipating elements. Preferably, the
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1 shaping block 246 has two protrusions 247 formed respectively on two
sides of
2 the shaping block 246. The protrusions 247 may be formed on the shaping
block
3 246 at different heights and may protrude from the shaping block 246 in
different
4 heights. In the illustrated embodiment the protrusions are shaped to
generally
5 follow and accommodate the shapes of human malleolus bones, which it is
6 anticipated will be accommodated within the skate shell.
7 [0068] With continued reference to Fig. 4, the base 244 is larger than
8 the shaping block 246 in cross section area, such that a ledge 245 is
formed
9 between the base 244 and the shaping block 246 and around the mold block
242.
10 The ledge 245 has a width corresponding to the desired thickness of the
skate
11 shell so that, when the mold is closed the ledge 245 defines a border of
the mold
12 cavity. The ledge 245 can be leveled or angled in shape as desired.
13 [0069] In the act of forming the sheet 10 into a shaped sheet 18, the
14 flat, expanded sheet 10 is formed into a three dimensional shape by
sewing,
15 adhering, pressing or otherwise processing to the shape as shown in Fig.
5 and is
16 preferably formed in a shape corresponding to that of the skate shell.
More
17 specifically, preferably the shaped sheet 18 includes vamp, quarter,
heel and sole
18 panels connected together. In other embodiments the shaped sheet 18 may
19 include more or less panels. For example, in one embodiment the shaped
sheet
may not include a sole panel.
21 [0070] A heel element 16 as shown in Figs. 2, 3 and 5 preferably is
22 attached to a heel segment of the shaped sheet 18 to enable the shaped
sheet 18 to
23 firmly hold at the three dimensional form and to close holes or notches
formed in
24 the shaped sheet 18 due to that the expanded sheet 10,10A is formed into
the
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1 shaped sheet 18 by sewing or adhering. The heel piece 16 can be made of a
2 material different from that of sheet 10,10A. For example, the heel piece
16 may
3 be thicker, thinner, more or less expandable, or the like, than other
portions of
4 the sheet 10.
100711 In the act of mounting the shaped sheet 18 around and
6 positioned on the inner mold 24, with reference to Figs. 4 and 5, the
shaped sheet
7 18 is mounted around the shaping block 246 and positioned on the base 244
of
8 the mold block 242 on the inner mold 24 with a positioning assembly. In
the
9 illustrated embodiment, the positioning assembly comprises multiple
hanging
stubs 248 configured to engage corresponding hanging holes 14 on the anchor
11 tabs 13. The hanging stubs 248 preferably are mounted on the base 244 of
the
12 mold block 242 at positions outside the mold cavity and are arranged
around the
13 mold cavity. The hanging holes 14 are separately defined through the
peripheral
14 rim 12 of the sheet 10 as shown in Fig. 2.
[0072] To position the shaped sheet 18 on the mold block 242 of the
16 inner mold 24, and the shaped sheet 18 is hung onto the hanging stubs
248 by the
17 hanging holes 14. Multiple separate anchor tabs 13 may be formed around
the
18 peripheral rim 12, and the hanging holes are defined respectively
through the
19 anchor tabs 13. In addition, with the hanging stubs 248 being mounted on
positions outside the mold cavity in the illustrated embodiment, the
peripheral
21 rim 12 extends out of the mold cavity when the mold assembly 20 is
closed. In
22 another embodiment, a portion of the peripheral rim 12 is within the
mold cavity
23 when the mold assembly 20 is closed. In a further embodiment,
substantially the
24 entire peripheral rim is within the mold cavity when the mold assembly
is closed,
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1 so that only the anchor tabs 13 extend out of the mold cavity so as to
engage the
2 hanging stubs 248. In still other embodiments, both the peripheral rim
and the
3 hanging stubs are within the mold cavity when the mold assembly is
closed.
4 Such embodiments may employ anchor tabs 13 or may have hanging holes
formed through the peripheral rim.
6 [0073] Preferably, engaging the hanging holes 14 onto the stubs 248
7 holds the shaped sheet 18 in place on the mold block 242. More
preferably, with
8 the positioning assembly engaged the shaped sheet 18 is held tightly on
the mold
9 block 242 so that the shaped sheet18 is under tension and is stretched or
expanded so as to conform to the mold block shape. For example, mounting the
11 shaped sheet 18 onto the mold block 242 preferably involves
12 stretching/expanding the shaped sheet in order to engage the holes 14
onto the
13 stubs 248. As such, the shaped sheet 18 is held tautly over the mold
block 242.
14 Preferably, the tension in the shaped sheet 18 is sufficient so that the
sheet will
not wrinkle when molten plastic is later injected, but not so taut as to break
16 during the plastic injection process.
17 [00741 With reference to Fig. 4, the hanging stub 248 is an integral
18 part of the base 244 of the mold block 242. With reference to Figs. 13
and 13A,
19 in another embodiment the hanging stub 248A is retractably mounted on
the
base 244 of the mold block 242. In this embodiment, multiple stub holes 2442
21 are defined in the base 244, and the hanging stubs 248A are mounted
22 respectively in the stub holes 2442 in the base 244. A spring 249 is
mounted in
23 each stub hole 2442 and abuts with the corresponding hanging stub 248A
to push
24 one end of the hanging stub 248A out of the stub hole 2442 and protrude
from
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1 the base 244.
Consequently, the shaped sheet 18 is also hung onto the hanging
2 stubs 248A by the hanging holes 14.
3 [0075]
Alternatively, the positioning assembly may include hooks,
4 dampers or the
like to position the rim 12 of the shaped sheet 18 securely on the
mold block 242. In further embodiments the shaped sheet 18 may be fit over the
6 mold block 242
without a positioning assembly, and may be held tightly in place
7 when the mold assembly is closed and engages the peripheral rim 12.
8 [0076] In the act
of closing the mold assembly 20, with reference to
9 Figs. 4, 6, 6A
and 6B, the side mold elements 222 and the top mold element 226
of the outer mold 22 are moved toward and combined with the inner mold 24,
11 such that the
mold cavity is formed between the inner mold 24 and the outer
12 mold 22 when the
mold assembly 20 is closed. The peripheral rim 12 of the
13 shaped sheet 18
is squeezed by the inner mold 24 and the side mold elements 222
14 of the outer mold 22 below the ledge 245.
[0077] In the illustrated
embodiment, multiple stub holes 224 are
16 defined in the
inner surfaces of the side mold elements 222 of the outer mold 22
17 and respectively
correspond to the hanging stubs 248 on the mold block 242 of
18 the inner mold
24. When the mold assembly 20 is closed, the hanging stubs 248
19 are respectively
inserted into the stub holes 224 in the side mold elements 222 to
enable the inner mold 24 and the outer mold 22 to be combined with each other
21 tightly.
22 [0078] In the
embodiment shown in Figs. 13 and 13A, when the mold
23 assembly 20 is
closed, the hanging stubs 248A are pushed to retract into the stub
CA 02759134 2011-11-15
19
1 holes 2442 in the base 244 by the side mold elements 222 to enable the
inner
2 mold 24 and the outer mold 22 to be combined with each other tightly.
3 [00791 Once the shaped sheet 18 is appropriately placed in the mold
4 and the mold closed, molten plastic material is injected into the mold
cavity via
injection channels 228 defined in the outer mold 22. The molten plastic
material
6 may be thermoplastic or thermosetting plastic. The injection channels 228
are
7 preferably defined in the top mold element 226 of the outer mold 22.
However,
8 it is to be understood that, in other embodiments, injection channels 228
can be
9 provided in other mold elements such as the side mold elements 222 or
even the
inner mold 24. In the illustrated embodiment the molten plastic material may
be
11 injected to surround the shaped sheet 18 that is mounted around the mold
block
12 242 on the inner mold 24. The molten plastic is injected under pressure
and,
13 because the shaped sheet 18 is expandable, the molten plastic will fill
the mold
14 cavity around the shaped sheet 18 and urge the sheet even more tightly
against
the mold block 242 so that the shaped sheet 18 assumes the shape of the mold
16 block 242 and the plastic assumes the shape of the outer mold 22. The
molten
17 plastic material cools to form the body of the skate shell 30, and the
shaped sheet
18 18 will be tightly and smoothly bonded to and fused with the inner
surface of the
19 body of the skate shell 30 in a three dimensional shape based on the
shape of the
shaping block 246 of the mold block 242 as shown in Fig. 7.
21 [00801 Alternatively, with reference to Fig. 8, the shaped sheet 18A
22 may further have at least one injection hole 182 defined through the
shaped sheet
23 18A, and at least one nozzle 229 is detachably mounted on the mold
assembly
24 20, is preferably detachably inserted into the injection channels 228 in
the top
CA 02759134 2011-11-15
1 mold element 226 of the outer mold 22 and extends respectively through
the at
2 least one injection hole 182 in the shaped sheet 18A when the mold
assembly 20
3 is closed. When the molten plastic material is injected into the mold
cavity, the
4 molten plastic material will be disposed between the mold block 242 and
the
5 shaped sheet 18A. Accordingly, the shaped sheet 18A will be forced
against, and
6 take on the shape of, the outer mold 22, and the plastic will take on the
shape of
7 the mold block 242 so that the skate shell 30A,30B can be formed between
the
8 mold block 242 and the shaped sheet 18A,18B, and the shaped sheet 18A,18B
9 can be expanded tightly by the molten plastic material and securely
bonded to
10 the outer surface of the skate shell 30A,30B after the molten plastic
material is
11 cooled as shown in Figs. 9 and 10.
12 [00811 Preferably the nozzle 229 is detachably inserted into the
13 injection channels 228. As such, the same mold assembly 20 can be
selectively
14 applied to form a skate shell 30,30A,30B with a shaped sheet 18,18A,18B
15 bonded onto the inner or outer surface of the body of the skate shell
30,30A,30B.
16 Therefore, the mold assembly 20 can be applied to different
manufacturing
17 needs and is versatile in use. In additional embodiments, one or more
injection
18 channels can be provided through the mold block 242 rather than through
the
19 outer mold 22.
20 [00821 As noted above, in some embodiments graphics are applied to
21 the sheet 10 before it is formed into the shaped sheet 18. Thus, in
embodiments
22 in which the shaped sheet is molded so as to be on the outer surface of
the body
23 of the skate shell, the graphics are already applied, and do not have to
be applied
24 to a three dimensional shell. In one embodiment in which the shaped
sheet is
CA 02759134 2011-11-15
21
I molded so as to be on the inner surface of the body of the skate shell,
the plastic
2 employed can be clear and/or otherwise configured so that graphics on the
3 shaped sheet 18 are visible through the plastic shell.
4 100831 In still further embodiments, mold pieces can be mixed and
matched in order to take the differing manufacturing approaches. For example,
6 in order to form an embodiment in which the plastic shell is on the
inside and the
7 shaped sheet is on the outside, a mold block with injection channels may
be
8 employed, and molten plastic injected only through the mold block
channels. In
9 order to form an embodiment in which the plastic shell is on the outside
and the
shaped sheet is on the inside, molten plastic will be injected only through
11 injection channels on the outer mold.
12 100841 Once the plastic has sufficiently cooled, the mold assembly 20
13 is opened, and the skate shell 30,30A,30B with the shaped sheet
18,18A,18B is
14 taken out of the mold assembly 20.
[00851 With the method in accordance with the present invention, a
16 one-piece, three-dimensional and non-lasted skate shell 30,30A,30B can
be
17 formed. The skate shell 30,30A,30B comprises a body including a vamp and
a
18 sole panel and may, in some embodiments, be kept free from a toecap
and/or a
19 tongue. The body of the skate shell 30,30A,30B has an inner surface and
an outer
surface, and a three dimensional shaped sheet 18,18A,1813 is bonded on one of
21 the inner surface and the outer surface of the body and covering
completely or
22 partially the vamp and the sole panel. With the protrusions 247 formed
on the
23 shaping block 246 of the inner mold 24, the body of the skate shell
30,30A,30B
24 has two ankle bone cavities defmed in the vamp to fit with the ankle
bones of a
CA 02759134 2011-11-15
22
1 user. Accordingly, the skate shell has a contour matching with that of
the foot of
2 the user.
3 100861 In the illustrated embodiment the skate shell 30,30A,30B is
4 formed as a single structure including the sole panel, and the thickness
and/or
material of the sole panel can be selected so that the sole panel is rigid
enough
6 without requiring additional outsole support to rivet or screw with a
skate blade
7 holder 60 as shown in Fig. 11 on the sole panel, the durability of the
skate shell
8 30,30A,30B is increased. Consequently, the force a user applies to move
the
9 skates can be more efficiently transmitted from the skate shell
30,30A,30B to the
skate blade holder 60 without the energy losses common to multipiece
11 constructions. Therefore, the force transmission between the sole panel
of the
12 body and the skate blade holder 60 is improved, and a skate with the
skate shell
13 30,30A,30B in accordance with the present invention is laborsaving. In
addition,
14 further proceeding steps, such as sewing, adhering or combining the sole
of the
skate shell, are unnecessary.
16 100871 After the molding step is complete, preferably the anchor tabs
17 13 are trimmed off the peripheral rim. As such, in the molded shell,
plastic is
18 bonded to one surface of most or all of the shaped sheet 18 except at
the
19 peripheral rim. Steps to complete a skate boot are then performed. For
example,
lace holes are formed through the shell, and the skate shell 30,30A,30B can be
21 combined with the other components of an ice skate or an in-line skate,
such as
22 lining, toecap, tongue, additional padding and/or impact absorbing
materials, a
23 blade holder 60, chassis, wheels and other elements that are known to
those
24 skilled in the art of a footwear directly as shown in Fig. 11.
Therefore, the
CA 02759134 2011-11-15
23
1 fabrication of an ice skate or an in-line skate can be efficiently
simplified, and
2 the cost of the fabrication of a skate can be decreased.
3 [0088] In a preferred embodiment the lining and/or padding and
4 impact absorbing materials are sewn, glued or otherwise attached to the
shell at
the portion of the peripheral rim to which plastic is not bonded. In further
6 embodiments, the lining may be sewn to the shell at the peripheral rim,
where
7 plastic does not interfere with the stitching, and may be attached to
other, spaced
8 apart portions of the shell to which plastic is bonded by other
attachment means,
9 such as glue.
[0089] In another embodiment, lace holes are formed through the
11 peripheral rim, which was not coinjected with the molten plastic. In
further
12 embodiments portions of the peripheral rim are trimmed along a trimmed
edge,
13 so that the peripheral rim to which plastic is not bonded is retained
adjacent a
14 portion of the length of the trimmed edge, and plastic is bonded to the
surface of
the shaped sheet up to the another portion of the length of the trimmed edge.
16 Further, in additional embodiments some lace holes are formed through
the
17 shell, and other lace holes are formed through a portion of the rim that
was not
18 coinjected with the plastic. In still further embodiments the entire
peripheral rim
19 is trimmed off after molding is complete so that plastic is bonded to
the surface
of the shaped sheet up to the trimmed edge.
21 [0090] In addition, because the sheet 18,18A,18B can be tightly and
22 smoothly bonded with the body of the skate shell 30,30A,30B along the
surfaces
23 of the skate shell 30,30A,30B, the sheet 18,18A,18B is bonded onto the
body of
24 the skate shell 30,30A,30B in a three dimensional arrangement instead of
only
CA 02759134 2011-11-15
24
1 limited to a single surface arrangement. Therefore, the appearance of the
skate
2 shell can be improved and versatile. In addition, the sheet 18,18A,18B
can be
3 arranged to completely cover the sole panel of the skate shell 30,30A,30B
as
4 shown in Figs. 7, 9 and 10. Alternatively, the sheet can be arranged to
partially
cover the sole panel of the skate shell, especially to cover two side edges of
the
6 sole panel of the skate shell. Therefore, the shape and the arrangement
of the
7 sheet 18,18A,18B can be varied to fit different design needs.
8 [0091] With reference to Fig. 12, the shaped sheet 18C may be
9 composed of three sheet pieces including a vamp sheet piece 181C, a sole
piece
182C and a heel piece 16C. The sole piece 182C and the vamp sheet piece 181C
11 may be made of different materials. Preferably, the sole piece 182C has
higher
12 expansibility than that of the vamp sheet piece 181C. Preferably, the
vamp sheet
13 piece 181C is made of composite material with a low expansibility and
the sole
14 piece 182C is made of fabric, textile or leather with a relatively high
expansibility. The heel piece 16C can be made of a material different from
those
16 for the vamp sheet pieces 181C or the sole piece 182C. Furthermore, a
17 decorative outsole can be attached to the sole panel of the body of the
skate shell
18 to improve the aesthetic effect of the skate shell.
19 [0092] With reference to Figs. 14 and 15, the sheet 10D may further
comprise at least one auxiliary sheet 11 mounted on the sheet 10D. With the
21 arrangement of the auxiliary sheets 11, the thickness of the sheet 1013
on the
22 position where the auxiliary sheets 11 are mounted is increased.
Accordingly,
23 after the body of the skate shell is formed, with reference to Figs. 16
and 17, the
24 thickness of the injected thermoplastic/thermosetting plastic body in
the area 31
CA 02759134 2011-11-15
1 where the
auxiliary sheets 11 and the sheet 10 are both presented is reduced. This
2 reduced
thickness gives the aforementioned area 31 of the skate shell higher
3 flexibility than those other segments of the body of the skate shell 30D.
4 Therefore, the
body of the skate shell has different pliancy in different areas to
5 accommodate the designs or needs for a skate.
6 [0093] In
another embodiment, the mold cavity can be provided with
7 different
thicknesses on positions corresponding to different segments of the
8 plastic body of
the skate shell 30 to fit different skate shell performance design
9 needs. For
example, rather than or in addition to having a thicker sheet as shown
10 in connection
with the embodiment illustrated in Figs. 14-15, the mold cavity
11 can be shaped so
as to have reduced thickness in the desired area, thus leading to
12 a skate shell
that is more flexible in the thin area than elsewhere in the shell. In
13 still further
embodiments the mold can be configured to create shapes conducive
14 to selective
bending. For example, the ankle area employing the auxiliary sheet
15 11 in Figure 14
can also, or instead, be configured so that the molten plastic is
16 formed into a shape having multiple elongate ribs that cooperate to
17 accommodate bending in a desired direction, but resist bending in other
18 directions. Such
structures can be incorporated into the mold shape, so that the
19 resultant shell
may include shapes that structurally enhance performance or, in
20 other
embodiments, provide desired decorative features. In another
21 embodiment, a
second mold is provided, and injection-molding of the sheet
22 involves a
second plastic injection process. For example, plastic having a first
23 set of
properties is injected in the first mold. The sheet is then removed and
24 placed in the
second mold for a second injection of plastic having a second set of
CA 02759134 2011-11-15
26
1 properties. As such, properties of the shell such as localized areas of
changing
2 thickness, flexibility, color and the like can be constructed. Further
3 embodiments may include still further injection processes.
4 [0094] Additionally, in other embodiments the shaped sheet 18 can
have inserts attached thereto. Such inserts may be made of plastic, metal,
etc.,
6 and cooperate with the mold cavity to create a shell having desired
structural and
7 graphical properties. Similarly, it is contemplated that in other
embodiments the
8 mold cavity can be configured so that no plastic is injected against some
portions
9 of the shaped sheet 18.
100951 Even though numerous characteristics and advantages of the
11 present invention have been set forth in the foregoing description,
together with
12 details of the structure and function of the invention, the disclosure
is illustrative
13 only. Changes may be made in detail, especially in matters of shape,
size, and
14 arrangement of parts within the principles of the invention to the full
extent
indicated by the broad general meaning of the terms in which the appended
16 claims are expressed.
17 (0096) Although this invention has been disclosed in the context of
18 certain preferred embodiments and examples, it will be understood by
those
19 skilled in the art that the present invention extends beyond the
specifically
disclosed embodiments to other alternative embodiments and/or uses of the
21 invention and obvious modifications and equivalents thereof. In
addition, while
22 a number of variations of the invention have been shown and described in
detail,
23 other modifications, which are within the scope of this invention, will
be readily
24 apparent to those of skill in the art based upon this disclosure. It is
also
CA 02759134 2011-11-15
27
contemplated that various combinations or subcombinations of the specific
2 features and aspects of the embodiments may be made and still fall within
the
3 scope of the invention. Accordingly, Applicants contemplate that various
4 features and aspects of the disclosed embodiments can be combined with or
substituted for one another in order to form varying modes of the disclosed
6 invention. Thus, it is intended that the scope of the present invention
herein
7 disclosed should not be limited by the particular disclosed embodiments
8 described above, but should be determined only by a fair reading of the
claims
9 that follow.
