Skate or other footwear

A skate (e.g., an ice skate) for a skater (e.g., a hockey player). The skate comprises a skate boot for receiving a foot of the skater and a skating device (e.g., a blade and a blade holder) disposed beneath the skate boot to engage a skating surface (e.g., ice). At least part of the skate boot and optionally at least part of one or more other components (e.g., the skating device) may be constructed from one or more materials (e.g., foams) molded by flowing in molding equipment during a molding process (e.g., injection molding or casting). This may allow the skate (or other footwear) to have useful performance characteristics (e.g., reduced weight, proper fit and comfort, etc.) while being more cost-effectively manufactured. Other articles of footwear are also provided.

FIELD

The invention generally relates to footwear, including skates (e.g., ice skates) such as for playing hockey and/or for other activities.

BACKGROUND

Skates are used by skaters in various sports such as ice hockey, roller hockey, etc. A skate comprises a skate boot that typically comprises a number of components that are assembled together to form the skate boot. This can include a shell, a toe cap, a tongue, a tendon guard, etc.

For example, an approach to manufacturing a shell of a skate boot of conventional skates consists of thermoforming different layers of synthetic material and then assembling these layers to form the shell. However, such conventional skates may sometimes be overly heavy, uncomfortable, lacking in protection in certain areas, and/or a bad fit on a skater's foot. Moreover, such conventional skates can be expensive to manufacture.

Similar considerations may arise for other types of footwear (e.g., ski boots, motorcycle boots, work boots, etc.). For these and/or other reasons, there is a need for improvements directed to skates and other footwear.

SUMMARY

In accordance with various aspects of the invention, there is provided a skate (e.g., an ice skate) for a skater. The skate comprises a skate boot for receiving a foot of the skater and a skating device (e.g., a blade and a blade holder) disposed beneath the skate boot to engage a skating surface. At least part of the skate boot and optionally at least part of one or more other components (e.g., the skating device) of the skate is constructed from one or more materials (e.g., foams) molded by flowing in molding equipment during a molding process (e.g., injection molding or casting). This may allow the skate to have useful performance characteristics (e.g., reduced weight, proper fit and comfort, etc.) while being more cost-effectively manufactured. Other articles of footwear are also provided.

In accordance with an aspect of the invention, there is provided a skate boot for a skate, the skate comprising a skating device disposed beneath the skate boot to engage a skating surface, the skate boot defining a cavity to receive a foot of a user, the skate boot comprising a body that comprises a medial side portion to face a medial side of the user's foot, a lateral side portion to face a lateral side of the user's foot, a heel portion to receive a heel of the user's foot, and an ankle portion to receive an ankle of the user, wherein: the medial side portion, the lateral side portion, the heel portion, and the ankle portion of the body are molded together and integral with one another; and the body comprises a plurality of layers comprising a plurality of materials that are different and molded by flowing.

In accordance with another aspect of the invention, there is provided a method of making a skate boot for a skate, the skate comprising a skating device disposed beneath the skate boot to engage a skating surface, the skate boot defining a cavity to receive a foot of a user, the method comprising: providing a molding apparatus; and molding a body of the skate boot using the molding apparatus, the body comprising a medial side portion to face a medial side of the user's foot, a lateral side portion to face a lateral side of the user's foot, a heel portion to receive a heel of the user's foot, and an ankle portion to receive an ankle of the user, wherein: the medial side portion, the lateral side portion, the heel portion, and the ankle portion of the body are molded together and integral with one another; and the molding comprises causing flow of a plurality of materials that are different in the molding apparatus to form a plurality of layers of the body.

In accordance with another aspect of the invention, there is provided an article of footwear for receiving a foot of a user, the article of footwear comprising a body that comprises a medial side portion to face a medial side of the user's foot, a lateral side portion to face a lateral side of the user's foot, a heel portion to receive a heel of the user's foot, and an ankle portion to receive an ankle of the user, wherein: the medial side portion, the lateral side portion, the heel portion, and the ankle portion of the body are molded together and integral with one another; and the body comprises a plurality of layers comprising a plurality of materials that are different and molded by flowing.

In accordance with another aspect of the invention, there is provided a skate boot for a skate, the skate comprising a skating device disposed beneath the skate boot to engage a skating surface, the skate boot defining a cavity to receive a foot of a user, the skate boot comprising a body that comprises a medial side portion to face a medial side of the user's foot, a lateral side portion to face a lateral side of the user's foot, a heel portion to receive a heel of the user's foot, and an ankle portion to receive an ankle of the user, wherein: the medial side portion, the lateral side portion, the heel portion, and the ankle portion of the body are molded together and integral with one another; and the body comprises a plurality of injection-molded layers comprising a plurality of materials that are different.

In accordance with another aspect of the invention, there is provided a method of making a skate boot for a skate, the skate comprising a skating device disposed beneath the skate boot to engage a skating surface, the skate boot defining a cavity to receive a foot of a user, the method comprising: providing an injection molding apparatus; and injection molding a body of the skate boot using the injection molding apparatus, the body comprising a medial side portion to face a medial side of the user's foot, a lateral side portion to face a lateral side of the user's foot, a heel portion to receive a heel of the user's foot, and an ankle portion to receive an ankle of the user, wherein: the medial side portion, the lateral side portion, the heel portion, and the ankle portion of the body are molded together and integral with one another; and the body comprises a plurality of injection-molded layers comprising a plurality of materials that are different.

In accordance with another aspect of the invention, there is provided a skate boot for a skate, the skate comprising a skating device disposed beneath the skate boot to engage a skating surface, the skate boot defining a cavity to receive a foot of a user, the skate boot comprising: a body comprising a medial side portion to face a medial side of the user's foot, a lateral side portion to face a lateral side of the user's foot, a heel portion to receive a heel of the user's foot, and an ankle portion to receive an ankle of the user; a tendon guard projecting upwardly from the body; and a slash guard comprising a cut-resistant material, extending above the body, and movable relative to the tendon guard.

These and other aspects of the invention will now become apparent to those of ordinary skill in the art upon review of the following description of embodiments of the invention in conjunction with the accompanying drawings.

In the drawings, embodiments of the invention are illustrated by way of example. It is to be expressly understood that the description and drawings are only for purposes of illustration and as an aid to understanding, and are not intended to be a definition of the limits of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

FIG. 1shows an example of footwear10for a wearer in accordance with an embodiment of the invention. In this example, the footwear10is a skate for a skater to skate on a skating surface12. In this embodiment, the skate10is a hockey skate for the skater who is a hockey player playing hockey. In this example, the skate10is an ice skate, a type of hockey played is ice hockey, and the skating surface12is ice.

The skate10comprises a skate boot22for receiving a foot11of the player and a skating device28disposed beneath the skate boot22to engage the skating surface12. In this embodiment, the skating device28comprises a blade26for contacting the ice12and a blade holder24between the skate boot22and the blade26. The skate10has a longitudinal direction, a widthwise direction, and a heightwise direction.

In this embodiment, as further discussed below, the skate10, including at least part of the skate boot22and possibly at least part of one or more other components (e.g., the blade holder24), is constructed from one or more materials (e.g., foams) molded by flowing in molding equipment during a molding process (e.g., injection molding or casting). This may allow the skate10to have useful performance characteristics (e.g., reduced weight, proper fit and comfort, etc.) while being more cost-effectively manufactured.

The skate boot22defines a cavity54for receiving the player's foot11. With additional reference toFIGS. 94 and 95, the player's foot11includes toes T, a ball B, an arch ARC, a plantar surface PS, a top surface TS, a medial side MS, and a lateral side LS. The top surface TS of the player's foot11is continuous with a lower portion of a shin S of the player. In addition, the player has a heel HL, an Achilles tendon AT, and an ankle A having a medial malleolus MM and a lateral malleolus LM that is at a lower position than the medial malleolus MM. The Achilles tendon AT has an upper part UP and a lower part LP projecting outwardly with relation to the upper part UP and merging with the heel HL. A forefoot of the player includes the toes T and the ball B, a hindfoot of the player includes the heel HL, and a midfoot of the player is between the forefoot and the hindfoot.

The skate boot22comprises a front portion56for receiving the toes T of the player, a rear portion58for receiving the heel HL and at least part of the Achilles tendon AT and the ankle A of the player, and an intermediate portion60between the front portion56and the rear portion58.

More particularly, in this embodiment, the skate boot22comprises a shell30, a toe cap32, a tongue34, a tendon guard35, a liner36, a footbed38, and an insole40. The skate boot22also comprises lace members441,442and eyelets461-46Eextending through (e.g., punched into) the lace members441,442, the shell30and the liner36vis-à-vis apertures48in order to receive laces for tying on the skate10. In some embodiments, the skate boot22may not comprise any lace members and the eyelets461-46Emay extend directly through the shell30and the liner36via the apertures48.

The shell30is a body of the skate boot22that imparts strength and structural integrity to the skate10to support the player's foot11. More particularly, in this embodiment, as shown inFIG. 3, the shell30comprises a heel portion62for receiving the heel HL of the player, an ankle portion64for receiving the ankle A of the player, medial and lateral side portions66,68for respectively facing the medial and lateral sides MS, LS of the player's foot11, and a sole portion69for facing the plantar surface PS of the player's foot11. The shell30thus includes a quarter75which comprises a medial quarter part77, a lateral quarter part79, and a heel counter81. The medial and lateral side portions66,68include upper edges70,72which, in this embodiment, constitute upper edges of the lace members441,442(i.e., the lace members441,442are made integrally with the shell as will be described later). The heel portion62may be formed such that it is substantially cup-shaped for following the contour of the heel HL of the player. The ankle portion64comprises medial and lateral ankle sides74,76. The medial ankle side74has a medial depression78for receiving the medial malleolus MM of the player and the lateral ankle side76has a lateral depression80for receiving the lateral malleolus LM of the player. The lateral depression80is located slightly lower than the medial depression78for conforming to the morphology of the player's foot11. The ankle portion64further comprises a rear portion82facing the lower part LP of the Achilles tendon AT of the player.

In this embodiment, with additional reference toFIG. 11, the shell30comprises one or more materials molded into a shape of the shell30by flowing in a molding apparatus150during a molding process (e.g., injection molding or casting). More particularly, in this embodiment, the shell30comprises a plurality of materials M1-MNthat are molded into the shape of the shell30by flowing in the molding apparatus150during the molding process. The materials M1-MNare different from one another, such as by having different chemistries and/or exhibiting substantially different values of one or more material properties (e.g., density, modulus of elasticity, hardness, etc.). In this example, the materials M1-MNare arranged such that the shell30comprises a plurality of layers851-85Lwhich are made of respective ones of the materials M1-MN. In that sense, in this case, the shell30may be referred to as a “multilayer” shell and the layers851-85Lof the shell30may be referred to as “subshells”. This may allow the skate10to have useful performance characteristics (e.g., reduced weight, proper fit and comfort, etc.) while being more cost-effectively manufactured.

The materials M1-MNmay be implemented in any suitable way. In this embodiment, each of the materials M1-MNis a polymeric material. For example, in this embodiment, each of the polymeric materials M1-MNis polyurethane (PU). Any other suitable polymer may be used in other embodiments (e.g., polypropylene, ethylene-vinyl acetate (EVA), nylon, polyester, vinyl, polyvinyl chloride, polycarbonate, polyethylene, an ionomer resin (e.g., Surlyn®), styrene-butadiene copolymer (e.g., K-Resin®) etc.), self-reinforced polypropylene composite (e.g., Curv®), or any other thermoplastic or thermosetting polymer).

In this example of implementation, each of the polymeric materials M1-MNis a foam. In this case, each of the polymeric materials M1-MNis a PU foam. This foamed aspect may allow the shell30to be relatively light while providing strength. For instance, in some embodiments, a density of each of the polymeric materials M1-MNmay be no more than 40 kg/m3, in some cases no more than 30 kg/m3, in some cases no more than 20 kg/m3, in some cases no more than 15 kg/m3, in some cases no more 10 kg/m3and in some cases even less. One or more of the polymeric materials M1-MNmay not be foam in other examples of implementation.

In this embodiment, the materials M1-MNof the subshells851-85Lof the shell30constitute at least part of the heel portion62, the ankle portion64, the medial and lateral side portions66,68, and the sole portion69of the shell30. More particularly, in this embodiment, the materials M1-MNconstitute at least a majority (i.e., a majority or an entirety) of the heel portion62, the ankle portion64, the medial and lateral side portions66,68, and the sole portion69of the shell30. In this example, the materials M1-MNconstitute the entirety of the heel portion62, the ankle portion64, the medial and lateral side portions66,68, and the sole portion69of the shell30.

The subshells851-85Lconstituted by the polymeric materials M1-MNmay have different properties for different purposes.

For instance, in some cases, a polymeric material Mxmay be stiffer than a polymeric material Mysuch that a subshell comprising the polymeric material Mxis stiffer than a subshell comprising the polymeric material My. For example, a ratio of a stiffness of the subshell comprising the polymeric material Mxover a stiffness of the subshell comprising the polymeric material Mymay be at least 1.5, in some cases at least 2, in some cases at least 2.5, in some cases 3, in some cases 4 and in some cases even more.

In some cases, a given one of the subshells851-85Lmay be configured to be harder than another one of the subshells851-85L. For instance, to provide a given subshell with more hardness than another subshell, the hardness of the polymeric materials M1-MNmay vary. For example, a hardness of the polymeric material Mxmay be greater than a hardness of the polymeric material My. For example, in some cases, a ratio of the hardness of the polymeric material Mxover the hardness of the polymeric material Mymay be at least 1.5, in some cases at least 2, in some cases at least 2.5, in some cases at least 3, in some cases at least 4, in some cases at least 5 and in some cases even more.

To observe the stiffness of a subshell85x, as shown inFIG. 72, a part of the subshell85xcan be isolated from the remainder of the subshell85x(e.g., by cutting, or otherwise removing the part from the subshell85x, or by producing the part without the remainder of the subshell85x) and a three-point bending test can be performed on the part to subject it to loading tending to bend the part in specified ways (along a defined direction of the part if the part is anisotropic) to observe the rigidity of the part and measure parameters indicative of the rigidity of the part. For instance in some embodiments, the three-point bending test may be based on conditions defined in a standard test (e.g., ISO 178(2010)).

For example, to observe the rigidity of the subshell85x, the three-point bending test may be performed to subject the subshell85xto loading tending to bend the subshell85xuntil a predetermined deflection of the subshell85xis reached and measure a bending load at that predetermined deflection of the subshell85x. The predetermined deflection of the subshell85xmay be selected such as to correspond to a predetermined strain of the subshell85xat a specified point of the subshell85x(e.g., a point of an inner surface of the subshell85x). For instance, in some embodiments, the predetermined strain of the subshell85xmay be between 3% and 5%. The bending load at the predetermined deflection of the subshell85xmay be used to calculate a bending stress at the specified point of the subshell85x. The bending stress at the specified point of the subshell85xmay be calculated as σ=My/l, where M is the moment about a neutral axis of the subshell85xcaused by the bending load, y is the perpendicular distance from the specified point of the subshell85xto the neutral axis of the subshell85x, and l is the second moment of area about the neutral axis of the subshell85x. The rigidity of the subshell85xcan be taken as the bending stress at the predetermined strain (i.e., at the predetermined deflection) of the subshell85x. Alternatively, the rigidity of the subshell85xmay be taken as the bending load at the predetermined deflection of the subshell85x.

A stiffness of the subshells851-85Lmay be related to a modulus of elasticity (i.e., Young's modulus) of the polymeric materials M1-MNassociated therewith. For example, to provide a given subshell with more stiffness than another subshell, the modulus of elasticity of the polymeric materials M1-MNmay vary. For instance, in some embodiments, the modulus of elasticity of the polymeric material Mxmay be greater than the modulus of elasticity of the polymeric material My. For example, in some cases, a ratio of the modulus of elasticity of the polymeric material Mxover the modulus of elasticity of the polymeric material Mymay be at least 1.5, in some cases at least 2, in some cases at least 2.5, in some cases at least 3, in some cases at least 4, in some cases at least 5 and in some cases even more. This ratio may have any other suitable value in other embodiments.

In some cases, a given one of the subshells851-85Lmay be configured to be denser than another one of the subshells851-85L. For instance, to provide a given subshell with more density than another subshell, the density of the polymeric materials M1-MNmay vary. For instance, in some embodiments, the polymeric material Mxmay have a density that is greater than a density of the polymeric material My. For example, in some cases, a ratio of the density of the material Mxover the density of the material Mymay be at least 1.1, in some cases at least 1.5, in some cases at least 2, in some cases at least 2.5, in some cases at least 3 and in some cases even more. a certain value

In this embodiment, as shown inFIG. 12, the subshells851-85Lcomprise an internal subshell851, an intermediate subshell852and an external subshell853. The internal subshell851is “internal” in that it is an innermost one of the subshells851-85L. That is, the internal subshell851is closest to the player's foot11when the player dons the skate10. In a similar manner, the external subshell853is “external” in that is an outermost one of the subshells851-85L. That is, the external subshell853is furthest from the player's foot11when the player dons the skate10. The intermediate subshell852is disposed between the internal and external subshells851,853.

The internal, intermediate and external subshells851,852,853comprise respective polymeric materials M1, M2, M3. In this embodiment, the polymeric materials M1, M2, M3have different material properties that impart different characteristics to the internal, intermediate and external subshells851,852,853. As a result, in certain cases, a given one of the subshells851,852,853may be more resistant to impact than another one of the subshells851,852,853, a given one of the subshells851,852,853may be more resistant to wear than another one of the subshells851,852,853, and/or a given one of the subshells851,852,853may be denser than another one of the subshells851,852,853.

For instance, a density of each of the internal, intermediate and external subshells851,852,853may vary. For example, in this embodiment, the densities of the internal, intermediate and external subshells851,852,853increase inwardly such that the density of the internal subshell851is greater than the density of the intermediate subshell852which in turn is greater than the density of the external subshell853. For example, the density of the internal subshell851may be approximately 30 kg/m3, while the density of the intermediate subshell852may be approximately 20 kg/m3, and the density of the external subshell853may be approximately 10 kg/m3. The densities of the internal, intermediate and external subshells851,852,853may have any other suitable values in other embodiments. In other embodiments, the densities of the internal, intermediate and external subshells851,852,853may increase outwardly such that the external subshell853is the densest of the subshells851-85L. In yet other embodiments, the densities of the internal, intermediate and external subshells851,852,853may not be arranged in order of ascending or descending density.

Moreover, in this embodiment, a stiffness of the internal, intermediate and external subshells851,852,853may vary. For example, in this embodiment, the stiffness of the internal subshell851is greater than the respective stiffness of each of the intermediate subshell852and the external subshell853.

In addition, in this embodiment, a thickness of the internal, intermediate and external subshells851,852,853may vary. For example, in this embodiment, the intermediate subshell852has a thickness that is greater than a respective thickness of each of the internal and external subshells851,853. For example, in some cases, the thickness of each of the internal, intermediate and external subshells851,852,853may be between 0.1 mm to 25 mm, and in some cases between 0.5 mm to 10 mm. For instance, the thickness of each of the internal, intermediate and external subshells851,852,853may be no more than 30 mm, in some cases no more than 25 mm, in some cases no more than 15 mm, in some cases no more than 10 mm, in some cases no more than 5 mm, in some cases no more than 1 mm, in some cases no more than 0.5 mm, in some cases no more than 0.1 mm and in some cases even less.

In order to provide the internal, intermediate and external subshells851,852,853with their different characteristics, the polymeric materials M1, M2, M3of the internal, intermediate and external subshells851,852,853may comprise different types of polymeric materials. For instance, in this example, the polymeric material M1comprises a generally soft and dense foam, the polymeric material M2comprises a structural foam that is more rigid than the foam of the polymeric material M1and less dense than the polymeric material M1, and the polymeric material M3is a material other than foam. For example, the polymeric material M3of the external subshell853may consist of a clear polymeric coating.

The subshells851-85Lmay be configured in various other ways in other embodiments. For instance, in other embodiments, the shell30may comprise a different number of subshells or no subshells. For example, in some embodiments, as shown inFIG. 39, the shell30may be a single shell and therefore does not comprise any subshells. In other embodiments, as shown inFIG. 40, the shell30may comprise two subshells851-85L.

Moreover, as shown inFIGS. 41A to 41C, when the shell30comprises two subshells, notably interior and exterior subshells85INT,85EXT, if the exterior subshell85EXThas a density that is greater than a density of the interior subshell85INT, a given one of the subshells85INT,85EXTmay have an opening, which can be referred to as a gap, along at least part of the sole portion69of the shell30(e.g., along a majority of the sole portion69of the shell30). For example, as shown inFIG. 41A, in some embodiments, the exterior subshell85EXTmay comprise a gap G at the sole portion69of the shell30such that the interior and exterior subshells85INT,85EXTdo not overlie one another at the sole portion69of the shell30(i.e., the interior subshell85INTmay be the only subshell present at the sole portion69of the shell30). As shown inFIG. 41B, in an embodiment in which the exterior subshell85EXThas a gap at the sole portion69of the shell30, the interior subshell85INTmay project outwardly toward the exterior subshell85EXTat the sole portion69of the shell30and fill in the gap of the exterior subshell85EXTsuch that a thickness of the interior subshell85INTis greater at the sole portion69of the shell30. As another example, as shown inFIG. 41C, in an embodiment in which the interior subshell85INThas a gap at the sole portion69of the shell30, the exterior subshell85EXTmay project inwardly toward the interior subshell85INTat the sole portion69of the shell30and fill in the gap of the interior subshell85INTsuch that a thickness of the exterior subshell85EXTis greater at the sole portion69of the shell30. As shown inFIG. 42, the footbed38may be formed integrally with the shell30such as to cover at least partially an inner surface of the innermost subshell (in this case, the interior subshell85INT) and overlie the sole portion69of the shell30. In other cases, the footbed38may be inserted separately after the molding process of the shell30has been completed.

In some embodiments, as shown inFIGS. 44A and 44B, when the shell30comprises three subshells, notably the internal, intermediate and external subshells851,852,853, and the external subshell853has a density that is greater than a density of the intermediate subshell852, the external subshell853may comprise a gap61at the sole portion69of the shell30and the intermediate subshell852may project into the external subshell853at the sole portion69of the shell30such as to fill in the gap61of the external subshell853. In such embodiments, the intermediate subshell852may have a greater thickness at the sole portion69of the shell30.

In some embodiments, as shown inFIG. 50, the subshells851-85Lof the shell30may include four subshells851,852,853,854.

In this embodiment, the subshells851-85Lconstituted by the polymeric materials M1-MNare integral with one another such that they constitute a monolithic one-piece structure. That is, the subshells851-85Lconstituted by the polymeric materials M1-MNare integrally connected to one another such that the shell30is a one-piece shell. In this example of implementation, this is achieved by the subshells851-85Lbonding to one another in the molding apparatus150during the molding process by virtue of chemical bonding of the polymeric materials M1-MN.

The subshells851-85Lconstituted by the polymeric materials M1-MNare molded into the shape of the shell30by flowing into the molding apparatus150during the molding process. In this embodiment, the molding process comprises causing the polymeric materials M1-MNto flow (i.e., in liquid or other fluid form) in the molding apparatus150so as to form the subshells851-85Land thus the shell30within the molding apparatus150and recovering the shell30from the molding apparatus150once its molding is completed.

In this embodiment, the molding process of the shell30is injection molding and the molding apparatus150comprises a male mold152(also commonly referred to as a “last”) with which all the polymeric materials M1-MNare molded into shape, as shown inFIG. 13. That is, in this example, the last152is a single last with which all of the subshells851-85Lof the shell30are formed. The molding apparatus150also comprises a plurality of female molds1541-154N, each female mold154ibeing configured to contain the last152at different stages of the molding process. In this embodiment, each female mold154icomprises first and second portions155,157that are secured together to contain the last152.

An example of a method for molding the shell30comprising the internal, intermediate and external subshells851,852,853will be described in more detail below with reference toFIGS. 14 to 16.

With additional reference toFIG. 14, in order to mold the internal subshell851, the last152is secured within a first female mold1541to form a mold cavity156between the last152and the first female mold1541. The mold cavity156has a shape of the desired internal subshell851. The mold cavity156is then filled with a desired polymeric material M1via a sprue, runner and gate system (not shown) of the first female mold1541and left to cure. Once the polymeric material M1has cured for a sufficient amount of time to form the internal subshell851, the first female mold1541is opened (i.e., its first and second portions155,157are separated from one another) and removed from the molding apparatus150while the last152remains on the molding apparatus150with the internal subshell851still on it.

At this stage, with additional reference toFIG. 15, in order to form the intermediate subshell852, a second female mold1542is installed on the molding apparatus150. The last152is secured within the second female mold1542to form a mold cavity158between the internal subshell851(and in some cases at least part of the last152) and the second female mold1542. The mold cavity158has a shape of the desired intermediate subshell852. The mold cavity158is then filled with a desired polymeric material M2via a sprue, runner and gate system (not shown) of the second female mold1542and left to cure. Once the polymeric material M2has cured for a sufficient amount of time to form the intermediate subshell852, the second female mold1542is opened (i.e., its first and second portions155,157are separated from one another) and removed from the molding apparatus150while the last152remains on the molding apparatus150with the internal subshell851and the intermediate subshell852still on it.

With additional reference toFIG. 16, in order to form the external subshell853, a third female mold1543is installed on the molding apparatus150. The last152is secured within the third female mold1543to form a mold cavity160between the intermediate subshell852(and in some cases at least part of the last152, and in some cases at least part of the internal subshell851) and the third female mold1543. The mold cavity160has a shape of the desired external subshell853. The mold cavity160is then filled with a desired polymeric material M3via a sprue, runner and gate system (not shown) of the third female mold1543and left to cure.

Once the polymeric material M3has cured for a sufficient amount of time to form the external subshell853, the shell30, including its now formed internal, intermediate and external subshells851,852,853, is demolded from (i.e., removed from) the last152. This may be achieved in various ways. For instance, in some cases, the polymeric materials M1, M2, M3which constitute the internal, intermediate and external subshells851,852,853may have sufficient elasticity to allow an operator of the molding apparatus150to remove the shell30from the last152by flexing the internal, intermediate and external subshells851,852,853of the shell30. In other cases, the shell30may be removed from the last152while at least a given one of the internal, intermediate and external subshells851,852,853has not fully cured such that the shell30has some flexibility that it would not have if the at least one given one of the internal, intermediate and external subshells851,852,853had fully cured. Moreover, in some cases, the last152may be an inflatable last that can be expanded and retracted by controlling a fluid pressure within the last152. For instance, the inflatable last152may be filled with air (or any other fluid) to expand the inflatable last152to a “molding” size at which the molding process is carried out, and then emptied of air to contract the inflatable last152to a “demolding” size that is less than the molding size and at which the demolding of the shell30from the last152can be carried out. In some cases, the last152may comprise a plurality of pieces that may be disassembled to facilitate removal of the shell30from the last152.

While the molding process has been described as being performed on a single molding apparatus150, in some embodiments, the molding process may utilize various molding apparatuses (e.g., molding stations), each apparatus comprising a different female mold154i. In such embodiments, the last152, still mounted with at least one subshell85i, can be moved from one molding station to the next without requiring removal of the female molds installed on the various molding apparatuses.

With additional reference toFIGS. 19 and 20, in some embodiments, the shell30may comprise a reinforcement115disposed between certain ones of the subshells851-85Lof the shell30such as, for example, between the intermediate and external subshells852,853. The reinforcement115is produced separately from the shell30and is configured to reinforce selected areas of the shell30(e.g., the medial and/or lateral side portions66,68of the shell30) such as, for example, to make it stronger or stiffer (e.g., increase resistance to deflection or impacts). In order to include the reinforcement115between the intermediate and external subshells852,853, the reinforcement115is affixed to an exterior surface of the intermediate subshell852after forming the intermediate subshell852and prior to forming the external subshell853. For instance, the reinforcement115may be mechanically affixed (e.g., stapled, stitched, etc.), glued (e.g., via an adhesive), ultrasonically bonded, or affixed in any other suitable way to the exterior surface of the intermediate subshell852.

The reinforcement115may be configured in any suitable way. For instance, as shown inFIG. 20A, the reinforcement115may comprise a plurality of ribs1171-117R(or a single rib117i) which project outwardly from the exterior surface of the intermediate subshell852when the reinforcement115is affixed to the intermediate subshell852. Moreover, the ribs1171-117Rmay extend on the shell30and/or on the blade holder24. As shown inFIG. 20B, in some embodiments, the ribs1171-117Rmay extend from the shell30to the blade holder24. That is, the ribs1171-117Rhave a vertical extent that spans the blade holder24and the shell30. In other examples, the ribs1171-117Rmay span the blade holder24, the shell30and the lace members441,442. Furthermore, in some cases, the ribs1171-117Rmay not all be disposed between the same subshells. For example, in some cases, a first rib117imay be disposed between the intermediate and external subshells852,853while a second rib117jis disposed between the internal and intermediate subshells851,852.

Alternatively, as shown inFIG. 21, the reinforcement115may comprise a reinforcing sheet119that is similarly affixed to the exterior surface of the intermediate subshell852(e.g., glued thereto). In this embodiment, the reinforcing sheet119comprises a material that is stiffer and/or harder than the polymeric material M2of the intermediate subshell852. For instance, the reinforcing sheet119may comprise a composite material comprising thermoset material, thermoplastic material, carbon fibers and/or fiberglass fibers. For example, the composite material may be a fiber-matrix composite material that comprises a matrix in which fibers are embedded. The matrix may include any suitable polymeric resin, such as a thermosetting polymeric material (e.g., polyester, vinyl ester, vinyl ether, polyurethane, epoxy, cyanate ester, etc.), a thermoplastic polymeric material (e.g., polyethylene, polypropylene, acrylic resin, polyether ether ketone, polyethylene terephthalate, polyvinyl chloride, polymethyl methacrylate, polycarbonate, acrylonitrile butadiene styrene, nylon, polyimide, polysulfone, polyamide-imide, self-reinforcing polyphenylene, etc.), or a hybrid thermosetting-thermoplastic polymeric material. The fibers may be made of any suitable material such as carbon fibers, polymeric fibers such as aramid fibers, boron fibers, glass fibers, ceramic fibers, etc.

Furthermore, in some embodiments, the reinforcing sheet119may comprise a fabric or textile material. For example, the reinforcing sheet119may comprise a fabric mesh such as a nylon mesh or any other suitable fabric material. For example, the reinforcing sheet119may envelop the subshell85xover which it is disposed such as to cover at least a majority (i.e., a majority or an entirety) of an outer surface of that subshell85x. Moreover, the reinforcing sheet119may also cover at least a majority of an internal surface of a subsequent subshell85yoverlying the subshell85x. Thus, the reinforcing sheet119may extend from the lateral side portion66to the medial side portion68of the shell30. In other cases, the reinforcing sheet119may be disposed at limited portions of the shell30(e.g., only the ankle portion64of the shell30).

In another example, as shown inFIG. 21C, the reinforcement115may comprise a single fiber111rather than a fabric mesh. The single fiber111is configured to apply tension forces on the shell30and/or other components of the skate boot22. In particular, the tension of the single fiber111is transmitted onto the shell30and thus may allow controlling its performance.

In some embodiments, multiple reinforcements115may be included between the subshells851-85Lof the shell30. For instance, a rib117imay be disposed at a selected area of the shell30while a reinforcing sheet119may be disposed at another selected area of the shell30.

Moreover, in some embodiments, rather than or in addition of the reinforcement115, the shell30may comprise a decoration121, which can be referred to as a design element, disposed between certain ones of the subshells851-85Lof the shell30such as, for instance, between the intermediate and external subshells852,853as shown inFIG. 19. The design element121constitutes an aesthetic element that is produced separately from the shell30and may be included in the shell30in order to affect its aesthetic look. For instance, the design element121may comprise a piece of material including a graphical representation of: one or more alphanumeric characters that may form text (e.g., a word, a message, etc.); one or more symbols (e.g., a logo, a sign, an emblem, etc.); one or more shapes or patterns; and/or one or more real or imaginary objects (e.g., a person, an animal, a vehicle, an imaginary or fictional character, or any other real or imaginary thing). The design element121is affixed to an exterior surface of the intermediate subshell852after forming the intermediate subshell852and prior to forming the external subshell853. For instance, the design element121may be mechanically affixed (e.g., stapled, stitched, etc.), glued (e.g., via an adhesive), ultrasonically bonded, or affixed in any other suitable way to the exterior surface of the intermediate subshell852. While a single design element121is depicted inFIG. 19, the shell30may comprise a plurality of such design elements which may be spaced apart from one another. Moreover, in some cases, the reinforcement115, which is depicted inFIG. 19spaced apart from the decoration121, itself may act as a decoration in addition to its reinforcing functionality.

Once the reinforcement115(or multiple reinforcements115) and/or the design element121(or multiple design elements121) has been affixed to the exterior surface of the intermediate subshell852, the molding process proceeds as described above. Notably, the next subshell, in this case the external subshell853, is formed such that it covers the reinforcement115and/or the design element121thus trapping the reinforcement115and/or the design element121between the intermediate subshell852and the external subshell853. In some embodiments, the external subshell853may be clear (i.e., translucent) and may thus allow displaying the reinforcement115and/or the design element121through the external subshell853. This may be particularly useful to display the design element121but may also be useful to display the reinforcement115for aesthetic purposes.

In this embodiment, the molding process employed to form the shell30is low-pressure injection molding. That is, the polymeric materials M1-MNthat constitute the subshells851-85Lare injected into the mold cavity formed by each mold154iat a relatively low pressure. In addition, the molding process employed to form the shell30may be characterized as a co-injection molding process since the polymeric materials M1-MNare injected into a same mold.

In this embodiment, no external heat is applied to the polymeric materials M1-MNof the shell30. Rather, in this embodiment, as shown inFIG. 22, in order to form a subshell85i, two or more constituents of a given polymeric material Mxchemically react when combined to release heat. In other words, the two or more constituents have an exothermic reaction when combined. For instance, in one example, the material Mxis polyurethane and includes constituents125,127that chemically react when combined. The constituents125,127may be polyols and isocyanates. The exothermic chemical reaction that characterizes the molding process of the shell30contrasts the conventional method of forming a skate boot shell which involves thermoforming whereby heat is applied to a thermoformable sheet of material in a mold such that the thermoformable sheet of material acquires the shape of the mold.

The molding process of the shell30may be implemented in any suitable way in other embodiments. For example, in some embodiments, injection molding at higher pressure may be used. As another example, in some embodiments, two or more lasts such as the last152may be used (e.g., different lasts for molding respective ones of the subshells851-85L). Moreover, the last152may be configured differently than the last shown inFIG. 13. For instance, the last152may not comprise projections for forming the apertures48and rather one or more of the female molds1541-154Nmay comprise such projections for forming the apertures48. In other cases, the projections on the last152for forming the apertures48may be retractable. As another example, in some embodiments, the molding process of the shell30may be casting in which the polymeric materials M1-MNare poured into one or more molds.

The skate boot22may comprise an overlay102on an external surface65of the shell30for aesthetic or functional purposes.

With additional reference toFIG. 23, in this embodiment, the overlay102comprises a plurality of overlay elements1041-104Othat can be disposed at any suitable part of the shell30. For example, in some cases, the overlay elements1041-104Omay be a graphic (e.g., a logo), a brand name, a pattern, a word, etc. While the overlay elements1041-104Omay improve an aesthetic appearance of the skate10, in some cases, certain overlay elements1041-104Omay also serve functional purposes. For instance, in some cases, the overlay elements1041-104Omay be configured to minimize wear of at least a portion of the external surface65of the shell30. For example, an overlay element104xmay be located close to a bottom portion of the medial and/or lateral sides of the shell30in order to prevent contact between the playing surface12and the shell30of the skate boot22. This may help in reducing undue wear of the skate10.

The overlay102may be affixed to the external surface65of the shell30in various ways. For instance, each of the overlay elements1041-104Omay be mechanically fastened to the external surface65of the shell30(e.g., via stitching, staples, etc.), glued thereto via an adhesive, or ultrasonically bonded. The overlay elements1041-104Omay be affixed to the external surface65of the shell30in any other suitable way.

The inner lining36of the skate boot22is affixed to an inner surface of the shell30and comprises an inner surface96for facing the heel HL and medial and lateral sides MS, LS of the player's foot11and ankle A in use. The inner lining36may be made of a soft material (e.g., a fabric made of NYLON® fibers or any other suitable fabric). The footbed38is mounted inside the shell30and comprises an upper surface106for receiving the plantar surface PS of the player's foot11and a wall108projecting upwardly from the upper surface106to partially cup the heel HL and extend up to a medial line of the player's foot11. The insole40has an upper surface25for facing the plantar surface PS of the player's foot11and a lower surface23on which the shell30may be affixed.

In some embodiments, the skate boot22may not comprise an inner lining36. For instance, the internal subshell851of the shell30of the skate boot22may serve as an inner lining already and thus the addition of the inner lining36may be redundant. In other cases, the inner lining36may be inserted during the molding process using the molding apparatus150. For example, a textile material may first be placed on the last152prior to forming the first subshell (i.e., the internal subshell851) such as to serve as a pre-formed “sock” onto which the internal subshell851is formed.

The toe cap32of the skate boot22is configured to face and protect the toes T of the player's foot11. As will be described in more detail below, in this example, at least part (i.e., part or all) of the toe cap32is formed integrally with the shell30. As shown inFIGS. 6, 8 and 9, the toe cap32comprises a bottom portion116for at least partially covering a front portion of the lower surface23of the insole40, a lateral side portion118for facing a small toe of the foot11of the player, a medial side portion120for facing a big toe of the foot11of the player, an end portion122between the lateral and medial side portions118,120, an upper portion124for facing a top of the toes T of the player's foot11, and a top extension126for affixing the tongue34to the toe cap32. The top extension126of the toe cap32may be affixed (e.g., glued and/or stitched) to a distal end portion of the tongue34in order to affix the tongue34to the toe cap32.

The toe cap32may comprise a synthetic material105that imparts stiffness to the toe cap32. For instance, in various embodiments, the synthetic material105of the toe cap32may comprise nylon, polycarbonate materials (e.g., Lexan®), polyurethane, thermoplastics, thermosetting resins, reinforced thermoplastics, reinforced thermosetting resins, polyethylene, polypropylene, high density polyethylene or any other suitable material. In some cases, the synthetic material105of the toe cap32may be a composite material comprising thermoset material, thermoplastic material, carbon fibers and/or fiberglass fibers. For example, the composite material may be a fiber-matrix composite material that comprises a matrix in which fibers are embedded. The matrix may include any suitable polymeric resin, such as a thermosetting polymeric material (e.g., polyester, vinyl ester, vinyl ether, polyurethane, epoxy, cyanate ester, etc.), a thermoplastic polymeric material (e.g., polyethylene, polyurethane, polypropylene, acrylic resin, polyether ether ketone, polyethylene terephthalate, polyvinyl chloride, polymethyl methacrylate, polycarbonate, acrylonitrile butadiene styrene, nylon, polyimide, polysulfone, polyamide-imide, self-reinforcing polyphenylene, etc.), or a hybrid thermosetting-thermoplastic polymeric material. The fibers may be made of any suitable material such as carbon fibers, polymeric fibers such as aramid fibers, boron fibers, glass fibers, ceramic fibers, etc.

The tongue34extends upwardly and rearwardly from the toe cap32for overlapping the top surface TS of the player's foot11. In this embodiment, with additional reference toFIG. 24, the tongue34comprises a core140defining a section of the tongue34with increased rigidity, a padding member (not shown) for absorbing impacts to the tongue34, a peripheral member144for at least partially defining a periphery145of the tongue34, and a cover member146configured to at least partially define a front surface of the tongue34. The tongue34defines a lateral portion147overlying a lateral portion of the player's foot11and a medial portion149overlying a medial portion of the player's foot11. The tongue34also defines a distal end portion151for affixing to the toe cap32(e.g., via stitching) and a proximal end portion153that is nearest to the player's shin S.

The tendon guard35extends upwardly from the rear portion82of the ankle portion64of the shell30in order to protect the player's Achilles tendon AT. As will be described in more detail below, in this embodiment, at least part (i.e., part or all) of the tendon guard35is integrally formed with the shell30of the skate boot22. In other embodiments, the tendon guard35may be a separate component from the shell30such that the tendon guard35is fastened to the shell30via a mechanical fastener (e.g., via stitching, stapling, a screw, etc.) or in any other suitable way.

The skate boot22may be constructed in any other suitable way in other embodiments. For example, in other embodiments, various components of the skate boot22mentioned above may be configured differently or omitted and/or the skate boot22may comprise any other components that may be made of any other suitable materials and/or using any other suitable processes.

As shown inFIG. 25, the blade26comprises an ice-contacting material220including an ice-contacting surface222for sliding on the ice surface while the player skates. In this embodiment, the ice-contacting material220is a metallic material (e.g., stainless steel). The ice-contacting material220may be any other suitable material in other embodiments.

As shown inFIGS. 4, 5 and 7, the blade holder24comprises a lower portion162comprising a blade-retaining base164that retains the blade26and an upper portion166comprising a support168that extends upwardly from the blade-retaining base164towards the skate boot22to interconnect the blade holder24and the skate boot22. A front portion170of the blade holder24and a rear portion172of the blade holder24define a longitudinal axis174of the blade holder24. The front portion170of the blade holder24includes a frontmost point176of the blade holder24and extends beneath and along the player's forefoot in use, while the rear portion172of the blade holder24includes a rearmost point178of the blade holder24and extends beneath and along the player's hindfoot in use. An intermediate portion180of the blade holder24is between the front and rear portions170,172of the blade holder24and extends beneath and along the player's midfoot in use. The blade holder24comprises a medial side182and a lateral side184that are opposite one another.

The blade-retaining base164is elongated in the longitudinal direction of the blade holder24and is configured to retain the blade26such that the blade26extends along a bottom portion186of the blade-retaining base164to contact the ice surface12. To that end, the blade-retaining base164comprises a blade-retention portion188to face and retain the blade26. In this embodiment, as shown inFIG. 26A, the blade-retention portion188comprises a recess190in which an upper portion of the blade26is disposed.

The blade holder24can retain the blade26in any suitable way. For instance, in this embodiment, the blade26may be permanently affixed to the blade holder24(i.e., not intended to be detached and removed from the blade holder24). For example, as shown inFIG. 27, the blade26and the blade-retaining base164of the blade holder24may be mechanically interlocked via an interlocking portion234of one of the blade-retaining base164and the blade26that extends into an interlocking void236of the other one of the blade-retaining base164and the blade26. For instance, in some cases, the blade26can be positioned in a mold used for molding the blade holder24such that, during molding, the interlocking portion234of the blade-retaining base164flows into the interlocking void236of the blade26(i.e., the blade holder24is overmolded onto the blade26). In some embodiments, as shown inFIGS. 26 and 28, the blade holder24may retain the blade26using an adhesive226and/or one or more fasteners228. For instance, in some embodiments, as shown inFIG. 26, the recess190of the blade holder24may receive the upper portion of the blade26that is retained by the adhesive226. The adhesive226may be an epoxy-based adhesive, a polyurethane-based adhesive, or any suitable adhesive. In some embodiments, instead of or in addition to using an adhesive, as shown inFIG. 29, the recess190of the blade holder24may receive the upper part of the blade26that is retained by the one or more fasteners228. Each fastener228may be a rivet, a screw, a bolt, or any other suitable mechanical fastener. In some embodiment, the blade holder24may retain the blade26via a press fit. For example, as shown inFIG. 26B, the recess190of the blade holder24may be configured (e.g., sized) such as to enter into a press fit with the blade26. More particularly, in this example of implementation, the blade26comprises an elastomeric coating237including an elastomeric material (e.g., polyurethane, rubber, or any other suitable elastomeric material) that forms at least part of an outer surface of the blade26. The elastomeric coating237has a greater friction coefficient than the ice-contacting material220of the blade26when interacting with the blade holder24such as to improve retention of the blade26by the blade holder24in a press fit. Alternatively or additionally, in some embodiments, as shown inFIG. 28, the blade-retention portion188of the blade holder24may extend into a recess230of the upper part of the blade26to retain the blade26using the adhesive226and/or the one or more fasteners228. For instance, in some cases, the blade-retention portion188of the blade holder24may comprise a projection232extending into the recess230of the blade26.

In this embodiment, the blade-retaining base164comprises a plurality of apertures2081-2084distributed in the longitudinal direction of the blade holder24and extending from the medial side182to the lateral side184of the blade holder24. In this example, respective ones of the apertures2081-2084differ in size. The apertures2081-2084may have any other suitable configuration, or may be omitted, in other embodiments.

The blade-retaining base164may be configured in any other suitable way in other embodiments.

The support168is configured for supporting the skate boot22above the blade-retaining base164and transmit forces to and from the blade-retaining base164during skating. In this embodiment, the support168comprises a front pillar210and a rear pillar212which extend upwardly from the blade-retaining base164towards the skate boot22. The front pillar210extends towards the front portion56of the skate boot22and the rear pillar212extends towards the rear portion58of the skate boot22. The blade-retaining base164extends from the front pillar210to the rear pillar212. More particularly, in this embodiment, the blade-retaining base164comprises a bridge214interconnecting the front and rear pillars210,212.

In this embodiment, at least part (i.e., part or all) of the blade holder24is integrally formed with the shell30of the skate boot22. That is, at least part of the blade holder24and the shell30of the skate boot22constitute a monolithic one-piece structure. The blade holder24thus comprises a portion215that is integrally formed with the shell30of the skate boot22such that the portion215of the blade holder34and the shell30of the skate boot22are formed together as one-piece in the molding apparatus150during the molding process.

In this embodiment, the portion215of the blade holder24includes one or more of the polymeric materials M1-MNof the subshells851-85Lof the shell30of the skate boot22. For instance, in this example, the portion215of the blade holder24includes the intermediate and external subshells852,853and therefore comprises the polymeric materials M2, M3associated therewith. In particular, in this example, a majority of the blade holder24is constituted by the polymeric material M2of the intermediate subshell852such that the blade holder24consists primarily of a structural foam material. Alternatively, the portion215of the blade holder24may include one or more different materials.

In this embodiment, at least a majority (i.e., a majority or an entirety) of the blade holder24may be integrally formed with shell30. That is, the portion215of the blade holder24may be a major portion or the entirety of the blade holder24. In this embodiment, an entirety of the blade holder24is integrally formed with the shell30.

Therefore, in this embodiment, the blade holder24is formed with the shell30in the molding apparatus150with the last152. In particular, the blade holder24is initially formed during forming of the intermediate subshell852of the shell30and is completed by the forming of the external subshell853of the shell30. That is, in this embodiment, as shown inFIG. 73, the intermediate subshell852is the innermost subshell of the blade holder24while the external subshell853is the outermost subshell of the blade holder24.

Moreover, in this embodiment, the blade26is attached to the blade holder24during the molding process by including the blade26in a given mold154isuch that the blade holder24overmolds the blade26during the molding process. For instance, the mold154imay be designed specifically to hold the blade26during the molding process prior to the forming of the intermediate subshell852.

In this embodiment, one or more other components (e.g., the toe cap32, the tendon guard35, the lace members441,442, the tongue34, the footbed38, etc.) of the skate boot22may be molded integrally with the shell30in the molding apparatus150during the molding process. The shell30and these one or more other components of the skate boot22may thus constitute a monolithic one-piece structure.

For example, in this embodiment, the toe cap32, the tendon guard35, and the lace members441,442are molded integrally with the shell30in the molding apparatus150during the molding process.

For instance, in this embodiment, the toe cap32comprises a portion217that is integrally formed with the shell30such that the portion217of the toe cap32of the skate boot22and the shell30of the skate boot22are formed together as one-piece in the molding apparatus150during the molding process. As such, the portion217of the toe cap32of the skate boot22may include one or more of the polymeric materials M1-MNof the subshells851-85Lof the shell30of the skate boot22.

In this embodiment, the portion217of the toe cap32includes one or more of the polymeric materials M1-MNof the subshells851-85Lof the shell30of the skate boot22. For instance, in this example, the portion217of the toe cap32includes the internal, intermediate and external subshells851,852,853and therefore comprises the polymeric materials M1, M2, M3associated therewith. Alternatively, the portion217of the toe cap32may include one or more different materials.

Moreover, in this embodiment, the tendon guard35comprises a portion219that is integrally formed with the shell30such that the portion219of the tendon guard35of the skate boot22and the shell30of the skate boot22are formed together as one-piece in the molding apparatus150during the molding process. As such, the portion219of the tendon guard35of the skate boot22may include one or more of the polymeric materials M1-MNof the subshells851-85Lof the shell30of the skate boot22. For instance, in this example, the portion219of the tendon guard35includes solely the external subshell853and therefore comprises the polymeric material M3associated therewith. Alternatively, the portion219of the tendon guard35may include one or more different materials. For example, in some embodiments, the portion219of the tendon guard219may also comprise the internal subshell851and/or the intermediate subshell852such that the portion219of the tendon guard35also comprises the polymeric material M1and/or the polymeric material M2associated therewith.

Moreover, in this embodiment, each of the lace members441,442comprises a portion221that is integrally formed with the shell30such that the portion221of each of the lace members441,442of the skate boot22and the shell30of the skate boot22are formed together as one-piece in the molding apparatus150during the molding process. As such, the portion221of each lace member44iof the skate boot22may include one or more of the polymeric materials M1-MNof the subshells851-85Lof the shell30of the skate boot22. For instance, in this example, the portion221of the lace member44iincludes solely the external subshell853and therefore comprises the polymeric material M3associated therewith. Alternatively, the portion221of the lace member44imay include one or more different materials. For example, in some embodiments, the portion221of the lace member44imay also comprise the internal subshell851and/or the intermediate subshell852such that the portion221of the lace member44ialso comprises the polymeric material M1and/or the polymeric material M2associated therewith. Moreover, in this embodiment, the apertures48that extend through the lace members441,442are formed during the molding process by appropriate structures (e.g., projections) of the last152and an associated female mold154i.

The skate10may be implemented in any other suitable manner in other embodiments.

For example, in some embodiments, as shown inFIGS. 30 to 32, only a limited part225of the blade holder24may be integrally formed with the shell30. For instance, in some embodiments, the part225of the blade holder24may comprise a projection227projecting from an underside of the shell30to which another part229of the blade holder24may be secured. As shown inFIGS. 31 and 32, the projection227of the part225of the blade holder24may be secured to the other part229of the blade holder24via an adhesive231that is applied between the two parts225,229or in some cases via mechanical fasteners such as a nut and bolt assembly233that traverses the parts225,229to secure them together. The parts225,229of the blade holder24may be secured to one another in any other suitable way in other embodiments. In other embodiments, a substantial part of the blade holder24may be molded integrally with the shell30. For example, in some cases, at least a majority of the blade holder24may be molded together with the shell30. In some case, substantially an entirety of the blade holder24may be molded integrally with the shell30.

For instance, in some embodiments, the blade holder24may retain the blade26in any other suitable way. For example, in other embodiments, as shown inFIG. 33, the blade holder24comprises a blade-detachment mechanism192such that the blade26is selectively detachable and removable from, and attachable to, the blade holder24(e.g., when the blade26is worn out or otherwise needs to be replaced or removed from the blade holder24).

More particularly, in this embodiment, the blade26includes a plurality of projections194,196. The blade-detachment mechanism192includes an actuator198and a biasing element200which biases the actuator198in a direction towards the front portion170of the blade holder24. In this embodiment, the actuator198comprises a trigger. To attach the blade26to the blade holder24, the front projection194is first positioned within a hollow space202(e.g., a recess or hole) of the blade holder24. The rear projection196can then be pushed upwardly into a hollow space204(e.g., a recess or hole) of the blade holder24, thereby causing the biasing element200to bend and the actuator198to move in a rearward direction. The rear projection196will eventually reach a position which will allow the biasing element200to force the actuator198towards the front portion170of the blade holder24, thereby locking the blade26in place. The blade26can then be removed by pushing against a finger-actuating surface206of the actuator198to release the rear projection196from the hollow space204of the blade holder24. Thus, in this embodiment, the blade-detachment mechanism192is free of any threaded fastener (e.g., a screw or bolt) to be manipulated to detach and remove the blade26from the blade holder24or to attach the blade26to the blade holder24.

Further information on examples of implementation of the blade-detachment mechanism192in some embodiments may be obtained from U.S. Pat. No. 8,454,030 hereby incorporated by reference herein. The blade-detachment mechanism192may be configured in any other suitable way in other embodiments.

The blade26may be implemented in any other suitable way in other embodiments. For example, in some embodiments, as shown inFIGS. 34 and 35, the blade26may comprise a runner238that is made of the ice-contacting material220and includes the ice-contacting surface222and a body240connected to the runner238and made of a material242different from the ice-contacting material220. The runner238and the body240of the blade26may be retained together in any suitable way. For example, in some cases, the runner238may be adhesively bonded to the body240using an adhesive. As another example, in addition to or instead of being adhesively bonded, the runner238and the body240may be fastened using one or more fasteners (e.g., rivets, screws, bolts, etc.). As yet another example, the runner238and the body240may be mechanically interlocked by an interlocking portion of one of the runner238and the body240that extends into an interlocking space (e.g., one or more holes, one or more recesses, and/or one or more other hollow areas) of the other one of the runner238and the body240(e.g., the body240may be overmolded onto the runner238).

In some embodiments, one or more other components (e.g., the tongue34, the footbed38, etc.) of the skate boot22may be molded integrally with the shell30in the molding apparatus150during the molding process. The shell30and these one or more other components of the skate boot22may thus constitute a monolithic one-piece structure. A given component of the skate boot22may therefore comprise a portion235that is integrally formed with the shell30such that the portion235of the given component of the skate boot22and the shell30of the skate boot22are formed together as one-piece in the molding apparatus150during the molding process.

As such, the portion235of the given component of the skate boot22may include one or more of the polymeric materials M1-MNof the subshells851-85Lof the shell30of the skate boot22. For instance, the portion235of the given component may include one or more of the internal, intermediate and external subshells851,852,853and therefore may comprise one or more of the polymeric materials M1, M2, M3associated therewith. Alternatively, the portion235of the given component may include one or more different materials.

For example, in some embodiments, with additional reference toFIG. 36, the toe cap32, the tongue34, the tendon guard35, the footbed38and the lace members441,442may be molded integrally with the shell30of the skate boot22. That is, at least a portion of (i.e., a part or an entirety of) each of the toe cap32, the tongue34, the tendon guard35, the footbed38and the lace members441,442may be formed integrally with the shell30as one-piece in the molding apparatus150during the molding process.

As shown inFIG. 42, in some embodiments, when the footbed38is formed integrally with the shell30during the molding process, one or more the subshells851-85Lmay form the footbed38. Moreover, in some embodiments, as shown inFIG. 43A, when the footbed38is formed integrally with the shell30during the molding process, a portion of the footbed38may project outwardly such as to fill a gap of a subshell85iin the sole portion69of the shell30.

In some embodiments, as shown inFIG. 45, when the footbed38is formed integrally with the shell30during the molding process, the footbed38may be configured to project outwardly such as to fill respective gaps of the internal and intermediate subshells851,852in the sole portion69of the shell30.

In some embodiments, at least a portion of (i.e., part or an entirety of) the blade holder24may be attached to a given one of the subshells851-85Lof the shell30. For instance, the portion of the blade holder24may be joined to the given one of the subshells851-85Lduring forming of the shell30. For example, as shown inFIG. 47A, the portion of the blade holder24may be affixed to an exterior surface of the internal subshell851and the intermediate and external subshells852,853may be formed around the portion of the blade holder24.

In other embodiments, as discussed above, the portion of the blade holder24may be formed during the molding process of the shell30. For example, as shown inFIG. 47B, a majority or an entirety of the portion of the blade holder24may be constituted by the external subshell853. Moreover, the footbed38may be formed or affixed directly on the portion of the blade holder24(i.e., on the external subshell853that makes up a majority or an entirety of the portion of the blade holder24).

In some embodiments, as shown inFIG. 48, the footbed38may be formed integrally with the shell30so as to project outwardly into a gap of the internal subshell851in the sole portion69of the shell30.

In some embodiments, as shown inFIG. 52, when the blade holder24is formed integrally with the shell30during the molding process, the portion of the blade holder24that is formed integrally with the shell30(e.g., a part or an entirety of the blade holder24) may be constituted by the intermediate subshell852such that the intermediate subshell852is exposed at the blade holder24. In other embodiments, as shown inFIG. 53, when the blade holder24is formed integrally with the shell30during the molding process, a given one of the subshells851-85Lmay be formed to envelop the blade holder24. That is, a given one of the subshells851-85Lmay be formed around the blade holder24but not around the shell30.

In some embodiments, with additional reference toFIG. 54, the shell30and possibly one or more other components of the skate boot22may be manufactured separately from the blade holder24, which may be manufactured separately and attached to the skate boot22.

For example, in some embodiments, as shown inFIG. 37, the shell30of the skate boot22may be formed alone in the molding apparatus150, i.e., separately from the toe cap32, the tongue34, the tendon guard35, the footbed38and the lace members441,442. As shown inFIG. 38, the toe cap32, the tongue34, the tendon guard35, the footbed38and the lace members441,442may be attached to the shell30after the shell30has been formed. For instance, any given one of the toe cap32, the tongue34, the tendon guard35, the footbed38and the lace members441,442may be formed on the shell30in a separate molding process similar to the one described above in respect of the shell30. For example, the given one of the toe cap32, the tongue34, the tendon guard35, the footbed38and the lace members441,442may be overmolded onto the shell30. In some cases, the given one of the toe cap32, the tongue34, the tendon guard35, the footbed38and the lace members441,442may be formed separately from the shell30during another molding process (e.g., a thermoforming process) and attached to the shell30via a fastener (e.g., stitching, stapling, etc.) or via gluing (e.g., using an adhesive).

In other embodiments, as shown inFIG. 46, the footbed38may be an insert that is placed between the internal subshell851and the intermediate subshell852and/or between the internal subshell851and the external subshell853during forming of the shell30in a manner similar to that described above in respect of the reinforcement115for example. In such embodiments, the player's foot11does not contact the footbed38directly, however the footbed38may still provide comfort to the player's foot11by interacting between the subshells.

As shown inFIGS. 49 and 51, in some embodiments, the blade holder24may be formed separately from the internal, intermediate and external subshells851,852,853of the shell30.

In such embodiments where the shell30and possibly one or more other components of the skate boot22are manufactured separately from the blade holder24, the skate boot22may comprise an outsole42, as shown in inFIG. 54. The outsole42is affixed to an underside of the shell30for forming the skate boot22. The outsole42comprises a rigid material for imparting rigidity to the outsole42. More particularly, in this embodiment, the rigid material of the outsole42comprises a composite material. For example, the composite material may be a fiber-matrix composite material that comprises a matrix in which fibers are embedded. The matrix may include any suitable polymeric resin, such as a thermosetting polymeric material (e.g., polyester, vinyl ester, vinyl ether, polyurethane, epoxy, cyanate ester, etc.), a thermoplastic polymeric material (e.g., polyethylene, polypropylene, acrylic resin, polyether ether ketone, polyethylene terephthalate, polyvinyl chloride, polymethyl methacrylate, polycarbonate, acrylonitrile butadiene styrene, nylon, polyimide, polysulfone, polyamide-imide, self-reinforcing polyphenylene, etc.), or a hybrid thermosetting-thermoplastic polymeric material. The fibers may be made of any suitable material such as carbon fibers, polymeric fibers such as aramid fibers, boron fibers, glass fibers, ceramic fibers, etc. In other embodiments, the rigid material may comprise any other suitable material (e.g., nylon, polycarbonate materials, polyurethane, thermoplastics, thermosetting resins, reinforced thermoplastics, reinforced thermosetting resins, polyethylene, polypropylene, high density polyethylene).

Moreover, in such embodiments where the skate boot22and the blade holder24are manufactured separately, the support168of the blade holder24and the skate boot22may be affixed to one another in any suitable way. For example, in some embodiments, as shown inFIG. 55, the front and rear pillars210,212are fastened to the skate boot22by fasteners (e.g., rivets, screws, bolts). In this example, each of the front and rear pillars210,212comprises a flange216including a plurality of apertures2181-218Fto receive respective ones of the fasteners that fasten the blade holder24to the skate boot22. The support168may be affixed to the skate boot22in any other suitable manner in other embodiments (e.g., by an adhesive).

In some embodiments, the skate boot22may comprise a reinforcement270molded integrally with the shell30to enhance a torsional strength of the skate boot22and/or protection of the player's foot11against impacts (e.g., from a puck or hockey stick).

For instance, the reinforcement270may comprise an extension272that extends beyond the ankle portion64of the shell30of the skate boot22in the longitudinal direction of the skate10. In contrast,FIG. 56illustrates a conventional configuration of the shell30without the reinforcement270and thus without the extension272. As shown, in such a conventional configuration, no part of the shell extends beyond the ankle portion64of the shell30in the longitudinal direction of the skate.

With additional reference toFIGS. 57A and 57B, the extension272may be located in front of the ankle portion64of the shell30in the longitudinal direction of the skate10. As such, the extension272may be configured to protect a front portion of the player's ankle A and the top surface TS of the player's foot11. The extension272may extend in front of the ankle portion64of the shell30to different extents. For instance, as shown inFIG. 57B, the extension272may extend from the medial ankle side74of the ankle portion64of the shell30and wrap around the player's ankle A such that the extension272crosses from a medial half278of the skate boot22over a centerline274that generally bisects a width the skate boot22and into a lateral half280of the skate boot22. In some cases, as shown inFIG. 57A, the extension272may be shorter and extend frontwards from the medial ankle side74of the ankle portion64of the shell30and wrap around over a portion of the player's foot11but does not cross over into the lateral half280of the skate boot22. Alternatively, in some cases, rather than extending from the medial ankle side74, the extension272may extend from the lateral ankle side76of the ankle portion64of the shell30.

In an example of the variant, as shown inFIG. 58, the extension272may connect the medial ankle side74of the ankle portion64of the shell30to the lateral ankle side76of the ankle portion64of the shell30in a direction frontwardly of the ankle portion64of the shell30. In other words, the extension272may be configured such that the shell30wraps around a front and a rear of the player's ankle A. As such, the shell30may be continuous in a region frontwardly of the ankle portion64of the shell30, and may thus lack an opening in which the tongue34of the skate boot22is typically located. Consequently, in such embodiments, the skate boot22may not comprise a tongue34or lace members441,442. Moreover, the extension272may create a gap275(i.e., a spacing) between the extension272and the player's foot11in the longitudinal direction of the skate10to facilitate motion (e.g., flexion) of the ankle A while skating. In other embodiments, as shown inFIG. 59, the extension272may be configured to wrap around the player's foot11such that there is substantially no gap between the extension272and the player's foot11in the longitudinal direction of the skate10.

In some embodiments, the extension272may comprise a plurality of free ends2761,2762that are movable relative to one another and converge toward one another. In some embodiments, as shown inFIG. 60, the free ends2761,2762of the extension272may meet in front of the ankle portion64of the shell30. For example, the free ends2761,2762may meet symmetrically about the centerline274of the skate10. In other embodiments, the free ends2761,2762may meet in the medial half278or the lateral half280of the skate boot22. WhileFIG. 60illustrates the free ends2761,2762as leaving a gap275between the player's foot11and the free ends2761,2762in the longitudinal direction of the skate10, in some embodiments, the free ends2761,2762may terminate relatively close to the player's foot11such that there is substantially no gap between the player's foot11and the free ends2761,2762.

In some embodiments, each free end276iof the extension272may comprise an overlapping portion282that overlaps another portion of the free end276iin the longitudinal direction of the skate10. For example, as shown inFIG. 61, the overlapping portion282of each free end276imay be a portion of the free end276ithat faces rearwardly toward the player's ankle A.

In a variant, the extension272may be in the rear portion82of the ankle portion64of the shell30. For instance, as shown inFIG. 62, the extension62may be configured such that the gap275is between a rear portion of the ankle A of the player and the extension272. In some cases, the reinforcement270may comprise more than one extension. For instance, with additional reference toFIGS. 63, 64 and 70, the skate boot22may comprise a first extension272extending frontwardly of the ankle portion64of the shell30and a second extension284extending rearwardly of the ankle portion64of the shell30. In some embodiments, as shown inFIG. 63, the second extension284may comprise the free ends2761,2762such that the free ends2761,2762extend rearwardly of the ankle portion64of the shell30.

In some examples of the variant where an extension272,284of the skate boot22extends rearwardly of the ankle portion64of the shell30, the tendon guard35may be omitted in order to provide additional flexibility when skating.

In another variant, the reinforcement270may comprise the lace members441,442of the skate boot22. That is, the lace members441,442may be configured to enhance a torsional strength of the skate boot22and/or protection of the player's foot11against impacts. For instance, as shown inFIGS. 66 to 68, a given one of the lace members441,442extending in a given one of the medial half278and the lateral half280of the skate boot22may cross over to the other one of the medial half278and the lateral half280of the skate boot22. The other one of the lace members441,442may generally follow a direction defined by the given one of the lace members441,442. This may be defined as a “twisted” configuration of the skate boot22.

As shown inFIG. 69, in some examples of the twisted configuration of the skate boot22, the reinforcement270may also comprise the extension272. For example, the extension272may extend from the medial ankle side74to the lateral ankle side76of the ankle portion64of the shell30in a direction frontwardly of the player's ankle A such that the gap275is present between the extension272and the player's foot11in the longitudinal direction of the skate10.

The twisted configuration of the skate boot22may increase the torsional rigidity and frontal impact protection of the skate boot22and thus may allow the shell30and/or other components of the skate boot22(e.g., the toe cap32) to have a reduced thickness compared to a conventional skate boot without the twisted configuration where the lace members are confined to a single one of the medial or lateral halves of the skate boot. Moreover, the twisted configuration of the skate boot22may allow the skate boot22to be flexed in a different direction compared to a conventional skate boot. For instance, the twisted configuration of the skate boot22may allow the player to flex the skate boot22in the medial half278of the skate boot22in an area around the toe cap32. As a result, the twisted configuration of the skate boot22may allow better conservation of energy used by the player to propulse himself/herself on the ice12.

In another variant, with additional reference toFIG. 65, the reinforcement270may comprise an opening285in the rear portion82of the ankle portion64of the shell30. The opening285may extend vertically for a substantial portion of a height of the skate boot22. For instance, in some cases, a ratio between a height of the opening285and the height of the skate boot22may be at least 0.3, in some cases at least 0.4, in some cases at least 0.5, in some cases at least 0.6 and in some cases even more.

In another variant, with reference toFIG. 74, the blade holder24may be configured such that there is no spacing between the front and rear pillars210,212. In such a variant, the support168of the blade holder24comprises a “single” pillar213which is constituted by material that extends from the front portion170of the blade holder24to a rear portion172of the blade holder24. In particular, in this example, the blade holder24does not have any openings extending from its lateral side to its medial side.

In another variant, the shell30and/or the blade holder24and/or another component of the skate boot22that is made integrally with the shell30may comprise one or more inserts3151-315Nover which one or more of the subshells851-85Lmay be molded. For instance, as shown inFIG. 75, in this example, the blade holder24comprises a front insert3151and a rear insert3152which respectively make up a part of the front and rear pillars210,212. More particularly, in this example of implementation, the front and rear inserts3151,3152make up at least a majority (i.e., a majority or an entirety) of the front and rear pillars210,212of the support168of the blade holder24. In this example, the front and rear inserts3151,3152are affixed to the shell30during the molding process of the shell30in order to make the blade holder24integrally with the shell30. For example, once a given number of the subshells851-85Lare molded, the front and rear inserts3151,3152are affixed to the formed subshells851-85L(e.g., by gluing, taping, or any other suitable way) and one or more other ones of the subshells851-85L, in this case the exterior subshell853, is molded over the front and rear inserts3151,3152and the formed subshells851-85Lsuch as to form a continuous subshell853extending from the shell30to the blade holder24. In other cases, as shown inFIG. 76, the blade holder24may comprise a single one of the inserts3151,3152(e.g., only the front insert3151or only the rear insert3152).

In other examples, the inserts3151-315Nmay not be part of the blade holder24but may instead form part of the shell30. For instance, as shown inFIG. 78A, in this example, the shell30comprises an insert315Mdisposed between given ones of the subshells851-85L. For example, the insert315Mmay be disposed on an outer surface of the intermediate subshell852such that the exterior subshell853may be molded over the insert315Mand the intermediate subshell852. The insert315Mmay be disposed at any portion of the shell30. In this example, the insert315Mis disposed at a middle portion of the shell30corresponding to the intermediate portion68of the skate boot22. In particular, the insert315Mis disposed such as to extend from the lateral side portion66of the shell30to the medial side portion68of the shell30and wrapping around under the sole portion69of the shell30. As shown inFIG. 78B, the insert315Mmay extend to various heights on the medial and lateral side portions66,68of the shell30. In some cases, the insert315Mmay extend substantially a full height of each of the lateral and medial side portions66,68. As shown inFIG. 78C, in some cases, the insert315Mmay not extend to the lateral and medial side portions66,68of the shell30but may rather be confined to be disposed under the sole portion69of the shell30.

In this example, the inserts3151-315Ncomprise a foam material. In particular, the foam material of the inserts3151-315Nhas a density that is less than the density of the exterior subshell853. This may be helpful to reduce the weight of the skate10.

In another variant, as shown inFIG. 79, a given subshell85x(or more than one of the subshells) may comprise one or more filled portions4151-415Nmade of a material Mzdifferent from the material Mx of the subshell85x. The filled portions4151-415Nconstitute a portion of an other subshell85ythat was formed such as to fill a void in the given subshell85x. As such the filled portions4151-415Ncan be said to be “inserted” into voids formed in the subshell85xand may thus be referred to as “inserts”. To implement the inserts4151-415N, the subshell85xis first molded to include a void. This may be achieved in various ways. For example, the void of the subshell85xmay be formed by placing a molding insert in the mold during molding of the subshell85x. Once the subshell85xhas been demolded, the molding insert is removed, leaving a void in the subshell85x. Alternatively or additionally, the void of the subshell85xmay be formed by removing (e.g., cutting out) a portion of the subshell85xto form a void. The subshell85x, which now includes a void, is then re-inserted into a corresponding mold and the material MZis injected to fill in the void in the subshell85x, effectively resulting in the subshell85xcomprising distinct materials. This can be useful to replace the material Mxof the subshell85xat selected locations with another material with desired characteristics such as to modify characteristics of the subshell85x. For example, the material Mzmay have a stiffness that is different (e.g., greater or less than) from a density of the material Mxof the subshell85x.In this example, the material Mzis stiffer than the material Mxof the subshell85x. Moreover, the material Mzmay have a density that is different (e.g., greater or less than) from a density of the material Mxof the subshell85x. In this example, the material Mzis denser than the material Mxof the subshell85x. In particular, the inserts4151-415Nmay modify the torsional characteristics of the skate boot22such that the skate boot22responds to torsional forces differently than if the subshell85xdid not comprise the inserts4151-415N.

The inserts4151-415Nmay thus be distributed to achieve a desired performance of the skate boot22. For example,FIGS. 80A to 80Fshow different potential distributions of the inserts4151-415N. It is understood that the inserts4151-415Nmay be positioned differently in other embodiments.

In some cases, rather than filling the void formed in the subshell85x, the void may be left unfilled. This may modify the torsional characteristics of the skate boot22. For example, as shown inFIG. 89, the void left in the subshell85xmay form an opening550that can extend to an edge of the shell30, such as the lateral or medial edges45,47of the shell30. The opening550comprises opposite edges551,552which converge towards one another at a proximal end and are distanced from one another at a distal end. In some cases, the torsional behavior of the skate boot22modified by the opening550may allow the opposite edges551,552to contact one another at the distal end. The act of contacting one another may act as a limit to the movement of the shell30allowed by the opening550which was otherwise not possible by the shell30without the opening550.

In another variant, with reference toFIGS. 81 and 82, the molding process of the shell30(and other components that are integrally made with the shell30) may include using a sheet615(e.g., a film) which may be helpful to facilitate the molding process and/or to facilitate the addition of aesthetic features (e.g, designs) to the skate boot22. In this embodiment, the sheet615is a polymeric sheet comprising a polymeric material such as a polycarbonate, polypropylene, polyethylene or any other suitable polymeric material. Moreover, in this example, the sheet615is a clear sheet (e.g., transparent or translucid) through which a person can see.

In an example, the sheet615is overlayed on one or more of the formed subshells851-85Lsuch as to acquire a shape of the underlying subshell85x(e.g., by thermoforming the sheet615). In this example, the sheet615extends over at least a majority of the subshell85x. In some cases, the sheet615may extend over substantially an entirety of the subshell85x. The sheet615may then be sealed (e.g., heat sealed) to form a seam617. A female mold154xis then installed over the formed subshells851-85Land a material Myof the subsequent subshell85yis injected between the sheet615and the underlying subshell85x. Once the subshell85yhas cured a desired amount, the subshell85yis demolded from the mold154x. The sheet615may allow the molding process of the subshell85yto be faster than if no sheet was used. Notably, the presence of the sheet615between the material Myand the female mold154xmay allow faster removal of the subshell85ytherefrom as the subshell85ycan be removed from the mold154xwithout the material Myhaving to have gone through its full polymerization. In contrast, if no sheet was used during the molding process, early removal of the subshell85yfrom the mold154xmay compromise the quality of the subshell85y(e.g., it may be deformed). Furthermore, due to the presence of the sheet615between the material Myand the female mold154x, the molding process may not require the addition of a mold release agent on surfaces of the mold154xwhich is typically included to facilitate demolding. As such, the presence of the sheet615facilitates demolding of the subshells851-85Lfrom the female mold154xwithout using a mold release agent. This may also decrease imperfections in the subshell85ysince mold release agents, while useful, have a tendency to introduce imperfections in a molded product. Moreover, if fewer imperfections are formed, this may improve bonding between a subsequent subshell85z(that is molded over the subshell85y) and the subshell85y,

Once the subshell85yis molded, the sheet615may be disposed of and a new sheet615used in a similar manner to mold a subsequent subshell if any. Due to the relatively low cost of manufacturing the sheet615, using the sheet615in the molding process may inexpensively increase quality of the subshells851-85Lformed therewith.

In another example, the sheet615may not be disposed of after molding. Instead, as shown inFIG. 82, the sheet615may be affixed to the shell30such as, for example, being integrated as a layer between given ones of the subshells851-85L. In this example, the sheet615is formed over the subshell851and the subshell853is molded over the sheet615. In examples where the subshell853overlying the sheet615is a clear subshell (e.g., transparent or translucent), this may be useful to display the sheet615in the finished product. Notably, the sheet615may comprise one or more design elements618. The design element618may constitute a graphic, a color, a pattern, a word, a letter, a symbol or any other desired visual element. The design element618may be provided on the sheet615in any suitable way. For example, the design element618may be provided on the sheet615via silk-screening, pad printing, flexo printing or offset printing. The presence of the design element618may on the sheet615may allow to hide or otherwise obscure visual imperfections in the subshells851-85Lwhich do not affect the mechanical properties of the subshells851-85L. Alternatively or additionally, the sheet615may comprise the reinforcement115(such as the ribs1171-1178or the reinforcing sheet119) which may be affixed thereto in any suitable way (e.g., gluing).

In the example ofFIGS. 81 and 82, the sheet615is configured to span the shell30and the toe cap32. In other examples, the sheet615may be configured to span the shell30, the blade holder24, the toe cap32, the lace members441,442or any other components of the skate boot22. Furthermore, the sheet615may constitute at least part of an external surface of the skate boot22. In other words, the sheet615may be exposed, not only visually, but physically (i.e., it can be touched). Moreover, in some cases, the sheet615may constitute a majority of the external surface of the skate boot22. For example, the sheet615may constitute substantially an entirety of the external surface of the skate boot22.

While in the examples given, the sheet615has been shown as being disposed between the subshells851-85L, in other examples the sheet615may be disposed between the inner lining36and the internal subshell851.

In another variant, as shown inFIG. 83, the skate boot22may comprise a slash guard515configured to protect the player from cuts at a level above lateral and medial upper edges45,47of the shell30. The slash guard515is movable with respect to the tendon guard35(or with respect to the rear portion82of the ankle portion64of the shell30if no tendon guard is included). This may provide cut-resistant protection of the player's ankle and/or shin while also allowing mobility thereof.

The slash guard515comprises a cut-resistant material516that resists cutting from impacts. In this example, the cut-resistant material516is a fabric consisting of aramid (e.g., Kevlar®) or any other suitable cut-resistant material. As such, the slash guard515may be pliable due to its fabric nature. In this embodiment, the slash guard515is movable with respect to the tendon guard35(or the rear portion82of the ankle portion64of the shell30) due to the pliability of the cut-resistant material.

In this embodiment, the slash guard515is integrated (i.e., built into) the shell30and is permanently affixed thereto. In other words, in this embodiment, the slash guard515is not intended to be disconnected from the shell30without causing damage to the slash guard515and/or the shell30. In particular, in this example of implementation, the slash guard515is affixed to the shell30by disposing the slash guard515between the subshells851-85Lof the shell30(i.e., at least one or more of the subshells is overmolded onto the slash guard515). More specifically, in this embodiment, the slash guard515is overlayed over a subshell85xand a subsequent subshell85yis molded over the slash guard515. As such, the slash guard515overlaps a portion of the shell30sufficient for the slash guard515to be permanently affixed between the subshells85x,85ywithout the possibility of accidental removal of the slash guard515. In this example, the slash guard515overlaps a significant portion of the shell30. In particular, the slash guard515extends over a majority of a length of the shell30(in the longitudinal direction of the skate10). A portion of the slash guard515extending below the lateral and medial upper edges45,47of the shell30may act as a reinforcement element (such as the reinforcement sheet119) between the subshells85x,85y.

The slash guard515extends vertically above the lateral and medial upper edges45,47of the shell30for a height HP that may be substantial. For example, the height HP of the slash guard515extending above lateral and medial upper edges45,47of the shell30may be significant in relation to a height HT of the tendon guard35measured from a top of the tendon guard35to the lateral and medial upper edges45,47of the shell30. For instance, in some cases, a ratio of the height HP of the slash guard515over the height HT of the tendon guard35may be at least 0.5, in some cases at least 0.7, in some cases at least 0.9, in some cases at least 1, in some cases at least 1.2, in some cases at least 1.5, in some cases at least 2 and in some cases even more.

As shown inFIG. 85, which shows a top view of the portion of the slash guard515which extends vertically above the lateral and medial upper edges45,47of the shell30, in this embodiment, the slash guard515comprises a lateral portion520for facing a lateral side of the skate boot22, a medial portion522for facing a medial side of the skate boot22, and a rear portion524for facing a rear side of the skate boot22. As such, in this embodiment, the slash guard515at least partially wraps around the player's ankle A and/or shin S to provide cut-resistant protection from the sides and the rear of the skate boot22. In other examples, the slash guard515may wrap completely around the player's ankle A and/or shin S such that the slash guard515also comprises a front portion for facing a front side of the skate boot22. In such an example, the slash guard515may comprise a type of sleeve through which the player must insert his/her foot11in order to don the skate10.

The slash guard515may be configured differently in other examples. For instance, the slash guard515may not comprise the rear portion524if the tendon guard35is considered to provide sufficient protection to the player.

In other embodiments, as shown inFIG. 84, the slash guard515may be removeably attachable to the skate boot22. That is, the slash guard515may be selectively attached to and detached from the skate boot22. In this example, the slash guard515is removeably attachable to the shell30via interaction between an attachment member519of the slash guard515and a portion517of the slash guard515. In particular, the attachment member519is configured to attach the portion517of the slash guard515to the shell30. In this example, the slash guard515does not overlap a substantial portion of the shell30. The portion517of the slash guard515is an extension of the slash guard515which extends vertically below the lateral and medial upper edges45,47of the shell30. In this embodiment, the attachment member519is a fastener which fastens the slash guard515to the shell30. For example, the attachment member519may be a pin, a nut and bolt assembly, a hook-and-loop fastener or any other suitable fastener.

In this example ofFIG. 84, the cut-resistant material516of the slash guard515may be rigid and/or pliable. For example, the cut-resistant material516may comprise a polymer such as nylon, polyurethane and/or any other suitable polymer. In other words, the cut-resistant material516is not limited to pliable fabrics. In this example, the slash guard515is movable with respect to the tendon guard35(or the rear portion82of the ankle portion64of the shell30) by moving with respect to the attachment member519. In some cases, the slash guard515may be pivotable about the attachment member519. Thus, in cases where the cut-resistant material516is a rigid material, the slash guard515may still be movable with respect to the tendon guard35or the rear portion82of the ankle portion64of the shell30) by pivoting about the attachment member519.

In a variant, as shown inFIGS. 86A to 86D, rather than integrally molding the shell30as a single piece, the shell30may be molded in a plurality of pieces710,712and the pieces may then be joined together. For example, this may allow using processes other than injection molding, notably such as casting or other molding methods. Moreover, the pieces710,712may be configured to interlock with one another. Notably, the pieces710,712may comprise protrusions and corresponding recesses for fitting the protrusions such as to interlock the pieces710,712with one another. An adhesive may be applied between the pieces710,712to permanently affix the pieces710,712to one another. As shown inFIG. 86A, each of the pieces710,712may constitute a part of the shell30and the blade holder24. In some cases, as shown inFIG. 86B, each of the pieces710,712may constitute a part of only the shell30or only the blade holder24. As shown inFIGS. 86C and 86D, the pieces may include three or more pieces710,712,714.

In another variant, one or more of the subshells851-85Lmay be sprayed rather than injection molded. For instance, this may allow to more easily form thinner subshells851-85L(e.g., of 0.1 mm).

In another variant, as shown inFIG. 87, the blade holder24may comprise an insert750configured to receive the blade26. The insert750is affixed to the lower portion162of the blade holder24in any suitable manner. In this example, the insert750comprises projections that interlock into recesses165of the blade holder24. The insert750further comprises a recess752configured to receive the blade26. The insert750may be made integral with the lower portion162of the blade holder24by inserting it into a corresponding mold during molding of the blade holder24. Alternatively, the insert750may be affixed to the lower portion162of the blade holder24after the lower portion162has already been formed. The insert750comprises a reinforced material that is stronger and/or stiffer than a material of the lower portion162of the blade holder24. For example, the reinforced material may be a composite material (e.g., a carbon fiber material).

In another variant, as shown inFIG. 88, the blade holder24may comprise a void350in one of its front and rear pillars210,212. More particularly, in this example, the void350of the blade holder24may be formed by separately molding the blade holder24with a molding insert, and removing the molding insert after molding the blade holder24to obtain a cavity in the blade holder24. Thus, once the blade holder24is assembled with the shell30, the blade holder24comprises the void350which is contained between surfaces of the blade holder24and the sole portion69of the shell30. In another example, rather than leaving the cavity of the blade holder24as a void, an insert, such as the insert3151, may be placed in the cavity and the blade holder24secured to the shell30such that the insert3151is contained between inner surfaces of a body of the blade holder24and a surface of the sole portion69of the shell30.

In another variant, the exterior subshell853may be configured to extend into the recess190of the blade-retention portion188of the blade-retaining base164of the blade holder24. As such, the subshell853may contact the blade26as it is inserted into the recess190. This may be useful in examples where the exterior subshell853is relatively rigid as it may provide compaction resistance when the blade26is inserted in the recess190.

In some embodiments, as shown inFIGS. 90 and 91, the material Miof a subshell85xof the skate boot22may comprise a mixture of a polymeric substance52and an expansion agent53. This may help the material Mito have desirable properties, such as being more shock-absorbent than it if was entirely made of the expansion agent53and/or being lighter than if it was entirely made of the polymeric substance52.

The polymeric substance52constitutes a substantial part of the material Miand substantially contributes to structural integrity to the subshell85x. For instance, in some embodiments, the polymeric substance52may constitute at least 40%, in some cases at least 50%, in some cases at least 60%, in some cases at least 70%, in some cases at least 80%, and in some cases at least 90% of the material Miby weight. In this example of implementation, the polymeric substance52may constitute between 50% and 90% of the material Miby weight.

In this embodiment, the polymeric substance52may be an elastomeric substance. For instance, the polymeric substance52may be a thermoplastic elastomer (TPE) or a thermoset elastomer (TSE).

More particularly, in this embodiment, the polymeric substance52comprises polyurethane. The polyurethane52may be composed of any suitable constituents such as isocyanates and polyols and possibly additives. For instance, in some embodiments, the polyurethane52may have a hardness in a scale of Shore 00, Shore A, Shore C or Shore D, or equivalent. For example, in some embodiments, the hardness of the polyurethane52may be between Shore 5A and 95A or between Shore 40D to 93D. Any other suitable polyurethane may be used in other embodiments.

The polymeric substance52may comprise any other suitable polymer in other embodiments. For example, in some embodiments, the polymeric substance52may comprise silicon, rubber, etc.

The expansion agent53is combined with the polyurethane52. In some cases, this may be done to enhance properties of the material Mi. Alternatively or additionally, in some cases, this may be done to enable expansion of the material Mito a final shape of the subshell85xin the mold154x. For instance, in some embodiments, the expansion agent54may constitute at least 10%, in some cases at least 20%, in some cases at least 30%, in some cases at least 40%, in some cases at least 50%, in some cases at least 60%, of the material Miby weight and in some cases even more. In this example of implementation, the expansion agent54may constitute between 15% and 50% of the material Miby weight.

In this embodiment, as shown inFIG. 91, the expansion agent53comprises an amount of expandable microspheres631-63M. Each expandable microsphere63icomprises a polymeric shell67expandable by a fluid encapsulated in an interior of the polymeric shell67. In this example of implementation, the polymeric shell67of the expandable microsphere63iis a thermoplastic shell. The fluid encapsulated in the polymeric shell67is a liquid or gas (in this case a gas) able to expand the expandable microsphere63iwhen heated during manufacturing of the subshell85x. In some embodiments, the expandable microspheres631-63Mmay be Expancel™ microspheres commercialized by Akzo Nobel. In other embodiments, the expandable microspheres631-63Mmay be Dualite microspheres commercialized by Henkel; Advancell microspheres commercialized by Sekisui; Matsumoto Microsphere microspheres commercialized by Matsumoto Yushi Seiyaku Co; or KUREHA Microsphere microspheres commercialized by Kureha. Various other types of expandable microspheres may be used in other embodiments.

In this example of implementation, the expandable microspheres631-63Minclude dry unexpanded (DU) microspheres when combined with the polymeric substance52to create the material Mibefore the material Miis molded. For instance, the dry unexpanded (DU) microspheres may be provided as a powder mixed with one or more liquid constituents of the polymeric substance52.

The expandable microspheres631-63Mmay be provided in various other forms in other embodiments. For example, in some embodiments, the expandable microspheres631-63Mmay include dry expanded, wet and/or partially-expanded microspheres. For instance, wet unexpanded microspheres may be used to get better bonding with the polymeric substance52. Partially-expanded microspheres may be used to employ less of the polymeric substance52, or mix with the polymeric substance52in semi-solid form.

In some embodiments, the expandable microspheres631-63Mmay constitute at least 10%, in some cases at least 20%, in some cases at least 30%, in some cases at least 40%, in some cases at least 50%, and in some cases at least 60% of the material Miby weight and in some cases even more. In this example of implementation, the expandable micropsheres631-63Mmay constitute between 15% and 50% of the material Miby weight.

The subshell85xcomprising the material Miwith the polymeric substance52and the expandable microspheres631-63Mmay have various desirable qualities.

For instance, in some embodiments, the subshell85xmay be less dense and thus lighter than if it was entirely made of the polyurethane52, yet be more shock-absorbent and/or have other better mechanical properties than if it was entirely made of the expandable microspheres631-63M.

For example, in some embodiments, a density of the material Mimay be less than a density of the polyurethane52(alone). For instance, the density of the material Miof the subshell85xmay be no more than 70%, in some cases no more than 60%, in some cases no more than 50%, in some cases no more than 40%, in some cases no more than 30%, in some cases no more than 20%, in some cases no more than 10% and in some cases no more than 5% of the density of the polyurethane52and in some cases even less. For example, in some embodiments, the density of the material Mimay be between 2 to 75 times less than the density of the polyurethane52(i.e., the density of the material Mimay be about 1% to 50% of the density of the polyurethane52).

The density of the material Mimay have any suitable value. For instance, in some embodiments, the density of the material Mimay be no more than 0.7 g/cm3, in some cases no more than 0.4 g/cm3, in some cases no more than 0.1 g/cm3, in some cases no more than 0.080 g/cm3, in some cases no more than 0.050 g/cm3, in some cases no more than 0.030 g/cm3, and/or may be at least 0.010 g/cm3. In some examples of implementation, the density of the material Mimay be between 0.015 g/cm3and 0.080 g/cm3, in some cases between 0.030 g/cm3and 0.070 g/cm3, and in some cases between 0.040 g/cm3and 0.060 g/cm3.

As another example, in some embodiments, a stiffness of the material Mimay be different from (i.e., greater or less than) a stiffness of the expandable microspheres631-63M(alone). For instance, a modulus of elasticity (i.e., Young's modulus) of the material IA may be greater or less than a modulus of elasticity of the expandable microspheres631-63M(alone). For instance, a difference between the modulus of elasticity of the material Miand the modulus of elasticity of the expandable microspheres631-63Mmay be at least 20%, in some cases at least 30%, in some cases at least 50%, and in some cases even more, measured based on a smaller one of the modulus of elasticity of the material Miand the modulus of elasticity of the expandable microspheres631-63M. In some cases, the modulus of elasticity may be evaluated according to ASTM D-638 or ASTM D-412.

As another example, in some embodiments, a resilience of the material Mimay be less than a resilience of the expandable microspheres631-63M(alone). For instance, in some embodiments, the resilience of the material Mimay no more than 70%, in some cases no more than 60%, in some cases no more than 50%, in some cases no more than 40%, in some cases no more than 30%, and in some cases no more than 20%, and in some cases no more than 10% of the resilience of the expandable microspheres631-63Maccording to ASTM D2632-01 which measures resilience by vertical rebound. In some examples of implementation, the resilience of the material Mimay be between 20% and 60% of the resilience of the expandable microspheres631-63M. Alternatively, in other embodiments, the resilience of the material Mimay be greater than the resilience of the expandable microspheres631-63M.

The resilience of the material Mimay have any suitable value. For instance, in some embodiments, the resilience of the material Mimay be no more than 40%, in some cases no more than 30%, in some cases no more than 20%, in some cases no more than 10%, and in some cases even less (e.g., 5%), according to ASTM D2632-01, thereby making the subshell85xmore shock-absorbent. In other embodiments, the resilience of the material Mimay be at least 60%, in some cases at least 70%, in some cases at least 80% and in some cases even more, according to ASTM D2632-01, thereby making the material Miprovide more rebound.

As another example, in some embodiments, a tensile strength of the material Mimay be greater than a tensile strength of the expandable microspheres631-63M(alone). For instance, in some embodiments, the tensile strength of the material Mimay be at least 120%, in some cases at least 150%, in some cases at least 200%, in some cases at least 300%, in some cases at least 400%, and in some cases at least 500% of the tensile strength of the expandable microspheres631-63Maccording to ASTM D-638 or ASTM D-412, and in some cases even more.

The tensile strength of the material Mimay have any suitable value. For instance, in some embodiments, the tensile strength of the material Mimay be at least 0.9 MPa, in some cases at least 1 MPa, in some cases at least 1.2 MPa, in some cases at least 1.5 MPa and in some cases even more (e.g., 2 MPa or more).

As another example, in some embodiments, an elongation at break of the material Mimay be greater than an elongation at break of the expandable microspheres631-63M(alone). For instance, in some embodiments, the elongation at break of the expandable material Mimay be at least 120%, in some cases at least 150%, in some cases at least 200%, in some cases at least 300%, in some cases at least 400%, and in some cases at least 500% of the elongation at break of the expandable microspheres631-63Maccording to ASTM D-638 or ASTM D-412, and in some cases even more.

The elongation at break of the material Mimay have any suitable value. For instance, in some embodiments, the elongation at break of the material Mimay be at least 20%, in some cases at least 30%, in some cases at least 50%, in some cases at least 75%, in some cases at least 100%, and in some cases even more (e.g. 150% or more).

In some embodiments, a material of the shell30(e.g., a given one of the materials M1-MN) may be a composite material. For example, the composite material may be a fiber-matrix composite material that comprises a matrix in which fibers are embedded. The matrix may include any suitable polymeric resin, such as a thermosetting polymeric material (e.g., polyester, vinyl ester, vinyl ether, polyurethane, epoxy, cyanate ester, etc.), a thermoplastic polymeric material (e.g., polyethylene, polyurethane, polypropylene, acrylic resin, polyether ether ketone, polyethylene terephthalate, polyvinyl chloride, polymethyl methacrylate, polycarbonate, acrylonitrile butadiene styrene, nylon, polyimide, polysulfone, polyamide-imide, self-reinforcing polyphenylene, etc.), or a hybrid thermosetting-thermoplastic polymeric material. The fibers may be made of any suitable material such as carbon fibers, polymeric fibers such as aramid fibers, boron fibers, glass fibers, ceramic fibers, etc.

Although in embodiments considered above the skate10is designed for playing ice hockey on the skating surface14which is ice, in other embodiments, the skate10may be constructed using principles described herein for playing roller hockey or another type of hockey (e.g., field or street hockey) on the skating surface14which is a dry surface (e.g., a polymeric, concrete, wooden, or turf playing surface or any other dry surface on which roller hockey or field or street hockey is played). Thus, in other embodiments, instead of comprising the blade26, the skating device28may comprise a set of wheels to roll on the dry skating surface14(i.e., the skate10may be an inline skate or other roller skate). Moreover, in other embodiments, the skate10may be a figure skate constructed using principles described herein for figure skating.

Furthermore, although in embodiments considered above the footwear10is a skate for skating on the skating surface14, in other embodiments, the footwear10may be any other suitable type of footwear. For example, as shown inFIG. 92, the footwear10may be a ski boot comprising a shell830which may be constructed in the manner described above with respect to the shell of the skate. In particular, the ski boot10is configured to be attachable and detachable from a ski802which is configured to travel on a ground surface8(e.g., snow). To that end, the ski boot10is configured to interact with an attachment mechanism800of the ski802. In another example, as shown inFIG. 93, the footwear10may be a boot (e.g., a work boot or any other type of boot) comprising a shell930which can be constructed in the manner described above with respect to the shell of the skate.

In some embodiments, any feature of any embodiment described herein may be used in combination with any feature of any other embodiment described herein.

Certain additional elements that may be needed for operation of certain embodiments have not been described or illustrated as they are assumed to be within the purview of those of ordinary skill in the art. Moreover, certain embodiments may be free of, may lack and/or may function without any element that is not specifically disclosed herein.

To facilitate the description, any reference numeral designating an element in one figure designates the same element if used in any other figures. In describing the embodiments, specific terminology has been resorted to for the sake of description but the invention is not intended to be limited to the specific terms so selected, and it is understood that each specific term comprises all equivalents.

In case of any discrepancy, inconsistency, or other difference between terms used herein and terms used in any document incorporated by reference herein, meanings of the terms used herein are to prevail and be used.

Although various embodiments have been illustrated, this was for the purpose of describing, but not limiting, the invention. Various modifications will become apparent to those skilled in the art and are within the scope of this invention, which is defined more particularly by the attached claims.