SKATE OR OTHER FOOTWEAR

A skate (e.g., an ice skate) or other footwear for a user. The skate or other footwear comprises a skate boot or other foot-receiving structure for receiving a foot of the user and possibly one or more other components, such as a skating device (e.g., a blade 5 and a blade holder) disposed beneath the skate boot to engage a skating surface (e.g., ice). In some cases, at least part of the skate boot or other foot-receiving structure 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 0 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.

FIELD

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

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 body, sometimes referred to as 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.

Also, a skating device, such as a blade holder holding a blade for ice skating or a wheel holder holding wheels for roller skating (e.g., inline skating), is normally fastened under a skate boot. This may add attachment, manufacturing, and/or other issues.

Similar considerations may arise for other types of footwear (e.g., ski boots, snowboarding 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 this disclosure, there is provided a skate (e.g., an ice skate) or other footwear for a user. The skate or other footwear comprises a skate boot or other foot-receiving structure for receiving a foot of the user and possibly one or more other components, such as a skating device (e.g., a blade and a blade holder) disposed beneath the skate boot to engage a skating surface. In some cases, at least part of the skate boot or other foot-receiving structure and optionally at least part of one or more other components (e.g., the skating device) of the skate or other footwear 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.

For example, in accordance with an aspect of the disclosure, there is provided a method of making a skate boot for a skate, the skate boot being configured to receive a foot of a user. The method comprises: providing a molding apparatus comprising a plurality of ports for receiving constituents that are different; determining a desired property of a material of a body of the skate boot; injecting respective ones of the constituents to produce the material of the body of the skate boot; and controlling proportions of the respective ones of the constituents to impart the desired property to the material of the body of the skate boot.

In accordance with another aspect of the disclosure, there is provided a method of making a skate boot for a skate, the skate boot being configured to receive a foot of a user. The method comprises: providing a molding apparatus comprising a plurality of ports for receiving an isocyanate, a first polyol, and a second polyol different from the first polyol; determining a desired property of a polyurethane of a body of the skate boot; injecting the isocyanate, the first polyol, and the second polyol to produce the polyurethane of the body of the skate boot; and controlling proportions of the isocyanate, the first polyol, and the second polyol to impart the desired property to the polyurethane of the body of the skate boot.

In accordance with another aspect of the disclosure, there is provided a method of making skate boots for skates. The method comprises: providing a molding apparatus comprising a plurality of ports for receiving constituents that are different; for each skate boot, injecting respective ones of the constituents to produce a material of a body of the skate boot. Proportions of the respective ones of the constituents injected to produce the material of the body of a first one of the skate boots differ from proportions of the respective ones of the constituents injected to produce the material of the body of a second one of the skate boots.

In accordance with another aspect of the disclosure, there is provided a method of making skate boots for skates. The method comprises: providing a molding apparatus comprising a plurality of ports for receiving an isocyanate, a first polyol, and a second polyol different from the first polyol; for each skate boot, injecting the isocyanate, the first polyol, and the second polyol to produce a polyurethane of a body of the skate boot. Proportions of the isocyanate, the first polyol, and the second polyol injected to produce the polyurethane of the body of a first one of the skate boots differ from proportions of the isocyanate, the first polyol, and the second polyol injected to produce the polyurethane of the body of a second one of the skate boots.

In accordance with another aspect of the disclosure, there is provided a plurality of skate boots for skates. Each of the skate boots comprises a body including a material produced by injecting respective ones of a plurality of constituents. Proportions of the respective ones of the constituents injected to produce the material of the body of a first one of the skate boots differ from proportions of the respective ones of the constituents injected to produce the material of the body of a second one of the skate boots.

In accordance with another aspect of the disclosure, there is provided a plurality of skate boots for skates. Each of the skate boots comprises a body including a polyurethane produced by injecting an isocyanate, a first polyol, and a second polyol. Proportions of the isocyanate, the first polyol, and the second polyol injected to produce the polyurethane of the body of a first one of the skate boots differ from proportions of the isocyanate, the first polyol, and the second polyol injected to produce the polyurethane of the body of a second one of the skate boots.

In accordance with another aspect of the disclosure, there is provided a method of making an article of footwear, the article of footwear being configured to receive a foot of a user. The method comprises: providing a molding apparatus comprising a plurality of ports for receiving constituents that are different; determining a desired property of a material of a body of the article of footwear; injecting respective ones of the constituents to produce the material of the body of the article of footwear; and controlling proportions of the respective ones of the constituents to impart the desired property to the material of the body of the article of footwear.

In accordance with another aspect of the disclosure, there is provided a method of making an article of footwear, the article of footwear being configured to receive a foot of a user. The method comprises: providing a molding apparatus comprising a plurality of ports for receiving an isocyanate, a first polyol, and a second polyol different from the first polyol; determining a desired property of a polyurethane of a body of the article of footwear; injecting the isocyanate, the first polyol, and the second polyol to produce the polyurethane of the body of the article of footwear; and controlling proportions of the isocyanate, the first polyol, and the second polyol to impart the desired property to the polyurethane of the body of the article of footwear.

In accordance with another aspect of the disclosure, there is provided a method of making articles of footwear. The method comprises: providing a molding apparatus comprising a plurality of ports for receiving constituents that are different; for each article of footwear, injecting respective ones of the constituents to produce a material of a body of the article of footwear. Proportions of the respective ones of the constituents injected to produce the material of the body of a first one of the articles of footwear differ from proportions of the respective ones of the constituents injected to produce the material of the body of a second one of the articles of footwear.

In accordance with another aspect of the disclosure, there is provided a method of making articles of footwear. The method comprises: providing a molding apparatus comprising a plurality of ports for receiving an isocyanate, a first polyol, and a second polyol different from the first polyol; and for each article of footwear, injecting the isocyanate, the first polyol, and the second polyol to produce a polyurethane of a body of the article of footwear. Proportions of the isocyanate, the first polyol, and the second polyol injected to produce the polyurethane of the body of a first one of the articles of footwear differ from proportions of the isocyanate, the first polyol, and the second polyol injected to produce the polyurethane of the body of a second one of the articles of footwear.

In accordance with another aspect of the disclosure, there is provided a method of making a plurality of articles of footwear. Each of the articles of footwear comprises a body including a material produced by injecting respective ones of a plurality of constituents. Proportions of the respective ones of the constituents injected to produce the material of the body of a first one of the articles of footwear differ from proportions of the respective ones of the constituents injected to produce the material of the body of a second one of the articles of footwear.

In accordance with another aspect of the disclosure, there is provided a method of making a plurality of articles of footwear. Each of the articles of footwear comprises a body including a polyurethane produced by injecting an isocyanate, a first polyol, and a second polyol. Proportions of the isocyanate, the first polyol, and the second polyol injected to produce the polyurethane of the body of a first one of the articles of footwear differ from proportions of the isocyanate, the first polyol, and the second polyol injected to produce the polyurethane of the body of a second one of the articles of footwear.

In accordance with another aspect of the disclosure, there is provided a skate for skating on ice. The skate comprises: a skate boot configured 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; and a blade holder disposed below the skate boot and configured to hold a blade for engaging the ice, the blade holder comprising an integrally-formed portion formed integrally with the body of the skate boot, the blade holder comprising a core formed separately from the integrally-formed portion of the blade holder and the body of the skate boot and affixed to the integrally-formed portion of the blade holder.

In accordance with another aspect of the disclosure, there is provided a skate for skating on ice. The skate comprises: a skate boot configured 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; and a blade holder disposed below the skate boot and configured to hold a blade for engaging the ice, the blade holder comprising an integrally-formed portion formed integrally with the body of the skate boot, the blade holder comprising a core formed separately from the integrally-formed portion of the blade holder and the body of the skate boot and affixed to the integrally-formed portion of the blade holder. The blade holder comprises a blade-retaining base configured to retain the blade and a front pillar and a rear pillar that extend upwardly from the blade-retaining base towards the skate boot. The core of the blade holder comprises a pillar-forming member extending upwardly from the blade-retaining base and constituting at least part of a given one of the front pillar and the rear pillar. The core of the blade holder comprises a cavity defined at least partly by the pillar-forming member. The pillar-forming member comprises a reinforcement.

In accordance with another aspect of the disclosure, there is provided a skate for skating on ice. The skate comprises: a skate boot configured 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; and a blade holder disposed below the skate boot and configured to hold a blade for engaging the ice, the blade holder comprising an integrally-formed portion formed integrally with the body of the skate boot, the blade holder comprising a core formed separately from the integrally-formed portion of the blade holder and the body of the skate boot and affixed to the integrally-formed portion of the blade holder. The blade holder comprises a blade-retaining base configured to retain the blade and a front pillar and a rear pillar that extend upwardly from the blade-retaining base towards the skate boot. The core of the blade holder comprises a pillar-forming member extending upwardly from the blade-retaining base and constituting at least part of a given one of the front pillar and the rear pillar. The core of the blade holder comprises a cavity defined at least partly by the pillar-forming member. The core of the blade holder comprises a cap capping the cavity at least partly defined by the pillar-forming member. The pillar-forming member comprises a reinforcement. The cap comprises a reinforcement.

In accordance with another aspect of the disclosure, there is provided a skate for skating on ice. The skate comprises: a skate boot configured 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; and a blade holder disposed below the skate boot and configured to hold a blade for engaging the ice, at least part of the blade holder being formed integrally with the body of the skate boot, the blade holder comprising a blade-retaining base configured to retain the blade and a front pillar and a rear pillar that extend upwardly from the blade-retaining base towards the skate boot, a given one of the front pillar and the rear pillar extending downwardly from a respective one of a front sole part of the skate boot and a rear sole part of the skate boot, a width of the given one of the front pillar and the rear pillar being at least 80% of a width of the respective one of the front sole part of the skate boot and the rear sole part of the skate boot.

In accordance with another aspect of the disclosure, there is provided a skate for skating on ice. The skate comprises: a skate boot configured 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; and a blade holder disposed below the skate boot and configured to hold a blade for engaging the ice, at least part of the blade holder being formed integrally with the body of the skate boot, the blade holder comprising a blade-retaining base configured to retain the blade and a front pillar and a rear pillar that extend upwardly from the blade-retaining base towards the skate boot, a given one of the front pillar and the rear pillar extending downwardly from a respective one of a front sole part of the skate boot and a rear sole part of the skate boot and being at least as wide as the respective one of the front sole part of the skate boot and the rear sole part of the skate boot.

In accordance with another aspect of the disclosure, there is provided a skate for skating on ice. The skate comprises: a skate boot configured 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; and a blade holder disposed below the skate boot and configured to hold a blade for engaging the ice, at least part of the blade holder being formed integrally with the body of the skate boot, the blade holder comprising a blade-retaining base configured to retain the blade and a front pillar and a rear pillar that extend upwardly from the blade-retaining base towards the skate boot, the blade holder being configured to hold the blade such that the blade is unsupported by the blade holder between the front pillar and the rear pillar.

In accordance with another aspect of the disclosure, there is provided a skate for skating on ice. The skate comprises: a skate boot configured 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; and a blade holder disposed below the skate boot and configured to hold a blade for engaging the ice, the blade holder comprising a blade-retaining base configured to retain the blade and a support extending upwardly from the blade-retaining base towards the skate boot, the blade-retaining base comprising a blade-receiving slot extending from a front portion of the blade-retaining base to a rear portion of the blade-retaining base and configured to receive the blade, the blade-receiving slot being wider in an intermediate portion of the blade-retaining base between the front portion of the blade-retaining base and the rear portion of the blade-retaining base than in the front portion of the blade-retaining base and in the rear portion of the blade-retaining base.

In accordance with another aspect of the disclosure, there is provided a skate for skating on ice. The skate comprises: a skate boot configured 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; and a blade holder disposed below the skate boot and configured to hold a blade for engaging the ice, the blade holder comprising a blade-retaining base configured to retain the blade and a front pillar and a rear pillar that extend upwardly from the blade-retaining base towards the skate boot, the blade-retaining base comprising a blade-receiving slot extending from a front portion of the blade-retaining base to a rear portion of the blade-retaining base and configured to receive the blade, the blade-receiving slot being wider between the front pillar and the rear pillar than beneath the front pillar and beneath the rear pillar.

In accordance with another aspect of the disclosure, there is provided a blade holder for a skate for skating on ice. The skate comprises a skate boot configured to receive a foot of a user. The skate boot comprises 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. The blade holder is configured to be disposed below the skate boot and hold a blade for engaging the ice. The blade holder comprises: a blade-retaining base configured to retain the blade; and a front pillar and a rear pillar that extend upwardly from the blade-retaining base. The blade-retaining base comprises a blade-receiving slot extending from a front portion of the blade-retaining base to a rear portion of the blade-retaining base and configured to receive the blade. The blade-receiving slot is wider between the front pillar and the rear pillar than beneath the front pillar and beneath the rear pillar.

In accordance with another aspect of the disclosure, there is provided a blade holder for a skate for skating on ice. The skate comprises a skate boot configured to receive a foot of a user. The skate boot comprises 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. The blade holder is configured to be disposed below the skate boot and hold a blade for engaging the ice. The blade holder comprises: a blade-retaining base configured to retain the blade; and a support extending upwardly from the blade-retaining base. The blade-retaining base comprises a blade-receiving slot extending from a front portion of the blade-retaining base to a rear portion of the blade-retaining base and configured to receive the blade. The blade-receiving slot is wider in an intermediate portion of the blade-retaining base between the front portion of the blade-retaining base and the rear portion of the blade-retaining base than in the front portion of the blade-retaining base and in the rear portion of the blade-retaining base.

In accordance with another aspect of the disclosure, there is provided a skate boot for a skate. The skate boot is configured to receive a foot of a user and comprises 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 face an ankle of the user. The body of the skate boot comprises graphical ink implementing graphics and provided by a film, the graphical ink covering at least a majority of a surface area of an ink-providing side of the film providing the graphical ink.

In accordance with another aspect of the disclosure, there is provided a method of making a skate boot for a skate, the skate boot being configured to receive a foot of a user. The method comprises: forming a body of the skate boot 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 face an ankle of the user; and positioning a film including graphical ink to implement graphics on the body of the skate boot, the graphical ink covering at least a majority of a surface area of an ink-providing side of the film providing the graphical ink.

In accordance with another aspect of the disclosure, there is provided a skate boot for a skate. The skate boot is configured to receive a foot of a user and comprises 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 face an ankle of the user. The body of the skate boot includes: a plurality of layers formed integrally with one another by flowing in a molding apparatus; and graphical ink implementing graphics and disposed between a first one of the layers and a second one of the layers of the body of the skate boot, the graphical ink being solventless.

In accordance with another aspect of the disclosure, there is provided a skate boot for a skate. The skate boot is configured to receive a foot of a user and comprises 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 face an ankle of the user. The body of the skate boot includes: a plurality of layers formed integrally with one another by flowing in a molding apparatus; and graphical ink implementing graphics and disposed between a first one of the layers and a second one of the layers of the body of the skate boot, a surface energy of the graphical ink being less than 32 dynes/cm.

In accordance with another aspect of the disclosure, there is provided an article of footwear configured to receive a foot of a user. The article of footwear comprises 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, and a heel portion to receive a heel of the user's foot. The body of the article of footwear includes: a plurality of layers formed integrally with one another by flowing in a molding apparatus; and graphical ink implementing graphics and disposed between a first one of the layers and a second one of the layers of the body of the article of footwear, the graphical ink being solventless.

In accordance with another aspect of the disclosure, there is provided an article of footwear configured to receive a foot of a user. The article of footwear comprises 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, and a heel portion to receive a heel of the user's foot. The body of the article of footwear includes: a plurality of layers formed integrally with one another by flowing in a molding apparatus; and graphical ink implementing graphics and disposed between a first one of the layers and a second one of the layers of the body of the article of footwear, a surface energy of the graphical ink being less than 32 dynes/cm.

In accordance with another aspect of the disclosure, there is provided a skate for skating on ice. The skate comprises: a skate boot configured 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; and a blade holder disposed below the skate boot and configured to hold a blade for engaging the ice, at least part of the blade holder being formed integrally with the body of the skate boot. The skate comprises a graphical element extending from the skate boot to the blade holder such that the skate boot comprises an upper portion of the graphical element and the blade holder comprises a lower portion of the graphical element visually continuous with the upper portion of the graphical element.

In accordance with another aspect of the disclosure, there is provided a skate boot for a skate. The skate boot is configured to receive a foot of a user. The skate boot comprises 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 face an ankle of the user. The body of the skate boot includes a plurality of layers formed integrally with one another by flowing in a molding apparatus. A given one of the layers comprises an opening that opens onto an adjacent one of the layers.

In accordance with another aspect of the disclosure, there is provided an article of footwear configured to receive a foot of a user. The article of footwear comprises 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 face an ankle of the user. The body of the article of footwear includes a plurality of layers formed integrally with one another by flowing in a molding apparatus. A given one of the layers comprises an opening that opens onto an adjacent one of the layers.

These and other aspects of this disclosure will now become apparent to those of ordinary skill in the art upon review of a description of embodiments that follows in conjunction with accompanying drawings.

In the drawings, embodiments 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 and should not be limitative.

DETAILED DESCRIPTION OF EMBODIMENTS

FIGS.1and2show an example of an embodiment of footwear10for a user. In this embodiment, the footwear10is a skate for the user to skate on a skating surface12. More particularly, in this embodiment, the skate10is a hockey skate for the user 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), 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 skate10to have useful performance characteristics (e.g., reduced weight, proper fit and comfort, etc.) while being more cost-effectively manufactured. Also, the skate10may facilitate installation and removal of the blade26and/or the blade holder24, such as for replacement of the blade26and/or the blade holder24, assemblage of the skate10, and/or other purposes. For example, in some embodiments, the skate boot22and the blade holder24may be at least partly formed integrally with one another (e.g., by injection molding or other material flow), while the blade26may be readily attachable to and detachable from the blade holder24.

The skate boot22is a foot-receiving structure defining a cavity54for receiving the player's foot11. With additional reference toFIGS.197and198, 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 body30, 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 body30and 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 body30and the liner36via the apertures48.

The body30of the skate boot22imparts strength and structural integrity to the skate10to support the player's foot11. More particularly, in this embodiment, as shown inFIG.3, the body30of the skate boot22, which will be referred to as a “shell”, comprises 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.4, 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., Curve), 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 kg/m 3, in some cases no more than 30 kg/m 3, in some cases no more than 20 kg/m 3, in some cases no more than 15 kg/m 3, in some cases no more 10 kg/m 3 and 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 cases3, in some cases4and 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.170, 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 I 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.

In this embodiment, as shown inFIG.5, 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/m 3, while the density of the intermediate subshell852may be approximately 20 kg/m 3, and the density of the external subshell853may be approximately 10 kg/m 3. 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.6, the shell30may be a single shell and therefore does not comprise any subshells. In other embodiments, as shown inFIG.7, the shell30may comprise two subshells851-85L.

Moreover, as shown inFIGS.8to10, 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.8, in some embodiments, the exterior subshell85EXTmay comprise a gap G at the sole portion69of the shell such 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.9, 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.10, 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.11, 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.12and13, 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.14, 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.15. 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 mold1541being configured to contain the last152at different stages of the molding process. In this embodiment, each female mold1541comprises 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.16to18.

With additional reference toFIG.16, 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.17, 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.18, 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 embodiments, 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 some 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 embodiments, with additional reference toFIGS.19to46, the last152may be reconfigurable to facilitate demolding (i.e., removal) of the shell30from the last152. That is, a configuration (e.g., shape) of the last152may be changeable between a “molding” configuration to mold the shell30on the last152and a “demolding” configuration to demold the shell30from the last152. The demolding configuration of the last152differs from the molding configuration of the last152, notably in that demolding of the shell30from the last152is easier in the demolding configuration of the last152than in the molding configuration of the last152(e.g., less effort has to be exerted on the shell30to remove the shell30from the last152in its demolding configuration than in its molding configuration, or removal of the shell30from the last152in its demolding configuration is readily allowed while removal of the shell30from the last152in its molding configuration is precluded without damaging the shell30). For example, the last152may contract (i.e., be reduced in size) in its demolding configuration relative to its molding configuration. Removal of the shell30from the last152, which may be by holding the shell30to move it away from the last152and/or holding and moving at least part of the last152away from the shell30, is thus facilitated.

This may be particularly useful to mold the shell30on the last152such that the shell30has undercuts511-516, i.e., recesses (e.g., depressions) or other reentrant portions, which would otherwise complicate demolding of the shell30. For example, in this embodiment, the undercuts511,512are the medial and lateral depressions78,80for receiving the medial and lateral malleoli MM, LM of the player, the undercuts513,514are recesses831,832defined by curvature of the heel portion62in the longitudinal and heightwise directions of the skate10and curvature of the heel portion62in the widthwise direction of the skate10such that the heel portion62is substantially cup-shaped, and the undercuts515,516are recesses861,862defined by curvature of the medial side portion66and curvature of the lateral side portion68in the longitudinal and heightwise directions of the skate10adjacent to the player's forefoot. The shell30may have any other suitable undercut such as the undercuts511-516in other embodiments.

Furthermore, this may facilitate demolding of the shell30from the last152without deforming the shell30. That is, a shape of the shell30once molding is completed can be maintained during and upon demolding. In this example, this may be useful as the shell30is rigid (e.g., to avoid stressing the shell30, etc.).

For example, in some embodiments, a volume occupied by the last152may be reduced from its molding configuration to its demolding configuration such that the volume occupied by the last152in its demolding configuration is smaller than the volume occupied by the last152in its molding configuration.

In some embodiments, as shown inFIG.19, the last152comprises a cavity163to receive a fluid167to vary the volume occupied by the last152, by expanding and contracting the last152. For instance, 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 the fluid167which is 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. The fluid167may be a liquid (e.g., water, oil, etc.) or any other suitable fluid in other cases.

As a variant, in some embodiments, as shown inFIG.20, the cavity163of the last152may contain particles1691-169P, such as beads, granules, sand, or other grit, that are configured to vary a rigidity of the last152in response to flow of the fluid167relative to (i.e., into or out of) the cavity163of the last152. For instance, the particles1691-169Pmay rigidify (i.e., increase the rigidity of the last152) when the fluid167flows out of the cavity167(e.g., by vacuum).

As another example, in some embodiments, as shown inFIGS.21to32, the last152may comprise a plurality of last members1751-175Mthat are movable relative to one another to change between its molding configuration and its demolding configuration. The last members1751-175Mmay be viewed as last “modules” so that the last152is a “modular” last. Each of the last members1751-175Mis shaped such that the last members1751-175Mcollectively form the shape of the last152to mold the shell30in its molding configuration.

In this embodiment, respective ones of the last members1751-175Mare movable relative to one another while remaining connected to one another as the last152changes between its molding configuration and its demolding configuration. The last152comprises a control system187to control movement of the last members1751-175Mrelative to one another. The control system187comprises a linkage181that includes links1831-183Clinking adjacent ones of the last members1751-175Mso that they are movable relative to one another and an actuating mechanism191that includes a plurality of actuators1931-1934operable to move the last members1751-175Mrelative to one another between the molding configuration of the last152and the demolding configuration of the last152.

Adjacent ones of the last members1751-175Mmay be translatable and/or rotatable relative to one to change the last152between its molding configuration and its demolding configuration. That is, adjacent ones of the last members1751-175Mmay move relative to one by translation, rotation, or a combination of translation and rotation to change the last152between its molding configuration and its demolding configuration. For example, in this embodiment, the linkage181comprises translation guides1951-1954for translating adjacent ones of the last members1751-175Mrelative to one another and a pivot197for pivoting adjacent ones of the last members1751-175Mrelative to one another.

In this embodiment, the last member1751is a front central last member to form part of a front region of the shell30including a central part of the toe cap32integrally formed with the shell30and a front central part of the sole portion69; the last member1753is a rear central last member to form part of a rear central region of the shell30including a central part of the heel portion62, a central part of the ankle portion64, and a rear central part of the sole portion69; the last member1752is an intermediate central last member disposed between the front central last member1751and the rear central last member1753to form an intermediate central part of the sole portion69; and the last members1754,1754are medial and lateral last members to form medial and lateral parts of the heel portion62, medial and lateral parts of the ankle portion64, medial and lateral parts of the sole portion69, medial and lateral parts of the toe cap32integrally formed with the shell30, and the medial and lateral side portions66,68of the shell30.

More particularly, in this embodiment, the last members1751-175Mare movable relative to one another to change the last152from its molding configuration to its demolding configuration by: (1) translating the intermediate central last member1752upwardly relative to the front central last member1751and the rear central last member1753via the translation guide1951,1952; (2) translating the intermediate central last member1752forwardly towards the front central last member1751via the translation guide1952that is slanted relative to the translation guide1951such that the front central last member1751and the rear central last member1753are closer to one another and the rear central last member1753clears the heel portion62of the shell30; (3) translating the rear central last member1753upwardly relative to the front central last member1751via the translation guide1952; (4) pivoting the front central last member1751, the rear central last member1753and the intermediate central last member1752together about the pivot197so that the front central last member1751clears the central part of the toe cap32integrally formed with the shell30; and (5) translating the medial and lateral last members1754,1754laterally towards one another to clear the medial and lateral parts of the heel portion62, the medial and lateral parts of the ankle portion64, the medial and lateral parts of the sole portion69, the medial and lateral parts of the toe cap32integrally formed with the shell30, and the medial and lateral side portions66,68of the shell30, thereby clearing all of the shell30that can be removed from the last152. The shell30can thus be molded and easily demolded, even with its undercuts511-516, without deforming it during demolding.

In a variant, in some embodiments, as shown inFIGS.33to37, last members1751,1752are movable relative to one another to change the last152from its molding configuration to its demolding configuration by: (1) rotating the last member1752, which forms the heel portion62of the shell30, relative to the last member1751to clear the heel portion62of the shell30; and then rotating the last member1751and the last member1752together to remove them from the shell30.

In some embodiments, respective ones of the last members1751-175Mof the last152may be movable relative to one another by disconnecting and separating them from one another. For example, one or more of the last members1751-175Mof the last152may be disassembled to facilitate removal of the shell30from the last152. In such embodiments, one or more of the links1831-183Clinking adjacent ones of the last members1751-175Mallow these adjacent last members to be connected to one another in the molding configuration of the last152and to be disconnected and separated from one another in the demolding configuration of the last152.

The last members1751-175Mmay comprise any suitable material. In this embodiment, the last members1751-175Mare rigid. For example, the last members1751-175Mmay be made of metal, rigid plastic, wood, or any other suitable material.

In a variant, in some embodiments, as shown inFIGS.38to42, the last152comprises a base199that includes last members1751,1752which are movable relative to one another, and a last member1753that is a removable covering179, i.e., sheath, which covers the base199and is removable from the base199. The sheath179may allow different sizes or shapes of the shell30to be molded on the152by using different sheaths similar to the sheath179, protect against leakage of the polymeric material M1during injection, and/or reduce or eliminate internal parting lines on the shell30.

In this embodiment, the sheath179is flexible to facilitate its placement onto the base199of the last152and its subsequent removal upon molding, yet sufficiently strong to maintain its desired shape during molding of the shell30. For instance, in some embodiments, the sheath179may comprise an elastomeric material, such as silicone rubber or any other polymeric material with suitable elasticity. For example, in some embodiments, a hardness of the elastomeric material of the sheath179may be between Shore A and 99 Shore A of have any other suitable value. This may create a sealing effect to protect against leakage of the polymeric material M1during injection. Also, the sheath179may have a smooth external surface that may reduce or eliminate internal parting lines on the shell30.

Thus, in this embodiment, the sheath179is placed over the base199of the last152for molding the shell30. This is facilitated by flexibility of the sheath179. Then, to demold the shell30, the last member1752is moved relative to the last member1751and the sheath179to clear a front region of the sheath179. In this example, the last member1751includes a cavity171and the last member1752is rotatable into the cavity171, thus effectively moving into an interior of the last member1751. The last member1751and the last member1752which is located in the cavity171are then moved upwardly out of the sheath179. The shell30may be removed by deforming the sheath179to take the shell30away from it. Alternatively, in some cases, the sheath179may be left in the shell30to be part of the skate boot22of the skate10.

The sheath179of the last152may be implemented in various other ways in other embodiments.

For example, in some embodiments, the sheath179may comprises a reinforcement (e.g., a layer of fabric such as mesh, a thin metallic layer, a plastic film, etc.) within its elastomeric material to reinforce it (e.g., protect against tearing).

As another example, in some embodiments, the sheath179may be injection molded using a thermoplastic material such as polypropylene, polyethylene (e.g., high-density polyethylene), or any other suitable material (e.g., with low surface adhesion).

As another example, in some embodiments, as shown inFIGS.43and44, a thickness of the sheath179may vary to define the undercuts511-516of the shell30while facilitating demolding of the shell30from the last152. For example, in this embodiment, the sheath179is thicker at locations of the medial and lateral depressions78,80of the shell30for receiving the medial and lateral malleoli MM, LM of the player, the recesses831,832defined by the curvature of the heel portion62in the longitudinal and heightwise directions of the skate10and the curvature of the heel portion62in the widthwise direction of the skate10, and the recesses861,862defined by the curvature of the medial side portion66and the curvature of the lateral side portion68in the longitudinal and heightwise directions of the skate10adjacent to the player's forefoot. Also, in this embodiment, the last member1751is shaped (e.g., straight or tapered downwardly) so as to me movable vertically during demolding and the last member1752can be removed from the shell30after moving the last member1751vertically.

As another example, in some embodiments, the sheath179may be a film placed (e.g., wrapped about) the base199of the last152.

As another example, in other embodiments, the sheath179may be an impermeable sock pullable onto and off the last152.

As another example, in some embodiments, as shown inFIGS.45to47, the sheath179may be covered with a film159prior to molding to protect the last152and increase its durability. In this embodiment, the film159may be a bag. The bag159may be connected the last152by using tape, by being pinched to the last152, or by any suitable means.

In this embodiment, the bag159is a reusable bag, that is, the bag159may be used to mold more the shell30and one or more other shells similar to the shell30. To this end, the bag159may be made of a material which eases installation of the bag159over the last152and the sheath179, facilitates molding by being relatively smooth, and is relatively durable. In this example, the bag159is made of an elastomeric material such as plastic or silicone.

In other embodiments, the bag159may not be reusable. That is, the bag159may be configured for being used for molding only one shell30. For instance, the bag159may be configured such that it remains affixed with the skate shell30after molding. More specifically, during molding, the bag159binds with the shell30and when the shell30is removed from the molding apparatus, the bag159remains with the skate shell. In some cases, a portion of the bag159may need to be cut off from the shell30so that no loose portion of the bag159remains attached to the shell30. In some embodiments, the bag159may include 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), to enhance the look of at least a portion of the shell30, such as the inner side of the shell30. In some embodiments, the bag159may be made of a polymeric material and may have a thickness between 0.01 mm and 1 mm, in some embodiments between 0.05 mm and 0.5 mm, in some embodiments about 0.1 mm.

The control system187to control movement of the last members1751-175Mrelative to one another may be implemented in any other suitable way in other embodiments.

For example, in some embodiments, as shown inFIGS.48and49, the control system187may be configured to control movement of last members1751,1752so that the last152is expandable into its molding configuration and contractible into its demolding configuration. In this embodiment, the links1831-183Cbetween the last members1751,1752include a central member186and arms1891-189Athat extend from the central member186to respective ones of the last members1751,1752, such that movement of the central member186in a given direction (e.g., downwardly) causes the arms1891-189Ato push the members1751,1752away from one another to expand the last152for molding the shell30, and movement of the central member186in an opposite direction (e.g., upwardly) causes the arms1891-189Ato pull the members1751,1752towards one another to contract the last152for demolding the shell30.

The last members1751-175Mmay be implemented in any other suitable way in other embodiments. For example, in various embodiments, the last members1751-175Mmay have any other suitable shape, there may be any other suitable number of last members (e.g., two, three, four, six, seven, etc. last members), respective ones of the last members1751-175Mmay move in any other way relative to one another, etc. Also, in various embodiments, features of the last members1751-175Mof different embodiments considered herein may be combined together in some examples of implementation.

With additional reference toFIGS.50to52, in some embodiments, a given one of the female molds1541-1543may comprise a flexible female mold member410comprising an inner surface414constituting at least part of an inner surface of the given one of the female molds1541-1543and preformed to define a given one of the mold cavities156,158,160between itself and the last152in which a given one of the polymeric materials M1-M3is injected to mold a given one of the subshells851-853such that the inner surface414creates an outer surface of the given one of the subshells851-853. The flexible female mold member410, which will also be referred to as a “membrane”, is configured to avoid at least one parting line on the shell30that would otherwise result because of the portions155,157of the given one of the female molds1541-1543if the membrane410was omitted.

For example, in this embodiment, the membrane410is part of the female mold1541such that its inner surface414is preformed to define the mold cavity156between itself and the last152in which the polymeric material M1is injected to mold the subshell851such that the inner surface414creates the outer surface of the subshell851.

The inner surface414of the membrane410is preformed in that it is formed to define the mold cavity156to mold the subshell851and create the outer surface of the subshell851before the membrane410is placed in the molding apparatus150. For instance, the membrane410may be preformed in a separate mold in a prior operation.

The membrane410is flexible to flex during movement of the portions155,157of the female mold1541when closing and opening the female mold1541and overlies one or more spaces where the portions155,157of the female mold1541move relative to one another. This allows one or more parting lines to be avoided as the membrane410overlies where these one or more parting lines would otherwise be located.

In this embodiment, the membrane410extends continuously to constitute to at least a majority (i.e., a majority or an entirety) of the inner surface of the female mold1541and to create at least a majority of the outer surface of the subshell851. More particularly, in this embodiment, the membrane410comprises medial and lateral side portions420,422, an ankle portion424, a heel portion426, and a sole portion428that are integral and continuous with one another as a one-piece structure. In this example, the membrane410is flexible and jointless (i.e., without any joint) at the heel portion426and a rear of the ankle portion424, while the medial and lateral side portions420,422and medial and lateral parts of the sole portion428are separable and movable relative to one another, to allow the membrane410to flex during movement of the portions155,157of the female mold1541when closing and opening the female mold1541.

Thus, in this embodiment, the membrane410is configured such that the subshell851may be free of parting lines opposite from one another (i.e., on opposite sides of the subshell851). For instance, in this embodiment, the subshell851may have a parting line263, which in this example is in a toe portion of the subshell851to enclose toes of the user's foot, but is free of any parting line opposite to the parting line263, i.e., at an opposite side of the subshell851, which in this example is a heel portion and a rear of an ankle portion of the subshell851, because of the membrane410.

In this embodiment, the membrane410may comprise an elastomeric material, such as silicone rubber, any other rubber, or any other polymeric material with suitable elasticity. For example, in some embodiments, a hardness of the elastomeric material of the membrane410may be between 10 Shore A and 99 Shore A of have any other suitable value.

The membrane410of the molding apparatus150may be implemented in various other ways in other embodiments.

For example, in other embodiments, the membrane410may be flexible and jointless at other areas while separable and movable elsewhere to allow the membrane410to flex during movement of the portions155,157of the female mold1541when closing and opening the female mold1541. For instance, in some embodiments, the membrane410may be flexible and jointless at the sole portion428, while medial and lateral parts of the ankle portion424, medial and lateral parts of the heel portion426, and the medial and lateral side portions420,422are separable and movable relative to one another, to allow the membrane410to flex during movement of the portions155,157of the female mold1541when closing and opening the female mold1541. In other embodiments, the membrane410may be flexible and jointless at a front portion, while medial and lateral parts of the sole portion428, medial and lateral parts of the ankle portion424, medial and lateral parts of the heel portion426and the medial and lateral side portions420,422are separable and movable relative to one another, to allow the membrane410to flex during movement of the portions155,157of the female mold1541when closing and opening the female mold1541.

As another example, in some embodiments, the membrane410may comprises a reinforcement (e.g., a layer of fabric such as mesh, a thin metallic layer, a plastic film, etc.) within its elastomeric material to reinforce it (e.g., protect against tearing).

As another example, in some embodiments, the membrane410may be injection molded using a thermoplastic material such as polypropylene, polyethylene (e.g., high-density polyethylene), or any other suitable material (e.g., with low surface adhesion).

As another example, in some embodiments, the membrane410may be incorporated into a rigid casting of a material (e.g., polyurethane, epoxy or other polymeric material; aluminum, steel or other metallic material; cement; etc.) stiffer and stronger than that of the membrane.

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. In some embodiments, molding stations may be horizontally distributed (e.g., linearly and/or in a carrousel or other rotary or otherwise curved arrangement). In other embodiments, molding stations may be vertically distributed such as being stacked vertically over one another, which may be more efficient space-wise.

With additional reference toFIGS.53and54, 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.53, the reinforcement115may comprise a plurality of ribs1171-117R(or a single rib1171) 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.54, 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 rib1171may be disposed between the intermediate and external subshells852,853while a second rib117jis disposed between the internal and intermediate subshells851,852.

Alternatively, as shown inFIGS.55A to57, 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.57, 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 another example, as shown inFIG.56the shell30may comprise more than one reinforcements1151-115rdisposed between certain ones of the subshells851-85Lof the shell30and each one of the reinforcements1151-115rmay comprise a material that is different from the material of another one of the reinforcements1151-115r. For instance, the materials of different ones of the reinforcements1151-115rmay differ in rigidity, in density, etc., such as to provide desired properties to different parts of the skate boot22and blade holder24.

In some embodiments, multiple reinforcements115may be included between the subshells851-85Lof the shell30. For instance, a rib1171may 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 graphical element or design element, disposed between certain ones of the subshells851-85Lof the shell such as, for instance, between the intermediate and external subshells852,853as shown inFIG.58. 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.58, the shell30may comprise a plurality of such design elements which may be spaced apart from one another.

The one or more design elements121may be disposed over various portions of the shell30and/or over various other portions of the skate boot22, for instance over the medial side portion68, over the lateral side portion66, over a top portion and/or over the toe portion32of the shell30, and may also be disposed over the tongue34, over the tendon guard35, over the liner36, over the footbed38, over the insole40, over the lace members441,442, over the eyelets461-46E, and so on, as shown inFIG.59. For instance, the design elements121may be disposed at least on a side of the toe portion32. In this example, the design elements121are disposed on a medial side, on a lateral side and on a top side of the toe portion32.

The design elements121may cover at least a substantial part (i.e., a substantial part or an entirety) of a surface area of the portion of the skate boot22(e.g., the toe portion32) over which they are disposed and that is externally visible (i.e., visible from outside of the skate boot22). For instance, in some embodiments, the design elements121covers at least a quarter (i.e., 25%), in some embodiments at least a third (i.e., 33%), in some embodiments at least a majority (i.e., at least 50%), in some embodiments at least 75%, and in some embodiments an entirety of the toe portion32.

Some of the design elements121may also be continuous with other design elements121of adjacent portions of the skate boot22. That is, there may be a continuity of the design element121between the toe portion32and a given one of the medial side portion68and the lateral side portion66of the shell30, thus providing an impression that the design elements121extend from a given one of the toe portion32, the medial side portion68and the lateral side portion66to another one of the toe portion32, the medial side portion68and the lateral side portion66. In this embodiment, there is continuity of design elements121between the toe portion32, the medial side portion68and the lateral side portion66of the shell30.

In this embodiment, an external one of the layers851-85Lof the shell30may be a clear layer overlying the design elements121such that the design elements121are visible through the clear layer and such that the clear layer protects the design elements121from flying pucks, sticks, etc.

The design elements121may include a design pattern, a printed image, and so on. In this embodiment, the design element is a graphic element which includes one or many different colors.

In this embodiment, at least some of (e.g., some of, a majority of, or an entirety of) the design elements121of the shell30may comprise graphical ink632implementing graphics635. These graphics635may include any desired color(s), shape(s), pattern(s), character(s), image(s), etc.

More specifically, in this embodiment, as shown inFIGS.60to62, the graphical ink632may be provided by a film615. In this embodiment, the film615is a sheet comprising a polymeric material such as a polycarbonate, polypropylene, polyethylene or any other suitable polymeric material. The film615may comprise an ink-providing side319that provides the graphical ink632and a plain side321opposite the ink-providing side319. In this embodiment, the ink-providing side319is an outer side of the film615and the plain side321is an inner side of the film615.

The graphical ink632may cover a substantial part of a surface area of the ink-providing side319of the film615. For example, in some embodiments, the graphical ink632may cover a majority, in some embodiments at least 60%, in some embodiments at least 80%, and in some embodiments substantially an entirety of the surface area of the ink-providing side319of the film615.

In some cases, the film615may be a clear film (e.g., transparent or translucid) through which a person can see. For instance, in some cases, it may be clear at areas free of the graphical ink632. In other examples, the film615may be opaque, colored (e.g., black, white or any other color), partially transparent, homogenous, and/or different at different areas.

In this embodiment, the film615is configured to be positioned on at least part of (i.e. part of, a majority of or an entirety of) the shell30to provide the design elements121of the shell30. For instance, in this embodiment, the film615is configured to cover the medial side portion, the lateral side portion, the heel portion, and the ankle portion of the shell30of the skate boot22and the graphical ink632is configured to cover the medial side portion, the lateral side portion, the heel portion, and the ankle portion of the shell30of the skate boot22when the film615is positioned on the shell30to provide the design elements121of the shell30. The film615may also be configured to cover various other portions of the skate boot22, including the toe cap32, the lace members441,442, the eyelets461-46e, and so on, as shown inFIG.63.

In particular, in this embodiment, the film615is configured to be positioned between consecutive layers851-85Lof the shell30. Specifically, the film615may be configured to be positioned over a layer85xprior to, during or after molding of that layer85x, and the layer85yexternal to the layer85xmay be molded over the layer85xand over the graphical ink632of the design elements121. In this embodiment, the layer85ymay be an external layer of the shell30and may be a clear layer.

In some embodiments, the film615may be configured to remain on the shell30after molding of the layer85xand during molding of the layer85y, such that the skate boot20, as an end product, comprises the film615.

The graphical ink632may be provided on the film615in any suitable way. For example, the graphical ink632may be provided on the film615via silk-screening, pad printing, flexo printing or offset printing, or any other printing (e.g., jet print, water decal, sublimation, ink transfer, laser, airbrushing, etc.).

The graphical ink632may be any suitable graphical ink. For instance, in some embodiments, the graphical ink632may be solventless (i.e., may not comprise and may have been provided without any solvent). In some embodiments, a surface energy of the graphical ink632may be less than 32 dynes/cm, in some embodiments less than 28 dynes/cm, in some embodiments less than 24 dynes/cm, and in some embodiments even less. Furthermore, in this embodiment, graphical ink632may have any suitable elongation to rupture (elasticity), opacity, opacity when stretched. In particular, in this embodiment, the graphical ink632may be configured to have a relatively high elongation to rupture at room temperature on a relatively thin substrate. The graphical ink632may be substantially free of volatile solvents and may be configured to prevent inhibiting chemical reaction with polyurethane, in particular with one or more isocyanate components of the polyurethane, while having a good bonding and a good chemical affinity with polyurethane.

In some embodiments, an entirety of the graphical ink632may comprise a relatively flexible ink (e.g. configured to have a relatively high elongation to rupture at room temperature on a relatively thin substrate). In some embodiments, the graphical ink632may comprise inks of different elasticities: for instance, in this example, a majority of the graphical ink632may comprise a relatively flexible ink and the graphical ink632may comprise a relatively stiff ink in areas where stretch is minimal.

For example, in some embodiments, the graphical ink632comprises one or more of a latex-based ink, a UV/LED cured ink, a flexography ink, a silkscreen ink, etc. In variants, the graphical ink932may comprise a water-and-solvent-based ink (e.g., a dried water-and-solvent-based ink free of residual water and solvents).

Moreover, in some cases, the reinforcement115, which is depicted inFIG.58spaced 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 some embodiments, the reinforcement115may be pre-shaped before being placed in the molding apparatus150with the subshells851-85Lof the skate boot22. For example, in some embodiments, the reinforcement115may be thermoformed before being placed in the molding apparatus150with the subshells851-85Lof the skate boot22.

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 mold1541at 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, as shown inFIG.64, the molding apparatus150comprises a plurality of ports1251-125Pfor receiving constituents1271-127Cthat are different from one another to injection mold a given one of the layers851-85L, referred-to as layer85xhereinbelow. In particular, in this example, the molding apparatus150may comprise at least three ports1251-1253for receiving three different constituents1271-1273, such as from containers1431-1433containing supplies of the constituents1271-1273. A desired property (e.g., stiffness) of the polymeric material Mxof the layer85xof the shell30of the skate boot22may be determined (e.g., based on input received from a user or from a component of a computer system). Respective ones of the constituents1271-1273may be injected to produce the polymeric material Mxwhile proportions of these respective ones of the constituents1271-1273(e.g., relative to one another and/or to their total) are controlled to impart the desired property of the polymeric material Mxof the layer85xof the shell30of the skate boot22.

In this embodiment, the molding apparatus150may be configured to allow customization of the shell30of the skate boot22by controlling the proportions of the respective ones of the constituents1271-127Cof the layer85xaccording to the desired property of the polymeric material Mx. Thus, in some embodiments, the shells30of a plurality of similar skate boots22manufactured by the molding apparatus150may have different proportions of the respective ones of the constituents1271-127Cof their layer85x. In particular, without changing in its configuration, the molding apparatus150may be configured to control the proportions of the respective ones of the constituents1271-127Csuch that these proportions for the layer85xof the shell30of a first skate boot22manufactured by the molding apparatus150are different from these proportions for the layer85xof the shell30of a second skate boot22manufactured by the molding apparatus150immediately after the first skate boot22without changing the physical configuration of the molding apparatus150.

For instance, in this embodiment, the molding apparatus150may comprise a controller192configured to control an injected amount for each one of the constituents1271-127C. The controller192may thus control the proportions of the respective ones of the constituents1271-127Cof the polymeric material Mxof the layer85xof the shell30of the skate boot22. The controller192may be combined with any suitable device and/or system. For example, in some embodiments, the controller192comprises a user interface with a display allowing an operator to enter a parameter value related to the desired property of the polymeric material Mxof the layer85xof the shell30of the skate boot22, and the controller192may be configured to control the proportions of the respective ones of the constituents1271-127Cto obtain the polymeric material Mxwith the desired property. In some embodiments, parameter data related to the desired property of the polymeric material Mxmay be provided via an internet connection to the controller192and the controller192may be configured to control the proportions of the respective ones of the constituents1271-127Cto obtain the polymeric material Mxwith the desired property.

In particular, in this embodiment, the constituents1271-127Cinclude at least three constituents and the respective ones of the constituents1271-127Cwhich are injected with their proportions controlled include at least three constituents. In other embodiments, the constituents1271-127Cmay include more than three constituents, and so may the respective ones of the constituents1271-127Cwhich are injected with their proportions controlled. In some cases, a given one of the constituents1271-127Cmay not be injected to produce the material Mxof the shell30of the skate boot22.

Specifically, in this embodiment, the material polymeric material Mxof the layer85xof the shell30of the skate boot22is a polyurethane. More specifically, the polyurethane is a polyurethane foam. In this embodiment, the constituents1271-127Cinclude an isocyanate, a first polyol, and a second polyol different from the first polyol. In examples that follow, for ease of reference, they may respectively be referred to as the isocyanate “A”, the first polyol “B1”, and the second polyol “B2”.

In some cases, the proportion of the polyol B1 injected in the molding apparatus150to obtain the polymeric material Mxmay be different from the proportion of the polyol B2 injected in the molding apparatus150to obtain the polymeric material Mx. In some cases, also, the respective ones of the constituents1271-127Cmay include the isocyanate A and the polyol B1 but not the polyol B2. In other cases, the respective ones of the constituents1271-127Cmay include the isocyanate A, the polyol B1 and the polyol B2.

The desired property of the material Mxof the shell30of the skate boot22may be a stiffness (i.e., rigidity) of the material Mxof the shell30of the skate boot22. For example, in this embodiment, the stiffness of the material Mxof the shell30of the skate boot22may be expressed as a modulus of elasticity of the material Mx.

In this embodiment, the molding apparatus150allows controlling the rigidity of the Mxover a certain rigidity range. For example, in some embodiments, the molding apparatus150and the constituents1271-127Cmay allow controlling the rigidity of the material Mxover a rigidity range which represents at least 10%, in some embodiments at least 40%, in some embodiments at least 70%, and in some embodiments even more, of a maximal rigidity that is achievable with the molding apparatus150and the constituents1271-127C.

The shell30of the skate boot22may comprise more than one of its layers851-85Lmanufactured in the fashion of the layer85x. For example, in some embodiments, the shell30of the skate boot22may comprise at least two of the layers851-85Lmanufactured likewise, in some embodiments at least three of the layers851-85Lmanufactured likewise, in some embodiments at least four of the layers851-85Lmanufactured likewise, etc. In this embodiment, prior to or after molding the layer85xof the shell30of the skate boot22, the molding apparatus150may be configured to mold a second one of the layers851-85L, referred-to as layer85yhereinbelow, in a similar fashion.

In particular, in this embodiment, the respective ones of the constituents1271-127Cused to form the polymeric material Mxare first ones of the constituents1271-127C, and second respective ones of the constituents1271-127Cmay be injected in the molding apparatus150with their proportions controlled to form the polymeric material Myof the layer85yof the shell30of the skate boot22.

In this embodiment, the layer85yof the shell30of the skate boot22may be disposed outwardly of the layer85xof the shell30of the skate boot22. Specifically, in this embodiment, the layer85yof the shell30of the skate boot22is an outermost layer of the shell30of the skate boot22.

The material Myof the layer85yof the shell30of the skate boot22may be a second polyurethane. More specifically, the material Myof the layer85yof the shell30of the skate boot22may be foamless. Also, in this embodiment, the material Myof the layer85yof the shell30of the skate boot22may be clear. For instance, in this embodiment, the material Myof the layer85yof the shell30may effectively constitute a clear coating.

In this embodiment, no external heat is applied to the polymeric materials M1-MNof the shell30. Rather, in this embodiment, in order to form a subshell85i, the 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. Thus, in this embodiment, a layer85iof the shell30is formed by reaction injection molding of respective ones of the constituents1271-127C. 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.

In other embodiments, external heat may be applied to one or more of the polymeric materials M1-MNof the shell30, such as, for instance, to facilitate a chemical reaction of the constituents of a given polymeric material Mx. Heat may be applied by radiation, by air convection, by steam convection, by heating the last152and/or the associated female mold154iprior to molding and/or by any other suitable means. The constituents may have an exothermic reaction or an endothermic reaction when combined and sufficiently heated. In this example, the external heat may furnish triggering energy to initiate the reaction of the two or more constituents and optionally catalyzing energy to catalyze the reaction. Although in this embodiment heat is applied, this manufacturing process still contrasts 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.

In other embodiments, no external heat is applied to some of the polymeric materials M1-MNof the shell30(e.g., the polymeric material M2of the intermediate subshell852, which may be injected and blown into its final form without external heat), while external heat is applied to other ones of the polymeric materials M1-MNof the shell30(e.g., the polymeric material M3of the external subshell853, the polymeric material Miof an insert315Mbetween the intermediate subshell852and the external subshell853, etc.).

In other embodiments, energy in a different form from heat may be applied to the polymeric materials M1-MNof the shell30in addition to or in replacement to heat. For instance, the polymeric materials M1-MNmay be radiated using electromagnetic radiation (e.g., UV, x-rays, microwaves) and/or acoustic radiation (e.g., ultrasound).

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.15. 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. In some embodiments, the last152may be customizable and/or otherwise configurable such as by adding or removing last attachments (e.g. shims), which may be created by additive manufacturing (e.g., 3D-printed), as described in U.S. patent application Ser. No. 16/448,622, which is incorporated herein.

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

With additional reference toFIG.65, 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, such as by means of air brushing, by means of water printing (e.g., water dripping), using a flexible membrane comprising the overlay, the flexible membrane being placed in the mold prior to molding, etc.

The inner liner36of 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. In some embodiments, as shown inFIG.69A, the inner liner36may comprise a sole portion for facing the plantar surface of the user's foot11, while in other embodiments the inner liner36does not comprise a sole portion, as shown inFIG.69B. The inner liner36may 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 insole40may be affixed to the shell30of the skate boot22. For instance, in some embodiments, as shown inFIG.66, the lower surface23of the insole40may be overmolded to the shell30of the skate boot22. In other embodiments, as shown inFIG.67, the insole40may be joined mechanically to the shell30of the skate boot22by a mechanical fastener141(e.g., a clip, a rivet, or any suitable fastener). In other embodiments, as shown inFIG.68, the insole40may be adhesively bonded to the shell30of the skate boot22via an adhesive142.

In some embodiments, as shown inFIGS.70A to71, the inner liner36of the skate boot may be a “3D liner”, i.e., may be formed of a three-dimensional sheet130of material (e.g., fabric). This may allow reducing the use of stitching and tape for manufacturing the inner liner36, thereby reducing weight, improving comfort and reducing manufacturing cost of the inner liner36. The 3D inner liner36may be manufactured in any suitable way. For instance, in some embodiments, the 3D inner liner36may be formed using a standard 2D sheet130′ of fabric that is thermoformed over a 3D last such that the 3D last imparts its shape to the sheet of fabric. The sheet of fabric, now having the 3D shape of the 3D last, may then be cut to pre-determined dimensions and finalized by affixing (e.g., by stitching, taping, etc.) portions of its edges to one another. As a result, a ratio of the amount of stiches and/or tape required for manufacturing the 3D inner liner36over the amount of stiches and/or tape required for manufacturing a standard inner liner36may be no more than 0.9, in some cases no more than 0.8, in some cases no more than 0.7, in some cases even less.

In some embodiments, the skate boot22may not comprise an inner liner36. For instance, the internal subshell851of the shell30of the skate boot22may serve as an inner lining already and thus the addition of the inner liner36may be redundant. In other cases, the inner liner36may 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 preformed “sock” onto which the internal subshell851is formed.

With additional reference toFIGS.72to78, 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 shell30and can thus be referred to as a toe portion of the shell30. As shown inFIGS.74,76and77, 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, as shown inFIG.79, 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.80, 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.72,73and75, the blade holder24comprises a body132including 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.81, the blade-retention portion188comprises a recess190, which can be referred to as a “blade-receiving slot”, extending from the front portion170to the rear portion172of the blade holder24in which an upper portion of the blade26is disposed. 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 base164respectively towards a front sole part95and a rear sole part97of the skate boot22. The front pillar210, which can be referred to as a front “pedestal”, extends towards the front portion56of the skate boot22and the rear pillar212, which can be referred to as a rear “pedestal”, extends 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, as shown inFIGS.75,82and83, the blade-receiving slot190may be wider in the intermediate portion180of the blade-retaining base164between the front portion170of the blade-retaining base164and the rear portion172of the blade-retaining base164than in the front portion170of the blade-retaining base164and in the rear portion172of the blade-retaining base164. In particular, in this embodiment, the blade-receiving slot190may be wider between the front pillar210and the rear pillar212than beneath the front pillar210and beneath the rear pillar212.

The blade-receiving slot190may be wider in the intermediate portion180by any suitable extent. Specifically, in some embodiments a ratio of a width WSiof the blade-receiving slot190in the intermediate portion180of the blade-retaining base164over the width WSiof the blade-receiving slot190in a given one of the front portion170of the blade-retaining base164and the rear portion172of the blade-retaining base164is at least 1.3, in some embodiments at least 1.5, in some embodiments at least 2, and in some embodiments even more (e.g., at least 2.5).

In some embodiments, a ratio of the width WSiof the blade-receiving slot190in the intermediate portion180of the blade-retaining base164over a narrowest dimension of the blade-receiving slot190in a widthwise direction of the blade holder24is at least 1.5, in some embodiments at least 2, in some embodiments at least 3, in some embodiments at least 5, in some embodiments at least 7.5, and in some embodiments even more.

In some embodiments, the width WSiof the blade-receiving slot190in the intermediate portion180of the blade-retaining base164is greater than 3 mm, in some embodiment at least 4 mm, in some embodiments at least 5 mm, in some embodiments at least 6 mm, in some embodiments at least 7 mm, in some embodiments at least 15 mm, in some embodiments at least 23 mm, in some embodiments even more. In some embodiments, the width WSiof the blade-receiving slot190is configured to create a gap G between each lateral surface of the blade26and the lateral surfaces of the blade-receiving slot190of at least 1.5 mm, in some embodiments at least 3 mm, in some embodiments of at least 5 mm, in some embodiments of at least 10 mm, and in some embodiments of even more.

The configuration of the blade-receiving slot190may allow the blade26to bend laterally when the skater turns on the ice, providing a parabolic feature to the blade26and facilitating the turn of the skater. For example, in some embodiments, the blade-receiving slot190may allow the blade26to have a maximal minimum radius of no more than 1700 mm, in some embodiments no more than 1000 mm, in some embodiments no more than 300 mm, and in some embodiments even more. In some cases, if the blade-receiving slot190is sufficiently wide in the intermediate portion180of the blade-retaining base164, the blade holder24may hold the blade26while the blade26is unsupported by the blade holder24in at least part of the intermediate portion180of the blade-retaining base164.

With additional reference toFIG.73, in this embodiment, the front pillar210and the rear pillar212of the support168may be relatively wide. For instance, in some embodiments, a width WPof the front pillar210may be at least 80%, in some embodiments at least 90%, in some embodiments at least 95%, in some embodiments at least 100%, of a width WSof the front sole part95of the skate boot22, and in some embodiments, the width WPof the rear pillar212may be at least 80%, in some embodiments at least 90%, in some embodiments at least 95%, in some embodiments at least 100%, of a width WSof the rear sole part97of the skate boot22. In this embodiment, the front pillar210and the rear pillar212of the support168are at least as wide as the respective one of the front sole part95of the skate boot and the rear sole part97of the skate boot.

In particular, in this embodiment, an external surface224of the pillars210,212is continuous with an external surface194of the skate boot22such that there may be no sharp angle or no angle at all between the external surface224of the pillars210,212and the external surface194of the skate boot22.

The pillars210,212may comprise any suitable material. For instance, in some embodiments, the pillars210,212may comprise a material having a modulus of elasticity of at least 300 MPa, in some embodiments at least 1000 MPa, in some embodiments at least 10 GPa, and in some embodiments even more. As another example, in some embodiments, the pillars210,212may comprise a material having a hardness of at least 55 Shore D, in some embodiments of at least 60 Shore D, in some embodiments of at least 65 Shore D, and in some embodiments even more.

The blade holder24may provide enhanced stiffness characteristics, notably since the pillars are relatively wider. One way to characterize stiffness of the blade holder is by doing a lateral force test on a dynamometer on the skate10. A force required to produce a 2 mm deformation on a specific point of the blade26is observed. This test is repeated to observe the force when the specific point of the blade26is under the front pillar210, when the specific point of the blade26is under the rear pillar212, and when the specific point of the blade26is under a midpoint between the front pillar210and the rear pillar212. For instance, in some embodiments, the stiffness of the blade holder24is stiffness of the blade holder24is such that: a lateral force require to deflect the blade holder24by 2 mm at the front pillar210is at least 205 N, in some embodiments at least 330 N, in some embodiments at least 420 N and in some embodiments even more; and a lateral force require to deflect the blade holder24by 2 mm at the rear pillar212is at least 130 N, in some embodiments at least 225 N, in some embodiments 450 N and in some embodiments even more.

In this embodiment, at least part (i.e., part or all) of the body132of the blade holder24is integrally formed with the shell30of the skate boot22. That is, at least part of the body132of the blade holder24and the shell30of the skate boot22constitute a monolithic one-piece structure. The body132of the blade holder24thus comprises an integrally-formed portion215that is integrally formed with the shell30of the skate boot22such that the portion215of the body132of the blade holder34and the shell of the skate boot22are formed together as one-piece in the molding apparatus150during the molding process.

In this embodiment, the integrally-formed portion215of the body132of 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 body132of 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 body132of the blade holder24is constituted by the polymeric material M2of the intermediate subshell852such that the body132of the blade holder24consists primarily of a structural foam material. Alternatively, the portion215of the body132of 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 body132of the blade holder24may be integrally formed with shell30of the skate boot22. That is, the integrally-formed portion215of the body132of the blade holder24may be a major portion or the entirety of the body132of the blade holder24. In this embodiment, an entirety of the body132of the blade holder24is integrally formed with the shell30of the skate boot22.

Therefore, in this embodiment, the body132of the blade holder24is formed with the shell30of the skate boot22in the molding apparatus150with the last152. In particular, the body132of the blade holder24is initially formed during forming of the intermediate subshell852of the shell30of the skate boot22and is completed by the forming of the external subshell853of the shell30of the skate boot22. That is, in this embodiment, as shown inFIGS.84and85, the intermediate subshell852is the innermost subshell of the body132of the blade holder24while the external subshell853is the outermost subshell of the body132of the blade holder24.

In some embodiments, with additional reference toFIGS.86to97, the body132of the blade holder24comprises a core260which may be manufactured prior to the molding of the skate boot22and the integrally-formed portion215of the body132of the blade holder24and which may be placed in the mold used during the molding process of the skate boot22and the integrally-formed portion215of the body132of the blade holder24, such that the skate boot22and the integrally-formed portion215of the body132of the blade holder24are overmolded onto the core260. This may, for instance, allow use of materials that could not be used during the molding process of the skate boot22; reduce geometric tolerances and increase standardisation of the skate boot22, increase stiffness of the blade holder24, reduce energy losses during skating, etc.

In this embodiment, the core260constitutes at least a substantial part (e.g., a majority) of the blade-retaining base164and comprises a front portion262configured to be disposed in the front pillar210of the blade holder24, a rear portion264configured to be in the rear pillar212of the blade holder24and a bridge portion266extending between the front and rear portions262,264and configured to be at least part of the bridge214of the blade holder24. In this embodiment, the bridge266of the core260defines the bridge214of the blade holder24.

The core260has a structural geometry to enhance properties of the blade holder24such as lightness, stiffness and energy conservation during skating. In this embodiment, the core260also comprises interfaces270at the front and rear portions262,264of the core260to interface with the intermediate and external subshells852,853and with the polymeric materials M2, M3associated therewith during and after the molding process. In particular, in this embodiment, the interfaces270are interlocking portions to mechanically interlock the intermediate and external subshells852,853and the polymeric materials M2, M3associated therewith. For instance, the interlocking portions270may comprise projections (e.g., ridges), recesses (e.g., grooves), and the like. During molding of the skate boot22, the polymeric materials M2, M3may fill recesses and/or engage projections to mechanically interlock the core260with the intermediate and external subshells852,853.

The core260comprises a material267that may allow the core260to be light and stiff and limit energy losses in some embodiments. For instance, in some embodiments, a modulus of elasticity of the material267may be at least 1 GPa, in some embodiments at least 2 GPa, in some embodiments at least 3 GPa, in some embodiments at least 4 GPa, in some embodiments even more.

The material267of the core260may be of any suitable kind. In this embodiment, the material267comprises a polymeric material. More particularly, in this embodiment, the material comprises nylon.

In some embodiments, the front and rear portions262,264of the core260of the body132of the blade holder24comprise upwardly-extending parts282,284extending towards the sole portion69of the shell30of the skate boot22. In this example, the upwardly-extending parts282,284of the core260are pillar-forming members that constitute at least part of the front and rear pillars210,212of the blade holder24. Also, in this example, the pillar-forming members282,284extend to the sole portion69of the shell30of the skate boot22. The pillar-forming members parts282,284may increase flexural stiffness, torsional stiffness, or area of surface of the interlock.

In some embodiments, the pillar-forming members282,284may be integrally made with lower parts272,274of the front and rear portions262,264(i.e., the pillar-forming member282and the lower part272may be unitary while the pillar-forming member284and the lower part274may be unitary) or, in other embodiments, the pillar-forming members282,284may be affixed to respective ones of the lower parts272,274of the front and rear portions262,264. Similarly, in some embodiments, the pillar-forming members282,284comprise a material287which may be identical to or different (e.g. having a higher or a lower modulus of elasticity) from the material267of the core260.

In this embodiment, the front and rear portions262,264of the core260, including their pillar-forming members282,284, define front and rear cavities296,298of the core260. These cavities296,298may be empty or may contain one or more materials in various embodiments.

In some embodiments, each of the front and rear portions262,264of the core260comprises a cap290that engages a respective one of the pillar-forming members282,284and caps a respective one of the front and rear cavities296,298of the core260. For instance, in some embodiments, the cap290may close the respective one of the cavities296,298to create an enclosure265which may be hermetic. The caps290may be connected to respective ones of the front and rear portions262,264by any suitable way. For instance, in this embodiment, the caps290comprise clips311configured to engage and clip to the front and rear portions262,264of the core260. In this embodiment, the enclosure265may be left empty, i.e., may not be filled by another material, in order to reduce weight of the blade holder24.

The front and rear portions262,264of the core260may facilitate the manufacturing of the blade holder24. For instance, in this embodiment, the front and rear portions262,264of the core260have a shape configured for facilitating the flowing of liquid and/or viscous material during the molding by flowing process. More specifically, by occupying a significant volume of the pillars210,212, the front and rear portions262,264of the core260may reduce the volume of material required for forming the pillars210,212of the blade holder24and may also reduce an average thickness of the material required for forming the pillars210,212of the blade holder24, thereby reducing the occurrence of jams of material being flowed or any other irregularities. Moreover, a surface of the front and rear portions262,264of the core260may facilitate the flowing of liquid and/or viscous material during the molding by flowing process by being smooth.

In particular, in this embodiment, the pillar-forming members282,284and the caps290of the front and rear portions262,264of the core260comprises reinforcements306. During molding of the skate boot22, injection of the constituents of the polymeric materials M2, M3may exert a pressure on the pillar-forming members282,284which could lead to crushing or other deformation of the members282,284. The pressure may be caused for example by an injection pressure and/or by a chemical reaction between components of the polymeric materials M2, M3.

In this embodiment, the reinforcements306comprise reinforcing projections309in the caps290and projections308in the pillar-forming members282,284of the core260. The reinforcements306may be configured to maintain an internal volume of the cavities296,298during molding of the skate boot22in order to have sufficient space for disposing a connector of a quick-connect system of the blade holder24in the front and/or rear cavities282,284of the core260, as discussed below.

For instance, the projections308,309may comprise elongated projections (e.g., ribs) and/or other shapes of projection such as projecting areas. Specifically, in this embodiment, the projections308,309of the caps290and the pillar-forming members282,284of the core260comprise reinforcing ribs317.

In this embodiment, with additional reference toFIGS.89,90,93to95A,96and97, the blade holder24comprises a connection system320configured to attach the blade26to and detach the blade26from the blade holder24. The connection system320facilitates installation and removal of the blade26, such as for replacement of the blade26, assemblage of the skate10, and/or other purposes.

More particularly, in this embodiment, the connection system320of the blade holder24is a quick-connect system configured to attach the blade26to and detach the blade26from the blade holder24quickly and easily.

Notably, in this embodiment, the quick-connect system320of the blade holder24is configured to attach the blade26to and detach the blade26from the blade holder24without using a screwdriver when the blade26is positioned in the blade holder24. In this example, the quick-connect system320is configured to attach the blade26to and detach the blade26from the blade holder24screwlessly (i.e., without using any screws) when the blade26is positioned in the blade holder24. It is noted that although the quick-connect system320is configured to attach the blade26to and detach the blade26from the blade holder24screwlessly, the quick-connect system320may comprise screws that are not used (i.e. manipulated) for attachment or detachment of the blade26. Thus, in this embodiment, the quick-connect system320is configured to attach the blade26to and detach the blade26from the blade holder24without using a screwdriver and screwlessly when the blade26is positioned in the longitudinal recess190of the blade holder24.

In this example, the quick-connect system320of the blade holder24is configured to attach the blade26to and detach the blade26from the blade holder24toollessly (i.e., manually without using any tool) when the blade26is positioned in the blade holder24. That is, the blade24is attachable to and detachable from the blade holder24manually without using any tool (i.e., a screwdriver or any other tool). Thus, in this example, the quick-connect system320is configured to attach the blade26to and detach the blade26from the blade holder24toollessly when the blade26is positioned in the longitudinal recess190of the blade holder24.

In this embodiment, the quick-connect system320of the blade holder24comprises a plurality of connectors330,332to attach the blade26to and detach the blade26from the blade holder24. The blade26comprises a plurality of connectors350,352configured to engage respective ones of the connectors330,332of the quick-connect system320of the blade holder24to be attached to and detached from the blade holder24. The connectors330,332of the quick-connect system320of the blade holder24are spaced apart in the longitudinal direction of the skate10, and so are the connectors350,352of the blade26.

In this embodiment, the connectors350,352comprise hooks531,532that project upwardly from a top edge of the blade26, with the hook531being a front hook and the hook532being a rear hook. The connector330of the quick-connect system320may include an actuator336and a biasing element337which biases the actuator36in a direction towards the front portion170of the blade holder24. To attach the blade26to the blade holder24, the front hook531is first positioned within a hollow space342(e.g., a recess or hole) of the blade holder24. The rear hook532can then be pushed upwardly into a hollow space344(e.g., a recess or hole) of the blade holder24, thereby causing the biasing element337to bend and the actuator336to move in a rearward direction. The rear hook532will eventually reach a position which will allow the biasing element337to force the actuator336towards the front portion66of the blade holder24, thereby locking the blade52in place. The blade52can then be removed by pushing against a finger-actuating surface338of the actuator336to release the rear hook532from the hollow space344of the blade holder24. The quick-connect system320may be configured in any other suitable way in other embodiments.

The quick-connect system320of the blade holder24may be connected to the body132of the blade holder24in any suitable way. In particular, in this embodiment, the connector330of the quick-connect system320of the blade holder24may be received in the rear cavity298of the core260of the body132of the blade holder24. In particular, in this embodiment, the connector330of the quick-connect system320may be installed in the rear cavity298of the core260of the body132of the blade holder24prior to molding of the skate boot22such that molded material of the shell covers the cavities296,298, thereby protecting the connector330of the quick-connect system320.

The quick-connect system320of the blade holder24may be implemented in various other ways in other embodiments. For example, in some embodiments, the quick-connect system320of the blade holder24may be implemented as described in International Patent Application No. PCT/CA2019/051531 filed on Oct. 29, 2019 and incorporated by reference herein. As another example, in some embodiments, as shown inFIG.95B, the biasing element may comprise a spring part341and a sliding surface343configured to slide onto a sliding surface339of the actuator336.

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, the constituents1271-127Cof the polyurethane foam Mx include a first isocyanate, a second isocyanate different from the first isocyanate, and one or more polyols. In examples that follow, for ease of reference, they may respectively be referred to as the first isocyanate “A1”, second isocyanate “A2”, and the one or more polyols “B”.

In some cases, the proportion of the isocyanate A1 injected in the molding apparatus150to obtain the polymeric material Mxmay be different from the proportion of the isocyanate A2 injected in the molding apparatus150to obtain the polymeric material Mx. In some cases, also, the respective ones of the constituents1271-127Cmay include the isocyanate A1 and the polyol B but not the isocyanate A2. In other cases, the respective ones of the constituents1271-127Cmay include the isocyanates A1 and A2 and the one or more polyols B.

In particular, proportions of the isocyanates A1, A2 and the polyols B may be monitored and controlled in a similar fashion as proportions of the polyols B1, B2 are controlled, as described above, in order to control and customize one or more characteristics (e.g., stiffness) of the polymeric material Mx.

As another example, in some embodiments, rather than determining a desired property of the polymeric material Mxof the layer85xof the shell30of the skate boot22prior to molding the layer85xof the shell30of the skate boot22, a desired property of the skate boot22or of the skate10in their entirety may be determined and the desired property of the polymeric material Mxof the layer85xof the shell30of the skate boot22may be inferred from the desired property of the skate10and/or the skate boot22. In this example, depending on the determination of the desired property of the skate boot22and/or the skate10as a whole, respective ones of the constituents1271-1273may be injected to produce the polymeric material Mxat proportions to impart the desired property of the polymeric material Mxof the layer85xof the shell30of the skate boot22.

As another example, in some embodiments, as shown inFIGS.98and99, the film615may carry at least some of (i.e., some of, a majority of, or an entirety of) the reinforcements115. In this variant, the reinforcement115(such as the ribs1171-117Ror the reinforcing sheet119) may be affixed to the film615(e.g., by gluing, stitching, welding, mechanical interlock, etc.) before the film615is positioned between consecutive layers851-85Lof the shell30.

As another example, in some embodiments, as shown inFIG.100, the film615may be configured to provide the graphical ink632and be removed after molding of the layer85xwhile the graphical ink632remains in the skate boot22, thus providing a layer of graphical ink without adding the weight of the film615to the weight of the skate boot22.

As another example, the quick-connect system320of the blade holder24and the blade26may configured in any other suitable way to attach the blade26to and detach the blade26from the blade holder24.

As another example, in some embodiments, as shown inFIGS.95B,101and107to109, the bridge266of the blade holder24may comprise an upper bridge element392, a lower bridge element390and a void394between the lower bridge element390. In particular, in this embodiment, the void394has a length in the longitudinal direction of the blade holder24that is substantial relative to the length of the bridge266and relative to the blade holder24. In this embodiment, the void394has a length that is at least a majority of a length of the bridge266in the longitudinal direction of the blade holder24. In particular, in this embodiment, the length of the void394is greater than the length of the bridge of the blade holder24. In this embodiment, also, the length of the void394may be at least a majority of the length of the blade holder24. In some embodiments, a ratio of the length of the void394over the length of the blade holder24may be at least 55%, in some embodiments at least 60%, in some embodiments at least 65% and in some embodiments even more. In this embodiment, the void394allows a reduction of a weight of the blade holder24and the upper and lower bridge elements390,392contribute to the stiffness of the blade holder24and to the stiffness of the skate10.

As another example, in some embodiments, as shown inFIG.102, the blade holder24may be configured to hold the blade26such that the blade26is unsupported by the blade holder24between the front pillar210and the rear pillar212when the blade26is at rest. In particular, in this embodiment, the blade holder24may be free of a bridge interconnecting the front pillar210and the rear pillar212. More specifically, in this embodiment, the front pillar210and the rear pillar212are stiff enough for being use without being interconnected and/or rigidified by a bridge. In this embodiment, the blade holder24still displays a relatively high stiffness. For example, in some embodiments, a stiffness of the blade holder24is such that: a lateral force require to deflect the blade holder24by 2 mm at the front pillar210is at least 206 N, in some embodiments at least 220 N, in some embodiments 236 N and in some embodiments even more; a lateral force require to deflect the blade holder24by 2 mm at a midpoint between the front pillar210and the rear pillar212is at least 180 N, in some embodiments at least 185 N, in some embodiments 190 N and in some embodiments even more; and a lateral force require to deflect the blade holder24by 2 mm at the rear pillar212is at least 131 N, in some embodiments at least 245 N, in some embodiments 380 N and in some embodiments even more.

With additional reference toFIG.103, in some embodiments, the upper portion of the blade26may comprise a silkscreen329that may serve as a visual indicator of the adjustment and alignment of the blade26relative to the blade holder24to ease attachment of the blade26to the blade holder24.

In some embodiments, a lower portion of the blade26may also comprise the silkscreen329, for example as a visual indicator of the use and condition of the blade26. For instance, when the blade26is used for play, it needs to be sharpened and sharpening of the blade26reduces height of the blade26and the ice-contacting surface222of the blade26gets closer to the upper portion of the blade26. In this example, the silkscreen329may comprise a mark indicating that the blade26needs to be changed for a new blade when the ice-contacting surface222meets the mark.

In some embodiments, the silkscreen329may be three-dimensional. As such, the silkscreen329may help reducing lateral movements of the blade26relative to the blade holder24and reduce loss of energy caused by these movements. For instance, the silkscreen329may comprise a material of the blade26. In other cases, the silkscreen329may comprise a material that is softer and/or less rigid than the material of the blade26, for instance aluminium or polymeric material. In some cases, the polymeric material may comprise an adhesive material.

As another example, in some embodiments, as shown inFIGS.104to106, 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.105and106, 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.

As another example, in some embodiments, as shown inFIGS.107and108, the skate10may comprises one or more graphical elements621(and-or, in some embodiments, design elements) extending from the skate boot22to the blade holder24such that the skate boot22comprises an upper portion635of the graphical element621and the blade holder24comprises a lower portion633of the graphical element621visually continuous with the upper portion635of the graphical element621. In particular, as shown inFIG.107, the front pillar210of the blade holder24may comprise the lower portion633of the graphical element621, and the rear pillar212of the blade holder24may also comprise the lower portion633of another one of the graphical elements621. In other cases, as shown inFIG.108, the front and rear pillars210,212of the blade holder may comprise lower portions633of a single graphical element621.

The graphical elements621may exhibit a plurality of different colors. For instance, the upper portion635of each graphical element621may exhibit the different colors of the graphical elements621and the lower portion633of each graphical element621may exhibit the different colors of the graphical elements621.

As another example, in some embodiments, as shown inFIGS.109to114, the shell may comprise uneven surface elements645to increase a stiffness of the shell30and to reduce thickness of denser layers for weight reduction.

In some embodiments, at least one of (i.e., one of, some of, a majority of, or an entirety of) the surface elements645may be an edge at the intersection of a first portion651of the shell30and a second portion652of the shell30, a thickness of a given one of the layers851-85Lbeing greater in the first portion651of the shell30than in the second portion652of the shell30. In particular, in this example, the given one of the layers851-85Lis the intermediate layer852. In this example, the thickness of the layers851-85Lthat are positioned outwardly from the intermediate layer852(such as the external layer853) is constant over the portions651,652and the edge645of the shell30, such that the edge645is visible from an outside of the shell30, as shown inFIG.111. In other cases, the thickness of the layers851-85Lthat are positioned outwardly from the intermediate layer852(such as the external layer853) may vary over the portions651,652and the edge645of the shell30, such that the edge645is not visible from the outside of the shell30, as shown inFIG.112.

In some embodiments, at least one of (i.e., one of, some of, a majority of, or an entirety of) the surface elements645may be a rib. A thickness of a given one of the layers851-85Lmay be greater at the rib645than in adjacent portions661adjacent to the rib645. In particular, in this example, the given one of the layers851-85Lis the intermediate layer852. In this example, the thickness of the layers851-85Lthat are positioned outwardly from the intermediate layer852(such as the external layer853) is constant over the rib645and over the adjacent portions661, such that the rib645is visible from the outside of the shell30, as shown inFIG.113. In other cases, the thickness of the layers851-85Lthat are positioned outwardly from the intermediate layer852(such as the external layer853) may vary over the rib645and over the adjacent portions661, such that the rib645is not visible from the outside of the shell30, as shown inFIG.114.

In some embodiments, at least one of (i.e., one of, some of, a majority of, or an entirety of) the surface elements645may be a recess. A thickness of a given one of the layers851-85Lmay be lower at the recess645than in adjacent portions661adjacent to the recess645. In particular, in this example, the given one of the layers851-85Lis the intermediate layer852. In this example, the thickness of the layers851-85Lthat are positioned outwardly from the intermediate layer852(such as the external layer853) is constant over the recess645and over the adjacent portions661, such that the recess645is visible from the outside of the shell30. In other cases, the thickness of the layers851-85Lthat are positioned outwardly from the intermediate layer852(such as the external layer853) may vary over the recess645and over the adjacent portions661, such that the recess645is not visible from the outside of the shell30.

In this embodiment, the skate boot22comprises at least some of the surface elements645of the shell30and the blade holder24also comprises at least some of the surface elements645of the shell30. Each one of the skate boot22and the blade holder24may comprise any suitable number of surface elements645.

As another example, in some embodiments, as shown inFIGS.115to119a given one of the layers851-85Lmay comprise openings678that open onto an adjacent one of the layers851-85L. In particular, in this embodiment, the given one of the layers851-85Lmay be disposed outwardly of the adjacent one of the layers851-85Land may be the outermost one of the layers851-85L—in this case the external layer853. In this example, the adjacent one of the layers851-85Lis the film615comprising the graphical elements621which are configured to be visible through the openings678from the outside of the shell30. In this embodiment, the external layer853is a clear layer.

The openings678may have any suitable shape and may comprise circular openings, elliptical openings, elongate openings, rectangular openings and/or square openings. The shell30may comprise any suitable number of openings678having any suitable dimensions.

The openings678may allow weight reduction and may cover any suitable area of surface. For instance, in some embodiments, a ratio of a total area of surface of the openings678(i.e. a sum of areas of surface of each openings678) over a total external area of surface of the shell30may be at least 0.1%, in some embodiments 10%, in some embodiments 50%, and in some embodiments even more.

The openings678may be created by the use of pushers688during manufacturing of the skate10. Practically, in this embodiment, the female mold1543that is used for injection molding the external subshell853may comprise pushers688. The pushers688may facilitate positioning the internal and intermediate subshells851,852and the film615in the cavity156of the female mold1543accurately by engaging an external surface of the subshells851,852and film615, which were previously formed. While in this embodiment, the pushers688are shown as being distinct from the bodies of the portions155,157of the female mold1543(for instance, the pushers688may be attachable to and removable from the bodies of the portions155,157), in other embodiments, the pushers688may be integrally formed with the bodies of the portions155,157of the female mold1543.

For instance, in some embodiments, the blade holder24may retain the blade26in any other suitable way. For example, in some embodiments, 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.120, 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). For example, in some embodiments, the blade26may be 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 some embodiments, as shown inFIGS.121and122, the blade holder24may retain the blade26using an adhesive226and/or one or more fasteners228. For instance, in some embodiments, as shown inFIG.121, 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.123, 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.124, 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.122, 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.

The blade26may be implemented in any other suitable way in other embodiments. For example, in some embodiments, as shown inFIGS.125and126, 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.127, 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.11, 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 inFIGS.128and129, 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.130, 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.131, 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.132, 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.133, 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.134, 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.135, when the blade holder24is formed integrally with the shell during 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.145, 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 inFIGS.137to139, the shell30of the skate boot22, the tendon guard35, the lace members441,442, the toe cap32and the tongue34may be formed integrally with one another in the molding apparatus150, while the blade holder24may be manufactured separately and connected to the skate boot22after the shell30of the skate boot22and these other components have been molded together in the molding apparatus150. To that end, the skate boot22comprises a connection system480configured to attach the blade holder24to the skate boot22.

In this embodiment, the connection system480comprises a connecting member484that is an insert placed in the molding apparatus150to mold the shell30of the skate boot22onto the connecting member484and configured to be fastened to the blade holder24. The connecting member484is therefore retained in the skate boot22by molding of the shell30of the skate boot22over it, i.e., the shell30of the skate boot22is overmolded on the connecting member484. More specifically, in this example, the sole portion69of the skate boot22is molded on the connecting member484. In this case, the connecting member484extends from a heel region of the skate boot22to a toe region of the skate boot22.

In some embodiments, the overmolding of the shell30of the skate boot22over the connecting member484covers a portion only of the connecting member484, while in other embodiments, the overmolding of the shell30of the skate boot22over the connecting member484covers an entirety of the connecting member484, i.e., the connecting member484is entirely enclosed within the shell30.

In this embodiment, the connecting member484comprises a plurality of fastening voids4921-492vto receive a plurality of fasteners4941-494fto fasten the blade holder24to the skate boot22. In this example, the fastening voids4921-492vare enlarged adjacent to an inner surface488of the connecting member484, the inner surface488being configured to face the user's foot. More specifically, the fastening voids4921-492vmay be countersunk or counterbore holes. The blade holder24may also comprise a plurality of fastening voids4971-497vto receive the plurality of fasteners4941-494fto fasten the blade holder24to the skate boot22.

In this embodiment, a dimension We of the connecting member484in a widthwise direction of the skate boot22may vary along the longitudinal direction of the skate boot22. The connecting member484may be larger in the widthwise direction of the skate boot22where the connecting member overlies the front pedestal210and the rear pedestal212of the blade holder24than where the connecting member484overlies the bridge214of the blade holder24. Also, in this example, the connecting member484is larger in the widthwise direction of the skate boot22where the connecting member484overlies the front pedestal210than where the connecting member484overlies the rear pedestal212.

The connecting member484may be relatively rigid to provide a relatively rigid connection between the skate boot22and the blade holder24. This may allow the ice skate10to be more reactive and to more effectively transmit forces between the ice12and the user's foot. As such, the connecting member484may comprise a material487that is stiffer, i.e., more rigid, than the material Mx of the skate boot22. For instance, in some embodiments, a ratio of a modulus of elasticity of the material487of the connecting member484over the modulus of elasticity of the material Mx of the skate boot22may be at least 1.5, in some embodiments at least 2, in some embodiments at least 3, in some embodiments even more.

In this embodiment, the connecting member484may comprise a front projection496configured to project downwardly towards the front pedestal210and a rear projection498configured to project downwardly towards the rear pedestal212, for reinforcing connection between the skate boot22and the blade holder24.

In some embodiments, as shown inFIGS.140and141, the front projection496may be configured to project downwardly into the front pedestal210and the rear projection498may be configured to project downwardly into the rear pedestal212. The projections496,498may underlie a front projection502of the skate boot22configured to project downwardly into the front pedestal210and a rear projection504of the skate boot22configured to project downwardly into the rear pedestal212.

The projections496,498may be configured to position the connecting member484relative to the blade holder24. Because the projections496,498are overmolded by the skate boot22, the projections496,498may also be configured to position the skate boot22relative to the blade holder24. For instance, the blade holder24may comprise a front void506at the front pillar210and a rear void508at the rear pillar212and the projections496,498, may be configured to project into respective ones of the voids506,508in a relatively tight fit. In some embodiments, the connecting member484and the blade holder24may be affixed to one another at the projections496,498and voids506,508by being pressed into and over one another, fastened to one another, glued to one another, etc.

The connecting member484may be configured to allow the shell30of the skate boot22to be molded in different positions relative to the connecting member484in the molding apparatus150, thereby allowing the blade holder24to be connected to the skate boot22in accordance with these different positions and/or allowing the user to choose between different sizes of the blade holder24to be connected to the skate boot22, based on preferences of the user. For example, in some embodiments, these different positions may be offset in the longitudinal direction of the skate10and/or the widthwise direction of the skate10. As another example, in some embodiments, these different positions allow the user to select a smaller or larger blade holder24, compared to the blade holder24that would normally be used with the skate boot22.

In some embodiments, wherein the projections496,498are configured to position the connecting member484relative to the blade holder24, this may be achieved by using inserts6251-625splaceable in the molding apparatus150to allow the shell30of the skate boot22to be molded in a desirable position relative to the connecting member484in the molding apparatus150, as shown inFIGS.142to144. For instance, the inserts may determine a position of the connecting member484relative to the skate boot22in the molding apparatus. The molding apparatus150may comprise a void622having a shape that corresponds to the shape of the skate boot22and voids6231-623vto receive each one of the inserts6251-625s. During the molding process, inserts6251-625smay be chosen according to preferences of the user and placed in the respective ones of the voids6231-623v. The connecting member484may be placed in the molding apparatus150and may engage partially or completely a surface of the inserts6251-625s. The molding by flowing may then proceed to form the skate boot22comprising the connecting member484, thereby overmolded by the shell30.

In other embodiments, wherein the positioning of the fastening voids4921-492vare configured to position the connecting member484relative to the blade holder24, this may be achieved by using a connecting member484that has fastening voids4921-492vpositioned and configured to fit with the blade holder24of the desired size and at the desired position relative to the skate boot.

In some embodiments, the fastening voids4971-497vof the blade holder24may be oversized, e.g., oblong, to allow a given blade holder24of a pre-determined size to be used with skate boots22of different sizes.

In this embodiment, the connection system480may be configured for removably attaching the blade holder24to the skate boot22, i.e., once the blade holder24is attached to the skate boot22, the user may detach the blade holder24from the skate boot22, such that when the blade holder24is used, broken or needs to be changed for any reason, it may be changed for another blade holder24. In other embodiments, the connection system480may be configured for attaching the blade holder24to the skate boot22in a manner such that the user may not be able to detach the blade holder24from the skate boot22, but such an operation may be doable by re-manufacturing the skate boot22in a manufacture facility. This could be achieved, notably, by using rivets as fasteners4941-494f. In other embodiments, the connection system480may be configured for attaching the blade holder24to the skate boot22in a permanent manner.

As another example, in some embodiments, as shown inFIGS.145to147, the shell of the skate boot22may comprise a blade-holder-connecting portion378projecting downwardly from and formed integrally with the sole portion69, while the skate boot22comprises a plurality of connecting member5881,5882disposed between the blade holder24and the blade-holder-connecting portion378of the shell of the skate boot22to fasten the blade holder24to the skate boot22.

In this embodiment, the connecting member5881,5882are separated from one another and spaced apart in the longitudinal direction of the skate boot22. The blade-holder-connecting portion378of the shell30of the skate boot22comprises a front projection582configured to project downwardly towards the void506of the front pedestal210and a rear projection584configured to project downwardly into towards void508of the rear pedestal212of the blade holder24. The front projection582is configured to connect with the first connecting member5881and the rear projection584is configured to connect with the second connecting member5882. The first connecting member5881is configured to engage the front projection582of the blade-holder-connecting portion378of the shell30and the second connecting member5882is configured to engage the rear projection584of the blade-holder-connecting portion378of the shell30.

In other embodiments, the connecting members5881,5882may be integrally formed with one another, i.e., may form one connecting member.

The connecting members5881,5882may be relatively rigid to provide a relatively rigid connection between the skate boot22and the blade holder24. This may allow the ice skate10to be more reactive and to more effectively transmit forces between the ice12and the user's foot. As such, the connecting members5881,5882may comprise a material589that is stiffer, i.e., more rigid, than the material Mxof the skate boot22. For instance, in some embodiments, a ratio of a modulus of elasticity of the material589of the connecting members5881,5882over the modulus of elasticity of the material Mx of the skate boot22may be at least 1.5, in some embodiments at least 2, in some embodiments at least 3, in some embodiments even more.

In this embodiment, the connecting members5881,5882comprise a plurality of fastening voids5951-595v,5971-597vto receive a plurality of fasteners6011-601f,6031-603fto fasten the blade holder24to the skate boot22. More particularly, each of the fastening voids5951-595v,5971-597vis disposed to receive a corresponding one of the fasteners6011-601f,6031-603f. For example, a first fastening void5951may be disposed to receive a first fastener6011extending from the blade holder24to the connecting members5881,5882; and a second fastening void5971may be disposed to receive a second fastener6031extending from the blade holder24to the blade-holder-connecting portion378of the shell30. The first and second fasteners6011,6031are oriented orthogonally to one another. As another example, the first ones of the fastening voids5951-595v,5971-597vmay be disposed to receive first ones of the fasteners6011-601f,6031-603fextending from the blade holder24to the connecting members5881,5882; and second ones of the fastening voids5951-595v,5971-597vmay be disposed to receive second ones of the fasteners6011-601f,6031-603fextending from the blade holder24to the blade-holder-connecting portion378of the shell30.

In this example, the connecting members5881,5882comprise a recess592to receive the blade-holder-connecting portion378of the shell30. The connecting members5881,5882comprise an extension593projecting away from the recess592. The first fastening voids5951-595vare disposed in the extension593of the connecting members5881,5882to receive the first fasteners6011-601fextending from the blade holder24to the connecting members5881,5882; and the second fastening voids5971-597vopen into the recess592to receive the second fasteners6031-603fextending from the blade holder24to the blade-holder-connecting portion378of the shell30of the skate boot22.

In this embodiment, the blade holder24comprises fastening voids6111-611vconfigured to receive the fasteners6011-601fextending from the blade holder24to the connecting members5881,5882. The projections582,584of the blade-holder-connecting portion378of the shell30of the skate boot22comprise fastening voids6131-613vconfigured to receive the fasteners6031-603fextending from the blade holder24to the blade-holder-connecting portion378of the shell30.

In this embodiment also, the connecting members5881,5882may be configured to connect the blade holder24to the skate boot22in a specific position desirable by the user and/or may allow the user to choose between different sizes of the blade holder24to be connected to the skate boot22, based on preferences of the user. In some embodiments, the connecting members5881,5882may be preselected from a selection of connecting members5881,588C, each pair of connecting members5881,5882corresponding to a size of blade holder or skate boot, and/or corresponding to a position of the blade holder24relative to the skate boot22. In some embodiments, the fastening voids6111-611vof the blade holder24may be oversized, e.g., oblong, to allow a given blade holder24of a pre-determined size to be used with skate boots22of different sizes.

In this embodiment, the blade-holder-connecting portion378and the connecting member5881,5882may be configured for removably attaching the blade holder24to the skate boot22, i.e., once the blade holder24is attached to the skate boot22, the user may detach the blade holder24from the skate boot22, such that when the blade holder24is used, broken or needs to be changed for any reason, it may be changed for another blade holder24. In other embodiments, the blade-holder-connecting portion378and the connecting member5881,5882may be configured for attaching the blade holder24to the skate boot22in a manner such that the user may not be able to detach the blade holder24from the skate boot22, but such an operation may be doable in by re-manufacturing the skate boot22in a manufacture facility. This could be achieved, notably, by using rivets as fasteners6011-601f. In other embodiments, the blade-holder-connecting portion378and the connecting member5881,5882may be configured for attaching the blade holder24to the skate boot22in a permanent manner.

As another example, in some embodiments, as shown inFIG.148, 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.149, the toe cap32, the tongue34, the tendon guard35, the footbed38and the lace members441,442may be attached to the shell after 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.150, 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.151and152, 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 inFIG.123. 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.153, 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 apertures2181-218F to 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 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.154, 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.155, 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 inFIGS.156, 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.157, 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.158, 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.159, 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 Mxof 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.160to165show 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.166, 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 shell without the opening550.

In another variant, rather than being disposed between the subshells851-85L, in other examples the sheet615may be disposed between the inner liner36and the internal subshell851.

As another example, in some embodiments, the sheet615may be placed in the cavity156of the female mold1541on the inner surface of the female mold1541before molding the polymeric material M1on the last152to form the internal subshell851of the shell30. This may allow molding of the polymeric material M1to form the internal subshell851and subsequent demolding without using a mold release agent.

As yet another example, in some embodiments, the sheet615may be placed on the last152before molding the polymeric material M1to form the internal subshell851of the shell30.

In some cases, the sheet615may be applied in planar form onto the last152or a given one of the subshells851-85Lthat is already molded to acquire the shape of the last152or that given one of the subshells851-85L. In other cases, the sheet615may be preformed in a non-planar form conforming to the shape of the last152or a given one of the subshells851-85Lbefore being placed on the last152or the given one of the subshells851-85L.

The sheet615may reduce or eliminate parting lines on the shell30(i.e., internal and/or external parting lines). For example, the sheet615may be configured to avoid at least one parting line on the shell30that would otherwise result because of the portions155,157of a given one of the female molds1541-1543if the sheet615was omitted. This allows one or more parting lines to be avoided as the sheet615overlies where these one or more parting lines would otherwise be located.

In a variant, as shown inFIGS.167to170, rather than integrally molding the shell as 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.167, each of the pieces710,712may constitute a part of the shell30and the blade holder24. In some cases, as shown inFIG.168, each of the pieces710,712may constitute a part of only the shell30or only the blade holder24. As shown inFIGS.169and170, the pieces may include three or more pieces710,712,714.

In another variant, one or more of the subshells851-85Lmay be sprayed or painted rather than injection molded. For instance, this may allow to more easily form thinner subshells851-85L(e.g., of 0.1 mm). Similarly, in another variant, material may be applied between some of the subshells851-85Lto enhance bonding of the subshells851-85L. For instance, in some embodiments, the material comprises an adhesive which may be sprayed over a given one of the subshells851-85Lbefore a subsequent one of the subshells851-85Lis molded. For instance, the subshell853may be a coating and the adhesive may be sprayed over the subshell852before the subshell853is formed to enhance bonding of the coating853. In this example, the adhesive is compatible with polyurethane plastics. More specifically, the adhesive may be compatible with thermoplastic polyurethanes and may comprise relatively low solvent contents. In some embodiments, the adhesive comprises a primer.

In another variant, as shown inFIG.171, 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.172, 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.173and174, 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 5 A and 95 A or between Shore 40 D to 93 D. 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.174, 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 Mimay 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.

As another example, as shown inFIGS.175to177E, in some embodiments, the tendon guard35may be affixed to the shell30of the skate boot22by overmolding. This may provide various advantages, such as: allowing the use of a material for the tendon guard35that is different from the materials of the shell30of the skate boot22; allowing the tendon guard35to have a stiffness that is more appropriate (e.g., lower) for its use; enhancing durability and reducing occurrence of breakage of the tendon guard35; etc. In this example, the tendon guard35is overmolded on a portion732of the shell30of the skate boot22. More specifically, the body30of the skate boot22comprises the portion732having a shape facilitating overmolding such as by being configured for creating a mechanical interlock after overmolding. In this example, the portion732is an interlocking hollow space and the tendon guard35comprises an interlocking part extending in the interlocking hollow space732to interlock the tendon guard35and the shell30. More specifically, in some embodiments, the portion732of the shell30comprises recesses and projection creating a mechanical interlock holding the tendon guard35and the shell30together after the tendon guard is overmolded on the shell30, as shown inFIG.176A. In some embodiments, also, the portion732of the shell30comprises voids or holes creating the mechanical interlock holding the tendon guard35and the shell30together after the tendon guard is overmolded on the shell30, as shown inFIG.176B.

In some embodiments, instead of having the tendon guard35being overmolded on the shell30of the skate boot22, the shell30of the skate boot22is overmolded onto the tendon guard35. More specifically, in this embodiment, respective ones of the subshells851-853are overmolded onto the tendon guard35. For instance, the tendon guard35may comprise a portion744having a shape facilitating overmolding such as by being configured for creating a mechanical interlock after overmolding. In this example, the portion744is an interlocking hollow space and the shell30of the skate boot22comprises an interlocking part extending in the interlocking hollow space to interlock the tendon guard35and the shell30. More specifically, in some embodiments, the portion744of the tendon guard35comprises recesses and projection creating a mechanical interlock holding the tendon guard35and the shell together after the respective ones of the subshells851-853of the shell30are overmolded on the tendon guard35. In some embodiments, also, the portion744of the tendon guard35comprises voids or holes creating the mechanical interlock holding the tendon guard35and the shell30together after the tendon guard35is overmolded on the shell30, as shown inFIGS.177B and177C.

In this embodiment, the portion744is a lower portion affixed to the shell30by overmolding of the at least one of the subshells851-853and the tendong guard35also comprises an upper portion free of overmolding.

In this embodiment, the tendon guard35comprises a material734that is different from the materials M1-ML of the shell30of the skate boot22at the overmold. The material734may be more flexible (i.e., less stiff) to increase comfort of the skate boot22and to increase durability. For instance, in some embodiments, a ratio of a modulus of elasticity of the material734over a modulus of elasticity of a given one of the materials M1-ML of the shell30of the skate boot22may be no more than 0.9, in some embodiments no more than 0.7, in some embodiments no more than 0.5, in some embodiments even less.

The material734of the tendon guard35may be implemented in any suitable way. In this embodiment, the material734may be a polymeric material. For example, in this embodiment, the material734is a polyester elastomer including is a thermoplastic resin. Any other suitable polymer may be used in other embodiments (e.g., polypropylene, ethylene-vinyl acetate (EVA), nylon, polyurethane (PU), 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., Curve), or any other thermoplastic or thermosetting polymer).

In some embodiments, as shown inFIGS.177D and177E, the material734of the tendon guard35may comprise one or more layers736of fabric to enhance overmolding, such as by creating a relief on a surface of the portion744of the tendon guard35. In some embodiments, the layer736may be a woven layer, while in other embodiments, the layer736may be a non-woven layer. For instance, the fabric of the layer of fabric736may comprise nylon, cotton, polyester, glass fibers, carbon fibers and/or any suitable material.

As another example, as shown inFIG.178, in some embodiments, the shell30may comprise pads7601-760Pdisposed at the ankle portion of the skate boot22and/or at any suitable portion of the skate boot22(e.g., at the medial side portion, at the lateral side portion, at the heel portion, etc.) to customize the inner shape of the skate boot22receiving the foot11of the user, to enhance comfort and fit, and/or for other purposes.

The shell30may comprise any suitable number (e.g., one, two or more) of pads7601-760Pspaced from one another. In some embodiments, the pads7601-760Pmay be disposed between the shell30and the liner36of the skate boot22. In some cases, the pads7601-760Pand the liner36may be integrated into the skate boot22during molding of the skate boot22. For instance, during molding, the liner36may be applied over the last and the pads7601-760Pmay be affixed to the liner36before the molding of the shell to impart a customized shape to the molded shell30. In some cases, also, the pads7601-760Pand the liner36may be integrated into the skate boot22after molding of the shell30. For instance, the shell30of the skate boot22may be molded without the liner36. The pads7601-760Pmay then be affixed to the inner surface of the shell30by any suitable means, such as by being adhesively bonded to and/or being stitched to the shell30. Optionally, the liner36may be affixed to the inner surface of the shell and to the pads7601-760Pby any suitable means, such as by being adhesively bonded to and/or being stitched to the shell30and/or the pads7601-760P.

In other embodiments, the pads7601-760Pmay be disposed between other elements of the skate boot22, such as between adjacent ones of the subshells851-85I(e.g., between the intermediate subshell852and the external subshell853of the skate boot22). For instance, after molding of some but not all of the subshells851-85i, the pads7601-760Pmay be affixed to the molded subshells851-85I, and molding of remaining ones of the subshells851-85Imay be achieved subsequently.

In this embodiment, the pads7601-760Pare shaped, manufactured and located based on information about a shape of the user's foot11to customize the skate boot22for the shape of the user's foot11. For instance, information about a shape of a user's foot11may be measured manually or provided by an imaging system such as described in U.S. Patent Application No. 62/692,057, which is incorporated herein.

The pads7601-760Pmay comprise lateral and medial ankle pads7601,7602disposed between the liner36and the ankle portion64of the skate boot22.

The pads7601-760Pmay comprise any suitable material. For instance, a material of the pads7601-760Pmay be soft enough (e.g., so that it can deform and does not prevent the foot11of the user from entering the cavity of the skate boot22and does not cause excessive pressure in use). In some embodiments, the material of the pads7601-760Pmay be softer or less stiff than a foam or another material of an underlying one of the subshells851-85Iof the skate boot22. For instance, the material of the pads7601-760Pmay comprise foam.

The pads7601-760Pmay have any suitable shape. For instance, a thickness of the pads7601-760Pmay be greater than a thickness of a given one of the subshells851-851such that the pads7601-760Phave a significant impact on the inner shape of the skate boot22and/or on the cavity of the skate boot22. For example, in some embodiments, a ratio of the thickness of a given one of the pads7601-760Pover the thickness of the internal subshell851at the location of the given one of the pads7601-760Pmay be at least 1.1, in some embodiments at least 1.5, in some embodiments at least 2, in some embodiments at least 3, in some embodiments even more. In some embodiments, also, the thickness of the pads7601-760Pmay vary in order to conform to the shape of the user's foot11.

In some embodiments, as shown inFIGS.179and180, the skate boot22may comprise a heel-locking member756projecting forwardly above a rearwardly-projecting part of the heel HL of the foot11to keep the heel HL of the user in place in the skate boot22. The heel-locking member756creates a protuberance766in the cavity receiving the foot11of the user above the heel HL and helps keeping the foot11of the user tightly into place.

In this example, the heel-locking member756comprises a heel-locking pad760h. In some embodiments, the heel-locking pad760hmay have a dimension in a heightwise direction of the skate boot22that is sufficiently low to create a sort of cup to keep the heel HL of the user in place in the skate boot22, while the ankle pads7601,7602may have a dimension in the heightwise direction of the skate boot22that is sufficiently great to provide padding to the ankle of the user. For instance, in this embodiment, the dimension of the heel-locking pad760hin the heightwise direction of the skate boot22may be less than the dimension of the lateral ankle pad7601in the heightwise direction of the skate boot22and less than the dimension of the medial ankle pad7602in the heightwise direction of the skate boot22.

The heel-locking pad760hmay be integrally made with the lateral and medial ankle pad7601,7602, such that the heel-locking pad760hand the ankle pads7601,7602constitute a single continuous padding member. In this embodiment, the heel locking pad760hcomprising a medial portion762, a lateral portion766and a bridge portion764linking the portions762and766to one another and configured to form the protuberance above the heel HL of the user.

In other embodiments, the heel-locking pad760h, the lateral ankle pad7601and the medial ankle pad7602are separate from one another.

A material of the heel-locking pad760hmay be soft enough (e.g., so that it can deform and does not prevent the foot11of the user from entering the cavity of the skate boot22and does not cause excessive pressure in use). In some embodiments, the material of the heel-locking pad760hmay be softer or less stiff than a foam or other material of an underlying one of the subshells851-851of the skate boot22. For instance, the material of the heel-locking pad760hmay comprise foam.

In other embodiments, the heel locking padding may have other configurations, e.g., the heel locking pad760hmay be devoid of any one of the portions762and766, and the heel locking padding may comprise more than one heel locking pad.

As another example, in some embodiments, instead of being injection molded in the molding apparatus150as discussed above, one or more of the subshells851-85Lof the shell30of the skate boot22may be formed differently in the molding apparatus. For instance, one or more of the subshells851-85Lof the shell30of the skate boot22may be molded in a mold of the molding apparatus150using pellets (e.g., beads) of polymeric material (e.g., polypropylene, polyethylene, etc.) that are expanded and cured in the mold to create foam. In order to form a subshell85i, the beads may be combined with a blowing agent and/or comprise two or more constituents of a given polymeric material Mxwhich chemically react when combined to polymerize and optionally release heat. In some cases, to initiate and/or to maintain an expansion and/or polymerization reaction, heat, such as by steaming, electromagnetic radiation and/or acoustic radiation, may be applied to the beads to make them foam. After expansion and/or polymerization, the subshell85iis formed and has a shape generally corresponding to the shape of the mold. In this example, the mold cavity is filled with a pre-determined quantity of beads and the mold may be closed prior to polymerisation, such that there is substantially no flow. In other examples, the beads may be injected into the mold through a mold injection gate, prior to or during polymerization of the beads.

As another example, in some embodiments, as shown inFIGS.181to186, the skate boot22may comprise zones8101-810zcomprising different materials Mi1-Mimwhich have different characteristics (e.g., stiffness, density, etc.) and thus imparting different characteristics to these zones8101-810zof the skate boot22.

For instance, in some embodiments, as shown inFIGS.173to183, a subshell85jmay only cover a given zone810jof the skate boot22. This may be achieved, for instance, by using a female mold that prevents material Miof the subshell85jfrom flowing to the zones that are not covered by the subshell85iduring manufacturing of the skate10.

In some embodiments, as shown inFIGS.184to186, a subshell85imay comprise different materials M1-Mm covering different zones8101-810zof the skate boot22. In this example, the different materials M1-Mm of the subshell85iare disposed adjacent to one another in a direction of extent of the subshell85ithat is normal to a thicknesswise direction of the subshell85i. For example, the subshell85imay comprise the materials M1, M1covering the zones8101,810jof the subshell85i. This may be achieved, for instance, by subsequently injecting predetermined volumes of materials Mi, Mjin the mold cavity, such the first injected material Migets pushed by the subsequently injected material Mito the zone8101of the subshell85iwhile the material Miremains in the zone810jof the subshell85i, as shown inFIG.187. In other embodiments, this may be achieved by injecting the materials M1, Mjsimultaneously in the zones810i,810jof the subshell85iusing different input channels814i,814jlocated towards the respective zones810i,810jof the subshell85i, as shown inFIG.188.

The materials Mi, Mjcovering the zones8101,810jmay provide characteristics (e.g., stiffness, weight, etc.) to the skate boot22by having properties (e.g., rigidity, density, color, etc.) varying more or less amongst the materials Mi, Mj. For instance, in some embodiments, a ratio of a density of the material Miover a density of the material Mimay be less than 0.25, in some embodiments between 0.25 and 0.5, in some embodiments between 0.5 and 0.75, in some embodiments between 0.75 and 1, in some embodiments between 1 and 2, in some embodiments between 2 and 4, in some embodiments even more. Similarly, in some embodiments, a ratio of a modulus of elasticity of the material M1over a modulus of elasticity of the material Mimay be less than 0.25, in some embodiments between 0.25 and 0.5, in some embodiments between 0.5 and 0.75, in some embodiments between 0.75 and 1, in some embodiments between 1 and 2, in some embodiments between 2 and 4, in some embodiments even more.

The materials Mi, Mjmay be any suitable materials. For instance, in some embodiments, the materials Mi, Mjare polymeric materials. More particularly, in some embodiments, the materials Mi, Mjare foams. In some embodiments, the materials Mi, Mjmay be composite materials, resins, plastics, and so on. In some embodiments, also, the materials Mi, Mjmay be different kind of materials (e.g. a foam and a plastic material).

As another example, in some embodiments, one or more of the subshells851-853may be formed differently than by molding by flowing. For instance, the one or more of the subshells851-853may be thermoformed. For example, one or more of the subshells851-853may be formed using a sheet of material that is heated and molded over (e.g., pressed onto) a last. The one or more of the subshells851-853may be affixed to underlying ones and/or overlying ones of the subshells851-853by any suitable means, such as may mechanical interlock, by fastening, etc. As another example, one or more of the subshells851-853may be formed using a sheet of material that is heated and molded over an underlying one of the subshells851-853that is already formed.

In some embodiments, the thermoformed subshell85imay cover an entirety of the surface of the shell30. In this case, the thermoformed subshell85isubstantially covers every portion of the user's foot11that is covered by the shell30. In other embodiments, the thermoformed subshell85imay cover a portion of the skate boot22; that is, the thermoformed subshell85icovers some, but not all, portions of the user's foot11that are covered by the shell30. For instance, the thermoformed subshell85imay comprise a toe cap that is thermoformed and incorporated in the shell30while the remainder of the shell30is molded by flowing.

The thermoformed subshell85imay be provided at any stage of the manufacturing process of the skate boot22. For instance, in some embodiments, the thermoformed subshell85iis provided and attached to the last152(e.g., by fastening) before the internal subshell851is produced. In some embodiments, the thermoformed subshell85iis provided and attached to the remainder of the shell30after the remainder of the shell is produced (e.g., by a molding by flowing process) by any suitable means, such as by being stitched or fastened to an underlying subshell85y. In some embodiments, the thermoformed subshell85iis provided after some, but not all, of the subshells851-85Lare produced (e.g., by a molding by flowing process). In this example, the thermoformed subshell85imay be attached to (e.g., by being stitched to, by being fastened to) an underlying one of the subshells851-85Lalready molded.

For instance, in some embodiments, the thermoformed subshell85imay be the insole40, as shown inFIGS.66to68.

As another example, in some embodiments, as shown inFIG.189one or more of the subshells851-853may be thermoformable, as described in U.S. patent application Ser. No. 14/867,962, which is incorporated herein. For instance, one or more of the polymeric materials M1-MNof the shell30may be thermoformable such that, prior to use, the skate boot22may be heated to a first temperature T1, the user may wear the heated skate boot22in a relatively tight manner such that the user's foot11compresses and impart its shape to the skate boot22and the polymeric materials M1-MNof the shell30. This may allow, notably, a more customizable fit.

In this embodiment, the thermoformable material MTmight preserve physical properties such as rigidity after the thermoformable material MTis thermoformed to conform to the user's foot11. For instance, after the thermoformable material MTis thermoformed to conform to the user's foot11, the thermoformable material MTmay have a modulus of elasticity and a yield strength. The thermoformable material MTmay thus deform when subject to a load and may regain its shape imparted by the thermoforming process to conform to the user's foot11after load is removed.

In some embodiments, the thermoformable material MTmay be a shape-memory material. That is, after the thermoformable material MTis thermoformed, the thermoformable material MTmay be heated to a temperature T2to expand and regain an original shape, i.e., the shape of the thermoformable material MTbefore the thermoforming process having imparted the shape of the user's foot11to the skate boot22and to the material MT.

In some embodiments, after the thermoformable material MTis heated to a temperature T2to expand and regain an original shape, the thermoformable material MTmay again be thermoformed such that the user's foot11compresses and impart its shape to the skate boot22and the polymeric materials M1-MNof the shell30.

The temperature T2may be equal or greater (i.e. hotter) than the temperature T1. That is, in some embodiments, the temperature T2may be approximately equal to the temperature T1. In some embodiments, the temperature T2may be at least 50° C. warmer than the temperature T1, in some embodiments at least 100° C. warmer, in some embodiments at least 200° C., in some embodiments even more.

The temperature T1may be low enough to ensure that the user's foot11compressing the skate boot22during thermoforming does not get burnt. For example, in some embodiments, the temperature T1may be no more than 100° C., in some embodiments no more than 80° C., in some embodiments no more than 60° C., in some embodiments even less.

The thermoformable material MTmay be of any nature. For instance, in this embodiment, the thermoformable material MTcomprises a polymeric material. More specifically, in this embodiment, the thermoformable material MTcomprises a foam material.

In this embodiment, the thermoformable subshell comprising the thermoformable material MTis the internal subshell851. In some embodiments, the pads7601-760Pmay comprise the thermoformable material MT.

As another example, in some embodiments, the skate boot22may be made using any other manufacturing processes, including conventional ones (e.g., using a conventional lasting machine, thermoforming, etc.), while including one or more features discussed herein, such as, for example, the heel-locking member756, the graphic elements121on the toe cap32, an overmolded connection for the tendon guard35, etc.

For instance, in some embodiments, as shown inFIG.190, the skate boot22is made using a standard toe cap32which is not integrally made with the shell30of the skate boot22. In this embodiment, the skate boot22comprises one or more design elements121which may be disposed over various portions of the shell30and/or over various other portions of the skate boot22, for instance over the medial side portion68of the shell30, over the lateral side portion66of the shell30, over a top portion of the shell30, and so on, and may also be disposed over the toe cap32, over the tongue34, over the tendon guard35, over the liner36, over the footbed38, over the insole40, over the lace members441,442, over the eyelets461-46E, and so on. For instance, the design elements121may be disposed at least on a side of the toe cap32. In this example, the design elements121are disposed on a medial side, on a lateral side and on a top side of the toe cap32.

The design elements121may cover at least a substantial part (i.e., a substantial part or an entirety) of a surface area of the toe cap32that is externally visible (i.e., visible from outside of the skate boot22). For instance, in some embodiments, the design elements121covers at least a quarter (i.e., 25%), in some embodiments at least a third (i.e., 33%), in some embodiments at least a majority (i.e., at least 50%), in some embodiments at least 75%, and in some embodiments an entirety of the toe cap32.

Some of the design elements121may also be continuous with other design elements121of adjacent portions of the skate boot22. That is, there may be a continuity of the design element121between the toe cap32of the skate boot and a given one of the medial side portion68of the shell30and the lateral side portion66of the shell30, thus providing an impression that the design elements121extend from a given one of the toe cap32, the medial side portion68and the lateral side portion66to another one of the toe cap32, the medial side portion68and the lateral side portion66. In this embodiment, there is continuity of design elements121between the toe cap32of the skate boot30, the medial side portion68of the shell30and the lateral side portion66of the shell30.

In this embodiment, an external clear layer may be applied over the design elements121such that the design elements121are visible through the clear layer and such that the clear layer protects the design elements121from flying pucks, sticks, etc.

The design elements121may include a design pattern, a printed image, and so on. In this embodiment, the design element is a graphic element which includes one or many different colors.

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 wheel holder holding a set of wheels to roll on the dry skating surface14(i.e., the skate10may be an inline skate or other roller skate). The wheel holder may be constructed using principles discussed herein in respect of the blade holder24. 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.192, the footwear may 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.193, 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 another example, as shown inFIG.194, the footwear10may be a snowboard boot comprising a shell1030which can be constructed in the manner described above with respect to the shell of the skate. In another example, as shown inFIG.195, the footwear10may be a sport cleat comprising a shell1130which can be constructed in the manner described above with respect to the shell of the skate. In another example, as shown inFIG.196, the footwear10may be a hunting boot comprising a shell1230which 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.

In describing the embodiments, specific terminology has been resorted to for the sake of description but this 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 purposes of describing, but should not be limiting. Various modifications will become apparent to those skilled in the art.