Abstract:
A hockey skate includes a fiber-reinforced, composite frame, or an injected plastic frame, including a boot form and integral pedestals that serve as a blade-holder. The pedestals are integral with the bottom of the boot sole and are optionally spaced relatively far apart to provide a long span between them. An optional bridge assembly may be used to connect the blade to the pedestals. The bridge assembly may provide increased stiffness and vibration damping, as well as customized fit options.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 62/067,241, filed Oct. 22, 2014 and now pending, which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    Hockey skates need to meet several criteria to perform at a high level. A hockey skate, for example, must support acceleration forces, cornering forces, and stopping forces. The modern sport of hockey, featuring ever-increasing athleticism of players, demands even more from a hockey skate. 
         [0003]    Traditional hockey skates generally include three main components: a boot, a blade-holder (or “holder”), and a steel blade. The boot receives the wearer&#39;s foot and is typically made of one or more lightweight materials. The holder is typically a plastic frame including pedestals that connect the boot to the steel blade. The pedestals of the holder are attached to a sole plate of the boot. Traditional holders are generally designed to substantially reduce or eliminate flex in the skate and to fix the blade to the boot such that minimal blade deflection occurs. 
         [0004]    Holders are typically connected to the boot via several metal rivets (for example, 14 metal rivets) or similar fasteners. Metal rivets, however, are relatively heavy and do not rigidly fix the holder to the skate boot. Rather, despite the numerous rivets used, energy losses typically result from relative movement that occurs between the boot and the holder. Manufacturing inconsistencies, such as varying rivet-hole locations, can cause improper alignment between the holder and the boot. Further, clearance typically occurs between the outer diameter of the rivet and the inner diameter of the holes in the holder, and the rivets tend to stretch or elongate the holes in the boot and holder during use. Thus, despite the many fasteners used to fix the holder to the boot, numerous variables exist that can negatively affect the energy transfer between the boot and the holder. 
         [0005]    Modern hockey players generally desire relatively light and stiff skates. A lighter skate is easier to maneuver, while a stiffer skate transmits leg motion to the skate more efficiently. While these features are generally preferred, certain skaters may prefer different performance properties from their skates. 
         [0006]    An effective and efficient skate provides efficient energy transfer during acceleration, cornering, and stopping. During forward acceleration, increased pressure is applied to the front portion of the blade as the skater applies downforce on the balls of the feet, much like a runner. In order to achieve efficient energy transfer to the ice, resulting in maximum blade contact with the ice, the skate or blade needs to deflect or bend. A skate that is capable of twisting allows the rear portion of the skate to rotate toward the lateral or medial side, which allows the blade to contact the ice in this area. If there is no torsional deflection, the blade will partially contact the ice in the front area where the downward force is concentrated, resulting in reduced power transfer. 
         [0007]    During cornering, the skater&#39;s leg angle changes and the cornering action places a high rotational force on the skate. To efficiently accommodate this change in force, the skate requires a relatively high rotational stiffness. A skate is also subjected to quick directional changes, often initiated by ankle movement. This movement generally distributes force to the interface between the boot and the holder. A traditional skate with an attached holder, however, allows some relative movement between the boot and the holder such that some energy is not transferred to the blade. 
         [0008]    During stopping, the skater applies the blade at a cross angle to the direction of travel while leaning inward to place the edge of the blade on the ice to stop momentum. This action places a higher rotational force on the skate than cornering. As with cornering, any relative movement between the boot and holder will reduce the transfer of energy, and thus the stopping force. 
       SUMMARY 
       [0009]    A hockey skate includes a fiber-reinforced, composite frame, or an injected plastic frame, including a boot form and integral pedestals that serve as a blade-holder. The pedestals are integral with the bottom of the boot sole and are optionally spaced relatively far apart to provide a long span between them. An optional bridge assembly may be used to connect the blade to the pedestals. The bridge assembly may provide increased stiffness and vibration damping, as well as customized fit options. Other features and advantages will appear hereinafter. The features described above can be used separately or together, or in various combinations of one or more of them. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    In the drawings, wherein the same reference number indicates the same element throughout the views: 
           [0011]      FIG. 1  is a side view of a traditional hockey skate. 
           [0012]      FIG. 2  is an exploded view of a skate, excluding an outer covering and other external features, according to one embodiment of the invention. 
           [0013]      FIG. 3  is an assembled view, excluding fasteners, of the skate shown in  FIG. 2 . 
           [0014]      FIG. 3A . is a front-end view of the front pedestal and bridge of the skate shown in  FIG. 3 . 
           [0015]      FIG. 3B  is a front-end view of a front pedestal attached to a bridge including a laterally offset groove that receives a blade, according to one embodiment. 
           [0016]      FIG. 3C  is a front-end view of a front pedestal attached to a bridge including a medially offset groove that receives a blade, according to one embodiment. 
           [0017]      FIG. 4  is an exploded view of the skate shown in  FIGS. 2 and 3  including fasteners. 
           [0018]      FIG. 5  is a front-end view of a pedestal including a split projection that receives a blade, according to one embodiment. 
           [0019]      FIG. 6  is a front-end view of a pedestal including a split projection and a spacer positioned between legs of the split projection and a blade, according to one embodiment. 
           [0020]      FIG. 6A  is a front-end view of a pedestal including a wide split projection and multiple spacers positioned between legs of the split projection and a blade, according to one embodiment. 
           [0021]      FIG. 7  is an exploded view of a skate, excluding an outer covering and other external features, including a boot form with integral pedestals and separate blade-holders that fit over the pedestals, according to one embodiment. 
           [0022]      FIG. 8  is a top view of the boot sole of the skate shown in  FIG. 7 . 
           [0023]      FIG. 9  is an exploded view of a skate, excluding an outer covering, including a boot form with integral pedestals and a blade longitudinally fastened to the pedestals, according to one embodiment. 
           [0024]      FIG. 10  is a perspective view of a skate including a boot form with integral pedestals and an outer covering, according to one embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0025]    Various embodiments of the invention will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures or functions may not be shown or described in detail so as to avoid unnecessarily obscuring the relevant description of the various embodiments. 
         [0026]    The terminology used in the description presented below is intended to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific embodiments of the invention. Certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this detailed description section. 
         [0027]    Where the context permits, singular or plural terms may also include the plural or singular term, respectively. Moreover, unless the word “or” is expressly limited to mean only a single item exclusive from the other items in a list of two or more items, then the use of “or” in such a list is to be interpreted as including (a) any single item in the list, (b) all of the items in the list, or (c) any combination of items in the list. Further, unless otherwise specified, terms such as “attached” or “connected” are intended to include integral connections, as well as connections between physically separate components. 
         [0028]    Turning now in detail to the drawings,  FIG. 1  illustrates an example of a traditional hockey skate  10 . The skate includes a boot  12  having a toe region  14 , a heel region  16 , a tongue  18 , a tendon guard  20 , and a sole  22 . A blade-holder or “holder”  24  is attached to the boot  12  along the boot sole  22  through holes  26 . A steel blade  28  is positioned in a groove  30  in the holder  24  and is attached via bolts  32   a  and  32   b  or screws through holes in the blade  28  and holder  24 . The holder  24  includes a front pedestal  34  and rear pedestal  36 . The length of the front pedestal  34  is approximately equal to the length of the rear pedestal  36 , which is approximately equal to the length of the opening between the pedestals  34  and  36 . 
         [0029]      FIGS. 2-4  illustrate the components of a skate  40 , excluding the outer boot-covering materials, tendon guard, laces, and so forth, according to one embodiment of the invention. The excluded portions of the skate  40  may be attached to or integrated with the skate as described, for example, in U.S. patent application Ser. No. 13/794,071, filed Mar. 11, 2013, which is incorporated herein by reference, or in any other suitable manner. One example of skate  300  including outer boot-covering materials  302 , a tendon guard  304 , laces  306 , lace eyelets  308 , and so forth, is shown in  FIG. 10 . In one embodiment, the tendon guard  304  may be directly or indirectly attached to the boot form described below. 
         [0030]    The skate  40  includes a boot form  42  that is integral with a front pedestal  44  and a rear pedestal  46  such that these components form a unitary structure. The boot form  42  includes a toe region  45 , a lateral upper region  48 , a medial upper region  50 , and a heel region  52 . The front and rear pedestals  44  and  46  are molded with or fused to a boot sole  54  to form a continuous, integrated structure. The front pedestal  44  includes a first projection  58  including a first hole or opening  60 , while the rear pedestal  46  includes a second projection  62  including a second hole or opening  64 . 
         [0031]    A blade  70  may be fastened to the pedestals  44  and  46 , directly or indirectly, in a variety of manners to provide a desired level of flex in the blade  70 . Adding flex to the blade  70  increases compliance between the skate  40  and the ice. Ice can become rough during use, resulting in the transmission of vibrations to the skater. Increased flex or compliance of the blade  70  improves comfort for the skater when these vibrations are transmitted. In another embodiment, one or more additional pedestals may be included on the boot form  42 . For example, a third pedestal may be positioned between the front and rear pedestals  44  and  46 , and fastened to the blade  70 , to add additional stiffness or strength. 
         [0032]    The boot form  42  may be formed from plies of composite, fiber-reinforced polymeric materials preimpregnated with resins, or from other suitable materials. In one embodiment, a boot preform is laid up using carbon-fiber-reinforced, epoxy-impregnated materials. Once the preform is complete, the plies may be consolidated in a molding operation that applies pressure and heat to crosslink and cure the resin. This construction facilitates precise positioning of the material plies and orienting of the fibers. The boot form  42  may alternatively be formed by plastic injection molding, or by a hybrid molding process using injection molding and preimpregnated fiber tapes to form the boot form  42 . In one embodiment, the tendon guard  304  may be injected using the same material, or a different material, than the boot form  42 . 
         [0033]    Other fibers may be used to construct the boot form  42 , such as glass, aramid, ceramic, liquid-crystal polymer, or other suitable materials. Different resins may also be used, such as vinyl-ester thermoset resins, or thermoplastic resins may be used, such as polyamide, polyester, polyurethane, or polyethylene resins. A combination of thermoset and thermoplastic resins may also be used. In one embodiment, thermoplastic resins having a relatively low melting temperature may be used to form a portion of the boot form  42  into a desired shape. 
         [0034]    Such a fiber-reinforced, composite structure offers anisotropic stiffness that may be tailored to achieve desired performance characteristics. In addition, the torsional stiffness and bending stiffness of the skate may be tailored for desired performance. The stiffness of the integrated structure may also be optimized by using fiber-reinforced, composite materials, and the stiffness and performance can be consistent between skates during the life of the skates. 
         [0035]    Further, the fiber-reinforced, integrated structure may be designed with specific fiber angles, in selected locations, to achieve specific performance objectives. For example, fibers aligned with the blade  70  provide high bending stiffness, while fibers angled relative to the blade  70  provide increased flexibility and higher torsional stiffness. Preimpregnated fiber patches may also be applied in specific locations to add reinforcement where desired. In this manner, the integrated structure may be reduced in weight, since reinforcements may be positioned only where needed, and in the proper orientations. Adjacent zones of the boot form  42  may be stiff or flexible if desired to optimize performance. 
         [0036]    The front pedestal  44  is optionally positioned at the front end of the toe region  45 , and the rear pedestal  46  is optionally positioned at the rear end of the heel region  52 . This positioning creates a relatively long span  66  between the pedestals  44  and  46  along the boot sole  54 . A long span  66  of this nature yields a boot form  42  with increased flexibility relative to one with pedestals positioned closer together, or with pedestals that engage a longer length of the blade. For example, a longer span  66  allows for greater torsional flex of the boot form  42  and greater bending flex of the blade  70 , both of which may be desirable during acceleration. The longer span  66  also creates a more comfortable skate because the blade  70  is able to absorb shock and vibrations better than a stiffer, shorter blade. 
         [0037]    In one embodiment, the blade  70  is optionally connected to a bridge  80  that generally increases the stiffness, strength, and vibration damping of the blade  70 . The blade  70  may be connected to the bridge  80  by fasteners  81  passing through holes  72 ,  74 , and  76  in the blade  70 , and through holes  82 ,  84 , and  86  in the bridge  80 . The bridge  80  may be made of a lightweight metal, such as aluminum, magnesium, or titanium, or of a fiber-reinforced composite material, or of another suitable material. The bridge  80  is connected to the pedestals  44  and  46  by fasteners  83  passing through holes  60  and  64  in the pedestals  44  and  46 , and through holes  88  and  90  in the bridge  80 . 
         [0038]    Inclusion of a bridge  80  is particularly desirable when the span  66  between the pedestals  44  and  46  is relatively long. This longer span  66  yields a more flexible blade  70 , and the bridge  80  provides added stability and strength. The thickness of the bridge  80  may be selected as needed to support a given blade  70  and to meet the preferences of a given skater. The bridge  80  may also vary in thickness along its cross section, with thicker sections providing additional support in local areas. For example, the bridge  80  may have a thicker cross section at the mid-region of the blade  70 , near the bridge hole  84 , than in other regions. 
         [0039]    As shown in  FIG. 3A , the bridge  80  may include a blade-receiving slot or groove  93  aligned with the center of the front pedestal  44  (or rear pedestal  46 ), or the blade-receiving groove may be offset relative to the center of the pedestal  44  or the central axis of the skate. For example,  FIG. 3B  illustrates an embodiment in which a bridge  95  includes a blade-receiving groove  97  that is positioned to the lateral side of the pedestal  44  and the central axis of the skate.  FIG. 3C , conversely, illustrates an embodiment in which a bridge  99  includes a blade-receiving groove  101  that is positioned to the medial side of the pedestal  44  and the central axis of the skate. Thus, the groove in the bridge may be positioned to meet the preferences of a given skater. 
         [0040]    This adjustability and customizability may be utilized at one or more of the pedestals. For example, in one embodiment, the horizontal angle of the blade  70  made be modified by including a laterally offset blade-receiving groove in the front portion of the bridge (or in the in the front pedestal  44  itself), and a medially offset blade-receiving groove in the rear portion of the bridge (or in the in the rear pedestal  46  itself), or vice versa. The pitch angle of the blade  70  may also be adjusted by raising the front connection portion and lowering the rear connection portion, or vice versa. Further, the cant or vertical angle of the blade  70  may be adjusted by including a varying cant angle of the blade groove. 
         [0041]    As shown in  FIG. 5 , in one embodiment, one or both pedestals  100  of a boot form may include a split projection including a first leg  104  and a second leg  106  that form a blade-receiving space  108  between them. An upper portion of a blade  110  is positioned in the space  108  and attached to the legs  104  and  106  via fasteners, such as the fasteners described above or other suitable fasteners. 
         [0042]    As shown in  FIG. 6 , in another embodiment, one or both pedestals  112  of a boot form may include a split projection including a first leg  114  and a second leg  116  that form a blade-receiving space  118  between them. An upper portion of a blade  122  is positioned in the space  118  and attached to the legs  114  and  116  via fasteners, such as the fasteners described above or other suitable fasteners. A spacer  120  is positioned between the blade  122  and the legs  114  and  116 . The spacer  120  may be made of a polymer film or plastic to add protection to the pedestal  112 . Alternatively, the spacer  120  may be made of a lightweight metal to provide support to the pedestal  112 . In one embodiment, a metal spacer  120  may optionally be coated with a polymer film to add protection to the pedestal  112  and the spacer  120 . 
         [0043]    The size of the spacer  120  may vary depending on how much protection or support is desired. The spacer  120  may also act as a bridge that connects the blade  122  to each pedestal  112 . In one embodiment, the thickness of the spacer  120  may vary in different regions to adjust the horizontal (i.e., medial-lateral) position of the blade  70  in those regions. 
         [0044]    As shown in  FIG. 6A , in one embodiment, one or both pedestals  103  may include a wide split to accommodate spacers  107  and  109  that adjust the horizontal (i.e., medial-lateral) position of the blade  105 . Any suitable number of spacers, each having any desired thickness, may be used to adjust the blade position. 
         [0045]    As shown in  FIG. 7 , in another embodiment, a boot form  130  includes an integral front pedestal  132  and rear pedestal  134 . The front and rear pedestals  132  and  134  may be shaped like truncated pyramids or similar shapes, with wider base regions  136  and  138  and narrower tip regions  140  and  142 , respectively. A front holder  148  and a rear holder  150  are shaped to fit precisely or snugly over the tips  140  and  142  of the pedestals  132  and  134 , respectively. In one embodiment, the holders  148  and  150  each include a perimeter skirt  176  and  178  to snugly secure the holders  148  and  150  to the pedestals  132  and  134 . The skirts  176  and  178  may also offer protection to the boot structure. The holders  148  and  150  may optionally be replaceable parts, similar to the blade  160 . 
         [0046]    The front and rear pedestals  132  and  134  may include internal holes or openings  144  and  146  for alignment with holes or openings  152  and  154  in holders  148  and  150 , respectively. The holders  148  and  150  may be secured to the pedestals  132  and  134  using fasteners that pass through openings  144  and  146  and openings  152  and  154 , or via other suitable connectors. In one embodiment, threads may be molded inside openings  144  and  146  or openings  152  and  154  to receive threaded connectors, such as bolts or screws. 
         [0047]    As shown in  FIG. 8 , in one embodiment, access to the openings  144  and  146  may be provided in the inner surface of the floor  156  of the boot form  130 . A wrench or other tool may be used to tighten the fasteners to secure the holders  148  and  150  to their respective pedestals  132  and  134 . 
         [0048]    The front holder  148  may include a longitudinal groove  158  configured to receive a tab or other engagement portion  162  of the blade  160 . Similarly, the rear holder  150  may include a longitudinal groove  164  configured to receive a tab or other engagement portion  166  of the blade  160 . Fasteners may be used to secure the blade  160  to the holders  148  and  150  through blade holes  168  and  170  and holder holes  172  and  174 , respectively. 
         [0049]    The embodiment shown in  FIGS. 7 and 8  offers several options and advantages. For example, the holders  148  and  150  may be made of a rigid or flexible material depending on the desired performance or feel, or they may be made of different materials than each other. The holders  148  and  150  may also be made of materials that provide vibration damping, if desired. Further, the holders  148  and  150  may have different configurations to vary the location of the blade relative to the boot form  130 . For example, one or more of the grooves  158  and  164  may be located closer to the lateral or medial sides of the holders  148  and  150 . The grooves  158  and  164  may also be oriented at an angle, for example, at an angle relative to a longitudinal axis of the boot, or at an angle relative to a vertical axis of the boot. The holders  148  and  150  may also vary the fore and aft position of the blade  160  relative to the boot form  130 . In one embodiment, the holders  148  and  150  may be connected to each other to act as a bridge that adds stability or stiffness to the blade  160 . 
         [0050]    As shown in  FIG. 9 , in another embodiment, a blade  180  is attached to a boot form  182  via longitudinal tabs or engagement portions  192  and  200  that include longitudinal protrusions  194  and  202 , respectively. The boot form  182  includes an integral front pedestal  184  and rear pedestal  186 . The front pedestal  184  may include a longitudinal groove  188  and an interior channel  190  that receive the engagement portion  192  and protrusion  194 , respectively, of the blade  180 . Similarly, the rear pedestal  186  may include a longitudinal groove  196  and an interior channel  198  that receive the engagement portion  200  and protrusion  202 , respectively, of the blade  180 . 
         [0051]    The ends of the protrusions  194  and  202  may be threaded or may include other openings that facilitate their securement to the pedestals  184  and  186 , using nuts and bolts or other fasteners. Alternatively, in one embodiment, only one of the rear protrusion  202  and the front protrusion  194  is attached such that, when the attachment is secured, the blade  180  is held under tension to secure it in place. In another embodiment, one or more quick-release or tool-less fasteners may be used to secure one or more of the protrusions  194  and  202  to their respective pedestals and  184  and  186 . 
         [0052]    The embodiments described herein provide several advantages. For example, relative movement between the boot form and the blade may be minimized or eliminated, depending on the objectives of a given design. The unitary boot form-and-pedestal structure eliminates many rivets or other energy-absorbing structures, resulting in a lighter and more responsive skate. Thus, the unitary structure will perform more consistently over a longer period of time. 
         [0053]    Further, a skate offering varied flexibility, or flexibility in a particular zone, provides benefits. Traditional skate boots are generally designed to be as stiff as possible in all directions. The boot forms described herein, conversely, may have different stiffness properties in different directions and locations. The integral pedestals, for example, may provide high stiffness because they are integrated with boot form. The region between the pedestals, conversely, may be considerably more flexible, allowing a controlled amount of twisting and bending in this area. The skate may also include geometric features that further tailor this zonal bending and twisting stiffness. 
         [0054]    Another benefit is the provision of consistent and reliable blade orientation and location. A typical skate has a separate boot and holder that are fastened together. The one-piece, boot form-and-pedestal structure, conversely, may be formed by tooling, such that multiple structures may be molded in the same geometry, resulting in precise and consistent orientation and positioning of the blade assembly. 
         [0055]    Any of the above-described embodiments may be used alone or in combination with one another. Further, the described skate may include additional features not described herein. While several embodiments have been shown and described, various changes and substitutions may of course be made, without departing from the spirit and scope of the invention. The invention, therefore, should not be limited, except by the following claims and their equivalents.