Patent Publication Number: US-7712173-B2

Title: Method of manufacturing an ice skate

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application is a divisional application of U.S. patent application Ser. No. 11/057,766 filed on Feb. 15, 2005. now U.S. Pat. No. 7,533,479. 

   FIELD OF THE INVENTION 
   The present invention relates to a method of making an ice skate. 
   BACKGROUND OF THE INVENTION 
   The construction of sporting boots used for sporting activities such as ice skating, roller skating, hiking, trekking and cross-country skiing has become quite complex over recent years. Existing sporting boots often include multiple different components, and multiple different materials in order to provide the sporting boot with the performance and aesthetic requirements imposed by consumers. As such, over recent years different manufacturing processes have been developed and new materials have ,been used. 
   The most recent trend in sporting boot construction is to manufacture a sporting boot using lightweight components, and where possible with a reduced number of components. 
   Accordingly, there is a need in the industry for a sporting boot that is lighter and/or has less components than existing skate boots. 
   SUMMARY OF THE INVENTION 
   In accordance with a first broad aspect, the invention provides a sporting boot for enclosing a human foot when in use, the foot having a heel, an ankle with a medial malleolus and a lateral malleolus, a plantar surface, medial and lateral sides and toes, the sporting boot comprising (a) an outer shell made of a thermoformable material, the outer shell being thermoformed such that it comprises: (i) a heel portion for receiving the heel of the foot; (ii) an ankle portion for receiving the ankle; (iii) medial and lateral side portions for facing the medial and lateral sides of the foot respectively; and (iv) a skirt portion integrally formed with one of the medial and lateral side portions, the skirt portion being folded inwardly to form a sole having an upper surface for facing the plantar surface of the foot and a bottom surface; and (b) an outsole mounted to the bottom surface of the sole. 
   In accordance with a second broad aspect, the present invention provides a sporting boot for enclosing a human foot when in use, the foot having a heel, an ankle with a medial malleolus and a lateral malleolus, a plantar surface, medial and lateral sides and toes, the sporting boot comprising (a) an outer shell made of a thermoformable material, the outer shell being thermoformed such that it comprises: (i) a heel portion for receiving the heel of the foot; (ii) an ankle portion for receiving the ankle; (iii) medial and lateral side portions for facing the medial and lateral sides of the foot respectively; and (iv) a medial skirt portion integrally formed with the medial side portion and a lateral skirt portion integrally formed with the lateral side portion, the medial and lateral skirt portions being folded inwardly to form a sole having an upper surface for facing the plantar surface of the foot and a bottom surface; and (b) an outsole mounted to the bottom surface of the sole. 
   In accordance with a third broad aspect, the present invention provides a skate boot for enclosing a human foot when in use, the foot having a heel, an ankle with a medial malleolus and a lateral malleolus, a plantar surface, medial and lateral sides and toes, the skate boot comprising an outer shell made of thermoformable material, the outer shell being thermoformed such that it comprises: (a) a heel portion for receiving the heel of the foot; (b) an ankle portion for receiving the ankle; (c) medial and lateral side portions for facing the medial and lateral sides of the foot respectively; and (d) a skirt portion integrally formed with one of the medial and lateral side portions, the skirt portion being folded inwardly to form a sole having an upper surface for facing the plantar surface of the foot and a bottom surface. 
   In accordance with a fourth broad aspect, the present invention provides a skate boot for enclosing a human foot when in use, the foot having a heel, an ankle with a medial malleolus and a lateral malleolus, a plantar surface, medial and lateral sides and toes, the skate boot comprising an outer shell made of thermoformable material, the outer shell being thermoformed such that it comprises: (a) a heel portion for receiving the heel of the foot; (b) an ankle portion for receiving the ankle; (c) medial and lateral side portions for facing the medial and lateral sides of the foot respectively; and (d) a medial skirt portion integrally formed with the medial side portion and a lateral skirt portion integrally formed with the lateral side portion, the medial and lateral skirt portions being folded inwardly to form a sole having an upper surface for facing the plantar surface of the foot and a bottom surface. 
   In accordance with a fifth broad aspect, the invention provides an ice skate comprising: (a) a skate boot comprising an outer shell made of thermoformable material, the outer shell being thermoformed such that it comprises: (i) a heel portion for receiving the heel of the foot; (ii) an ankle portion for receiving the ankle; (iii) medial and lateral side portions for facing the medial and lateral sides of the foot respectively; and (iv) a skirt portion integrally formed with one of the medial and lateral side portions, the skirt portion being folded inwardly to form a sole having an upper surface for facing the plantar surface of the foot and a bottom surface; and (b) an ice skate blade holder mounted on the bottom surface of the sole. 
   In accordance with a sixth broad aspect, the invention provides a method of manufacturing a sporting boot for enclosing a human foot when in use, the foot having a heel, an ankle with a medial malleolus and a lateral malleolus, a plantar surface, medial and lateral sides and toes, the method comprising: (a) providing a sheet of thermoformable material; (b) thermoforming the sheet of thermoformable material to form an outer shell comprising (i) a heel portion for receiving the heel of the foot; (ii) an ankle portion for receiving the ankle; (iii) medial and lateral side portions for facing the medial and lateral sides of the foot respectively, the medial and lateral side portions extending forwardly from the heel portion and the ankle portion, one of the medial and lateral side portions comprising a skirt portion being integrally formed therewith; (c) folding the skirt portion to form a sole having an upper surface for facing the plantar surface of the foot and a bottom surface; and (d) affixing an outsole to the bottom surface of the sole. 
   In accordance with a seventh broad aspect, the invention provides a method of manufacturing a sporting boot for enclosing a human foot when in use, the foot having a heel, an ankle with a medial malleolus and a lateral malleolus, a plantar surface, medial and lateral sides and toes, the method comprising: (a) providing a sheet of thermoformable material; (b) thermoforming the sheet of thermoformable material to form an outer shell that comprises: (i) a heel portion for receiving the heel of the foot; (ii) an ankle portion for receiving the ankle; (iii) medial and lateral side portions for facing the medial and lateral sides of the foot respectively, the medial and lateral side portions extending forwardly from the heel portion and the ankle portion; the medial and lateral side portions each comprising a respective medial and lateral skirt portion being integrally formed therewith; (c) folding the medial and lateral skirt portions inwardly to form a sole having an upper surface for facing the plantar surface of the foot and a bottom surface; and (d) affixing an outsole to the bottom surface of the sole. 
   In accordance with a eighth broad aspect, the invention provides a method of manufacturing an ice skate for enclosing a human foot when in use, the foot having a heel, an ankle with a medial malleolus and a lateral malleolus, a plantar surface, medial and lateral sides and toes, the method comprising: (a) providing a sheet of thermoformable material; (b) thermoforming the sheet of thermoformable material to form an outer shell comprising (i) a heel portion for receiving the heel of the foot; (ii) an ankle portion for receiving the ankle; (iii) medial and lateral side portions for facing the medial and lateral sides of the foot respectively, the medial and lateral side portions extending forwardly from the heel portion and the ankle portion, one of the medial and lateral side portions comprising a skirt portion being integrally formed therewith; (c) folding the skirt portion to form a sole having an upper surface for facing the plantar surface of the foot and a bottom surface; and (d) mounting an ice skate blade holder to the bottom surface of the sole. 
   In accordance with a ninth broad aspect, the invention provides a method of manufacturing an ice skate for enclosing a human foot when in use, the foot having a heel, an ankle with a medial malleolus and a lateral malleolus, a plantar surface, medial and lateral sides and toes, the method comprising: (a) providing a sheet of thermoformable material; (b) thermoforming the sheet of thermoformable material to form an outer shell that comprises: (i) a heel portion for receiving the heel of the foot; (ii) an ankle portion for receiving the ankle; (iii) medial and lateral side portions for facing the medial and lateral sides of the foot respectively, the medial and lateral side portions extending forwardly from the heel portion and the ankle portion; the medial and lateral side portions each comprising a respective medial and lateral skirt portion being integrally formed therewith; (c) folding the medial and lateral skirt portions inwardly to form a sole having an upper surface for facing the plantar surface of the foot and a bottom surface; and (d) mounting an ice skate blade holder to the bottom surface of the sole. 
   These and other aspects and features of the present invention will now become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A detailed description of examples of embodiments of the present invention is provided hereinbelow with reference to the following drawings, in which: 
       FIG. 1  is a side view of a human foot with the integument of the foot shown in stippled lines and the bones shown in solid lines; 
       FIG. 2  is a front view of the human foot of  FIG. 1 ; 
       FIG. 3  is a perspective view of an ice skate comprising an outer shell in accordance with a first embodiment of the present invention; 
       FIG. 4  is an exploded view of the ice skate of  FIG. 3 ; 
       FIG. 5  is a perspective view of the outer shell of  FIGS. 3 and 4 , wherein the outer shell is in a partial state of completion; 
       FIG. 6  is a perspective view of the outer shell of  FIGS. 3 and 4 ; 
       FIG. 7  is a perspective view of an outer shell in accordance with a second embodiment of the present invention; 
       FIG. 8  is a perspective view of an outer shell in accordance with a third embodiment of the present invention in a partial state of completion; 
       FIG. 9  is a perspective view of an outer shell in accordance with a fourth embodiment of the present invention in a partial state of completion; 
       FIG. 10  is a top perspective view of an outer shell in accordance with a fifth embodiment of the present invention in a partial state of completion; 
       FIG. 11  is a perspective view of an outer shell in accordance with a sixth embodiment of the present invention in a partial state of completion; 
       FIG. 12  is a bottom perspective view of the outer shell of  FIG. 11 ; 
       FIG. 13  shows a sheet of thermoformable material; and 
       FIG. 14  shows a machine suitable for thermoforming an outer shell in accordance with the present invention. 
   

   In the drawings, embodiments of the invention are illustrated by way of example. It is to be expressly understood that the description and drawings are only for the purposes of illustration and as an aid to understanding, and are not intended to be a definition of the limits of the invention. 
   DETAILED DESCRIPTION OF THE EMBODIMENTS 
   To facilitate the description, any reference numerals designating an element in one figure will designate the same element if used in any other figures. In describing the embodiments, specific terminology is resorted to for the sake of clarity but the invention is not intended to be limited to the specific terms so selected, and it is understood that each specific term comprises all equivalents. 
   Shown in  FIGS. 1 and 2  is a typical human foot F that includes toes T, a plantar surface PS, a medial side MS and a lateral side LS. In addition, the human foot includes a heel H, an Achilles tendon AT and an ankle A having a lateral malleolus LM and a medial malleolus MM, the lateral malleolus LM being at a lower position than the medial malleolus MM. 
   Shown in  FIGS. 3 and 4  is an ice skate  1  that comprises a sporting boot  10  suitable for enclosing a right human foot F. Although the sporting boot  10  shown in the figures is being used for an ice skate  1 , it is understood that the sporting boot  10  can be used for a variety of different sporting activities such as roller skating, hiking, trekking, football, basketball, soccer and cross-country skiing. A person skilled in the art will understand that variations, modifications and refinements are possible. For example, a roller chassis or a walking, hiking, trekking, cross-country skiing, football, basketball, or soccer outsole can replace the ice skate blade holder  16 . Moreover, for a shoe, it is understood that the medial and lateral sides around the ankle A may not extend as high up as the medial and lateral sides of a skate and there is not necessarily a need for a rear upper portion covering the Achilles tendon AT. 
   As best shown in  FIG. 4 , the ice skate  1  has outer shell  12 , a toe cap  14 , a tongue  24 , a rigid ankle support  26  (optional component), an inner lining  22 , a footbed  28 , an insole  29  (optional component), an outsole  31  (optional component), an ice skate blade holder  16  and a blade  18 . 
   The outer shell  12  will now be described in more detail below with respect to  FIGS. 4 to 6 . The outer shell  12  is made of a thermoformable material. As used herein, the expression “thermoformable material” refers to a material that is capable of softening when heated and of hardening again when cooled. Some non-limiting examples of different types of thermoformable material comprise ethylene vinyl acetate (EVA) foam, polyethylene foam, polystyrene foam, polypropylene foam and thermoformable materials sold under the trade-marks MEGABIX®, SURLYN®, SONTARA®, FORMO500®, BYLON®, MOSOCA® and NYLON® 66. 
   The outer shell  12  is thermoformed such that it comprises a heel portion  36  for receiving the heel H, an ankle portion  38  for receiving the ankle A and medial and lateral side portions  40 ,  42  for facing the medial and lateral sides MS, LS respectively. These components form a foot receiving cavity that conforms to the general shape of the foot F. The medial and lateral side portions  40 ,  42  extend forwardly from the heel portion  36 . The heel portion  36  is substantially cup shaped for following the contour of the heel H. The outer shell  12  has an inner surface  44  facing the foot F when in use, and an outer surface  46 . For a skate, the outer shell  12  may comprise a tendon guard portion  48  covering the Achilles tendon AT. 
   In addition, the ankle portion  38  comprises medial and lateral ankle sides  62 ,  64  respectively. The medial ankle side  62  has a medial cup-shaped depression  52  for receiving the medial malleolus MM and the lateral ankle side  64  has a lateral cup-shaped depression  54  for receiving the lateral malleolus LM. The lateral depression  54  is located slightly lower than the medial depression  52 , for conforming to the morphology of the foot F. 
   The medial and lateral side portions  40 ,  42  of the outer shell  12  comprise respective medial and lateral skirt portions  56 ,  58  that are integrally formed therewith and extend therefrom. As shown in  FIG. 6 , in order to complete the outer shell  12 , the medial and lateral skirt portions  56 ,  58  are folded inwardly to form a sole  60  having an upper surface  61  for facing a substantial portion of the plantar surface PS and a bottom surface  63  for receiving an outsole, a blade holder or a roller chassis. 
   As shown in  FIG. 4 , the boot  10  may comprises the insole  29  that has an upper surface for facing the plantar surface PS of the foot and a bottom surface on which the upper surface  61  of the sole  60  may be affixed. The boot  10  may also comprise the outsole  31  that has a bottom surface of which the blade holder  16  is mounted. It is however understood that the insole  29  and outsole  31  are optional components and may be eliminated. Alternatively, only the outsole  31  may be eliminated and the insole  29  may still be used in the construction of the boot  10  if the sole  60  is sufficiently rigid for receiving the blade holder  16  or a roller chassis. 
   As shown in  FIGS. 4 and 6 , the medial and lateral skirt portions  56 ,  58  may be affixed together via stitching  59 . It should however be understood that the skirt portions  56 ,  58  could be affixed together in a variety of different manners without departing from the spirit of the invention. For example, the medial and lateral skirt portions  56 ,  58  could be affixed together via thermal bonding, piping, zipper, adhesive or staples. Alternatively, the medial and lateral skirt portions  56 ,  58  could be affixed together via interlocking components that fit together in order to affix the two skirt portions together. For example, one of the skirt portions can include an arrangement of grooves, and the other skirt portion can include an arrangement of corresponding projections that are able to interlock with the grooves. As such, by interlocking the corresponding grooves and projections, the medial and lateral skirt portions can be affixed together. 
   It is to be understood that the sole  60  may not face the entire plantar surface PS of the foot F. As shown in  FIGS. 4 and 6 , the upper surface  61  of the sole  60  does not face the entire bottom surface of the toes T. Moreover, it is possible that the medial and lateral skirt portions  56 ,  58  do not project from the entire length of the medial and lateral side portions  40 ,  42 , and instead only begin to project from the medial and lateral side portions  40 ,  42  a few inches forward from the heel portion  36 . In such an embodiment, when the skirt portions  56 ,  58  are folded inwardly, the sole  60  will not include a portion for facing the entire heel H. In a further example, it is possible that when the medial and lateral skirt portions  56 ,  58  are folded inwardly, there remains a small gap between the two skirt portions  56 ,  58 , such that the upper surface  61  of the sole  60  does not face a portion of the foot F along a longitudinal line of the outer shell  12 . In that sense, the sole  60  may only face a portion of the plantar surface PS. In fact, as used herein, the terms “the sole faces the plantar surface of the foot” must be understood as referring to a sole having a surface that is sufficient for supporting the foot and/or for allowing mounting the blade holder on the bottom surface of this sole and/or to a sole having a surface that does not cover the entire plantar surface of the foot. 
   As shown in  FIGS. 5 and 6 , the medial and lateral skirt portions  56 ,  58  may have equal widths, such that when folded inwardly they are affixed together along a central longitudinal axis of the outer shell  12 . It should be understood, however, that the medial and lateral skirt portions can be of different widths, such that when they are folded inwardly, they are affixed together along a longitudinal line that is closer to either the medial side portion  40  or the lateral side portion  42 . 
   In yet another alternative embodiment, it is possible that the medial and lateral skirt portions  56  do not have a constant width along their entire length. For example, the width of the medial skirt portion  56  might be greater at a position closer to the heel portion  36 , and decrease in width as it extends away from the heel portion  36 , and the width of the lateral skirt portion  56  might be less at a position closer to the heel portion  36 , and increase in width as it extends away from the heel portion  36 . In such an embodiment, when the medial and lateral skirt portions  56  are folded inwardly, they may be affixed together along a substantially diagonal line. 
   Shown in  FIG. 7 , is an outer shell  65  in accordance with a second embodiment of the invention. Outer shell  65  is identical to the outer shell  12  to the exception that it comprises an integrated toe portion  67  for covering the toes T. Because the outer shell  65  comprises an integrated toe portion  67 , there is no need for a separate toe cap  14  that is secured to the outer shell  12  as illustrated in  FIG. 4 . An outer toe protector as the one disclosed in U.S. Pat. Nos. 6,505,422 and 6,647,576 can be used for covering the toe portion  67  of the outer shell  65 . It is understood that the sole of the outer shell  65  may further comprise a portion that faces bottom surface of the toes T. 
   Shown in  FIG. 8  is an outer shell  70  in accordance with a third embodiment of the present invention. The outer shell  70  has a heel portion  72  for receiving the heel H, medial and lateral side portions  74 ,  76  for facing the medial and lateral sides MS, LS and an ankle portion  78  with a medial cup-shaped depression  80  and a lateral cup-shaped depression  82 . The outer shell  70  has a skirt portion  84  that extends from, and is integrally formed with, the lateral side portion  76 . It should be understood that the skirt portion  84  may extend from the medial side portion  74  without departing from the spirit of the invention. 
   As shown in  FIG. 8 , the skirt portion  84  is of substantially the same shape as the gap formed between the medial and lateral side portions  74 ,  76 . As such, when the skirt portion  84  is folded inwardly, it spans the gap between the medial and lateral side portions  74 ,  76 , so as to form a sole facing the plantar surface PS of the foot F. The skirt portion  84  may be affixed to the bottom edge of the medial side portion  74  via a groove and projection arrangement, as shown in  FIG. 8 . It should however be understood, that the skirt portion  84  can be affixed to the other side of the outer shell  70  via stitching, thermal bonding, piping, zipper, adhesive and staples, among other possibilities known in the art. 
   Shown in  FIG. 9  is an outer shell  130  in accordance with a fourth embodiment of the present invention. Outer shell  130  is substantially the same as the outer shell  70  shown in  FIG. 8 , however, outer shell  130  has a foldable toe portion  132  that is integrally formed with one of the medial and lateral side portions, and is adapted for being folded inwardly in order to form a toe portion  132  that is integrally formed with the outer shell  130 . Because the outer shell  130  comprises an integrated toe portion  132 , there is no need for a separate toe cap  14  that is secured to the outer shell  12  as illustrated in  FIG. 4 . An outer toe protector as the one disclosed in U.S. Pat. Nos. 6,505,422 and 6,647,576 can be used for covering the toe portion  67  of the outer shell  65 . 
   Shown in  FIG. 10  is an outer shell  140  in accordance with a fifth embodiment of the present invention. Outer shell  140  is substantially the same as the outer shell  130  shown in  FIG. 9 , however, in addition to a foldable toe portion  142 , the outer shell  140  has a tongue portion  144  that is integrally formed with the toe portion  142 , and extends upwardly from the toe portion  142 , in order to form a tongue that is integrally formed with the outer shell  140 . 
     FIGS. 11 and 12  show another outer shell  150  that is thermoformed such that it comprises a sole integrally formed with one of the medial side portions (the medial side portion as shown in  FIGS. 10 and 11 ) and the medial and lateral side portions may be affixed together at the rear and along the sole. 
   In a non-limiting embodiment, the thermoformed shells  12 ,  65 ,  70 ,  130 ,  140 ,  150  are made of a single sheet made of thermoformable material. However, it should be understood that these thermoformed shells could also be made of multiple sections. For example, the thermoformed shells could be made from separate medial and lateral side portions that are affixed together. 
   In order to manufacture the outer shells  12 ,  65  a pre-cut sheet of thermoformable material may be inserted in the cavity a male-female mold. The male and female portions of the molds define the inner and outer surfaces of the outer shells  12 ,  65  respectively. Shown in  FIG. 13  is a sheet of thermoformable material  90  with a profile  92  of one of the outer shells depicted thereon. Machines and methods for die-cutting a shape  94  from the sheet of material  90  are known in the art, and as such will not be described in more detail herein. As shown in  FIG. 13 , the shape  94  may include a plurality of projections  95  in the region close to the heel portion. 
   The pre-cut sheet is aligned and temporarily secured to one of the mold portions using any suitable means to accurately position the pre-cut sheet within the mold and maintain same in position when the mold is closed. Once the mold is closed over the pre-cut sheet, the mold is heated up to the thermoforming temperature of the pre-cut sheet and male and female portions are pressed against the pre-cut sheet. 
   The pre-cut sheet of thermoformable material may be a composite sheet comprising layers of different thermoformable materials. It is understood that the pre-cut sheet can be thermoformed with a pre-cut sheet of the inner lining  22 , instead of securing the inner lining  22  to outer shell  12  after the thermoforming operation. Naturally, the material of the inner lining  22  must be selected from materials that may sustain the thermoforming temperature of the outer shell  12 . 
   In a preferred embodiment of the invention, heat and pressure are applied simultaneously for a period of 15 seconds to 2 minutes after which the mold is allowed to cool down so that the pre-cut sheet will set to the three-dimensional shape defined by the male and female portions of the mold. Preferably, heat and pressure are applied simultaneously for a period of 45 seconds to 1 minute. The applied heat is generally between 250° F. and 350° F., with the preferred temperature being approximately 325° F. The applied pressure is generally between 75 psi and 150 psi, with the preferred pressure being approximately 125 psi. It is understood that the amount of time, temperature and pressure may be different if a cooled mold is used. 
   Instead of using a male-female mold, an apparatus  96  as shown in  FIG. 14  may be used for thermoforming a pre-cut sheet of thermoformable material into the shape of the outer shells  12 ,  65 ,  70 ,  130 ,  140 ,  150 . For the purposes of the present application, the method will be described with respect to the outer shell  12 , shown in  FIGS. 4 to 6 . However, it should be appreciated that the method could also have been described with respect to the outer shells  65 ,  70 ,  130 ,  140 ,  150 . 
   The first step in manufacturing the outer shell  12  is to die-cut the shape of the outer shell  12  from the sheet of thermoformable material  90  in order to obtain the die cut shape  94 . 
   The sheet of material  90  may be a composite sheet having a layer of thermoformable foam. Some non-limiting examples of different types of thermoformable foam include ethylene vinyl acetate (EVA) foam, polyethylene foam and polypropylene foam. High density polyethylene (HDPE)  1300 ,  1100  and  0907  foams can also be used. The sheet may be made of thermoforming materials such as those sold under the trade-mark MEGABIX™ (a core of extruded SURLYN®, a backing of SONTARA® and a hot melt coating; thickness of 0.95 mm), FORMO500® (non woven polyester with a core of extruded polyolefinic, stiffening layers of synthetic latex on each side and an ethylene vinyl acetate hot melt adhesive on one side; thickness of 1.50 mm), BYLON® (a nylon multifilament with a backing of black saturated needle punched polyester nonwoven and a face coating of non-fray urethane) and MOSOCA® (NYLON® 66 with a core of SURLYN® and a PU coating). The composite sheet may also be made of a first sheet of polyethylene high density (HDPE) foam; a second sheet of thermoplastic; and a third composite sheet made of a first layer of cotton, a second layer of surlyn fibers, a third layer of a mesh of nylon fibers and a coating. These sheets being laminated together before or during the thermoforming process of the outer shell. 
   The sheet of material  90  may include two or three layers, wherein the layer that will form the outer surface  46  of the outer shell  12  is more rigid that the layer that will form the inner surface  44  of the outer shell  12 . A layer of thermoformable foam may be sandwiched between the inner and outer layers. 
   The second step in manufacturing the outer shell  12  is to thermoform the die cut shape  94  of thermoformable material into the three-dimensional shape of the outer shell  12  shown in  FIG. 6 . 
   Reverting to  FIG. 14 , the apparatus  96  comprises a supporting frame  98  having an outer shell traverse  100  and two pillars  102 A and  102 B. The two pillars  102 A and  102 B are joined together at mid-height by a ledge  104  that contains a control panel (not shown) with control buttons (not shown) for enabling an operator to control the apparatus  96 . In the specific embodiment shown, the ledge  104  surrounds a last  106  that is supported by a movable support  108 . The movable support  108  is a hydraulic or pneumatic piston cylinder  110  that is movable up and down in a vertical direction, as indicated by arrow A. It should be understood that lasts  106  of different shapes and sizes can be installed on apparatus  96  in order to manufacture outer shells  12  of different shapes and sizes. 
   The apparatus  96  further comprises a pair of clamps  112 A,  112 B that are mounted to the outer shell traverse  100  and positioned directly above last  106 . Clamps  112 A,  112 B are adapted to open and close, as indicated by arrows B in order to clamp around the last  106 . The clamps  112 A,  112 B comprise pressure pads  114  for receiving the shape  94  of thermoformable material. In addition, each of the clamps  112 A,  112 B comprises a bladder (not shown) having an inflated membrane and a fluid pressure delivery circuit (not shown) for causing the membrane to inflate, such that it is able to surround the last  106  during use. 
   In operation, the die-cut shape  94  of thermoformable material is placed on the last  106  and is accurately positioned and secured in place via the use of clips (not shown). Once the shape  94  of thermoformable material is securely in place, the operator activates the apparatus  96  which causes the piston-cylinder  110 , and therefore the last  106 , to raise up between the two open clamps  112 A,  112 B. When the last  106  reaches the pressure pads  114 , the piston-cylinder  110  reaches a set value and stops. It should be understood that in an alternative embodiment, the last  106  can remain stationary, and the clamps  112 A,  112 B can be connected to piston-cylinders for lowering the clamps  112 A,  112 B around the last  106 . 
   Once the last  106  is positioned between clamps  112 A,  112 B, the clamps  112 A,  112 B begin to close thereby causing the pressure pads  114  to apply an initial pressure to the shape  94  of thermoformable material positioned on the last  106 . When the clamps  112 A,  112 B are completely closed, the bladders are then inflated by air or liquid injection, which forces the flexible membranes of the bladders to encircle the shape  94  of thermoformable material around the last  106  and apply pressure thereto. Once the pressure within the bladders has reached a set value wherein the bladder membranes apply an even pressure to the thermoformable material, the pressure is maintained for a certain amount of time, and is then released. In a non-limiting embodiment, a pressure of between 30 psi and 120 psi is maintained around the last  106  for approximately 1 to 2 minutes. In addition to the pressure, heat is also applied to the thermoformable material. The applied heat is generally between 250° F. and 550° F., with the preferred temperature being approximately 350° F. Once heated, the thermoformable material becomes malleable and, as such, is able to acquire the three-dimensional shape applied to it by the last  106 . 
   In accordance with a first example, when the bladders  114  apply pressure and heat to the shape  94  of the thermoformable material, they are able to press the thermoformable material around the last, and are also able to cause the medial and lateral skirt portions  56 ,  58  to fold inwardly, such that they are pushed against the sole portion  116  of the last for forming the sole  60 . 
   In accordance with an alternative example, the thermoforming process is a two part-procedure, wherein in the first stage the clamps  112 A,  112 B as described above are able to thermoform the outer shell  12  into the partial state of completion, as shown in  FIG. 5 , wherein the medial and lateral skirt portions  56 ,  58  have not yet have been folded inwardly. In the second stage of the thermoforming procedure, other clamps (not shown) fold the two skirt portions  56 ,  58  inwardly, and apply the necessary pressure and heat thereto in order to thermoform the two skirt portions  56 ,  58  into the sole  60 . 
   In either case, once the outer shell  12  has been thermoformed into the final shape shown in  FIG. 6 , the last  106  is lowered by the piston cylinder  110  to its original position. The medial and lateral skirt portions  56 ,  58  may be affixed together. The step of affixing the medial and lateral skirt portions  56 ,  58  together can be performed while the outer shell  12  is on the last  106 . 
   Reverting to  FIG. 4 , the method of assembling the ice skate  1  will be described. The first step in assembling the skate boot  10  is to insert the rigid ankle support  26  into the outer shell  12  in order to provide more support and rigidity in that general area. It should be understood that the rigid ankle support  26  is an optional component, and that there is no need to include it if the outer shell  12  has enough rigidity. 
   The inner lining  22  is then glued or sewed to the inner surface  44  of outer shell  12 . The inner lining  22  is made of a layer of soft material such as a sheet of polyester laminated with a layer of foam, or a layer of fabric made from 100% nylon fibers. The inner lining  22  comprises an inner surface that is adapted to contact the skin of the foot F in use. 
   As shown in  FIG. 4 , two narrow bands  30  are secured to the upper portion of each of the side portions  40 ,  42 . The narrow bands  30  are made of fabric, textile or leather. In an alternative embodiment, a single continuous band that covers the upper portion of each of side portions  40 ,  42  and wraps around the rear of the ankle portion  38  can be used instead of two distinct bands  30 . 
   Apertures  32  are then punched through the narrow bands  30 , the outer shell  12  and the inner lining  22 . Once punched, the apertures  32  are reinforced by metallic rivets  34  or any suitable means as is well known in the art of footwear construction. 
   The tongue  24  and toe cap  14  are then affixed to the outer shell  12 . In a non-limiting embodiment, the toe cap  14  and the tongue  24  are pre-assembled prior to installation to outer shell  12 . The tongue  24  is affixed to the toe cap  14  and extends upwardly and rearwardly from the toe cap  14  for covering the forefoot of the foot F. The frontal edge of tongue  24  can be sewn directly to toe cap  14  or can be fixed in an alternative manner known in the art. The toe cap  14  can be secured to the outer shell  12  by sewing both sides of toe cap  14  to the side portions  40 ,  42 . 
   A last may be inserted into the inside cavity of the outer shell  12  in order to complete the construction of the boot. The last enables the outer shell  12  to maintain its shape when the skirt portions  56 ,  58  are folded and affixed together. As shown in  FIGS. 4 and 6 , the skirt portions  56 ,  58  may be affixed together via stitching  59  along a longitudinal central line. As indicated previously, the skirt portions  56 ,  58  may be affixed together in a variety of different manners without departing from the spirit of the invention, such as via adhesive, thermal bonding, piping, zipper staples and a projection/groove arrangement. Once the skirt portions  56 ,  58  are firmly attached together to form the sole  60  and the boot has acquired its final shape, a light sanding of the sole  60  may be performed to partially even the lower surface of the boot and provide a flat surface on which the blade holder  16  can be mounted via adhesive, rivets, screws, nails, or any other mounting means known in the art. An outsole such as the outsole  31  shown in  FIG. 4  may be affixed to the sole  60  and the blade holder  16  may then be mounted on the outsole  31  instead of being directly mounted on the sole  60 . As indicated previously, the outsole  31  is an optional component and may not be required if the rigidity of the sole  60  is sufficient. 
   Alternatively, an insole such as the insole  29  shown in  FIG. 4  may be positioned inside the skirt portions  56 ,  58 . As indicated previously, the insole  29  is an optional component. Once the assembly of the upper boot is completed, the upper boot is placed upside down into a lasting machine. Glue is first applied to the bottom surface of the insole  29  along its periphery. Skirt portions  56 ,  58  are then folded over the last onto the bottom surface of the insole  29 . Once folded, skirt portions  56 ,  58  form the sole  60  that is bonded to the insole  29  by the glue that was previously laid on the bottom surface of the insole  29 . The skirt portions  56 ,  58  are further nailed, stitched, or tacked all around the insole  29  to provide the necessary mechanical grip and allow the glue to properly set between the sole  60  and the insole  29 . Once the sole  60  is firmly attached to the insole  29  and the boot has acquired its final shape, a light sanding of the sole  60  may be performed to partially even the lower surface of the boot and provide a flat surface on which the outsole  31  or blade holder  16  can be mounted via adhesive, rivets, screws, nails, or any other mounting means known in the art. 
   A footbed  28  can be inserted into the outer shell  12  in order to sit upon the sole  60  formed by the two skirt portions  56 ,  58 . In this manner, the footbed  28  covers the seam where the two skirt portions  56 ,  58  meet, or in the case of outer shell  70 , the footbed  28  covers the seam where the skirt portion  84  meets one of the side portions. 
   The footbed  28  has an upper surface  120  for receiving the plantar surface PS of the foot F, and a padding wall  122  that projects upwardly from the upper surface for partially cupping the heel H and extending up to a medial line of the foot F. 
   It is understood that the boot  10  may comprise a roller chassis mounted to the bottom surface of the sole  60 , a roller chassis mounted to the outsole  31  covering the sole  60  or a walking, trekking, hiking, cross-country skiing, football, basketball or soccer outsole mounted to the sole  60 . 
   The above description of the embodiments should not be interpreted in a limiting manner since other variations, modifications and refinements are possible within the spirit and scope of the present invention. The scope of the invention is defined in the appended claims and their equivalents.