Patent Publication Number: US-2005126046-A1

Title: Skate boot

Description:
This application is a continuation application of U.S. patent application Ser. No. 10/202,868 filed on Jul. 26, 2002, the content of which is hereby incorporated in its entirety by reference. 
    
    
     FIELD OF THE INVENTION  
      The invention relates to a lasted skate boot for ice skates or in-line roller skates comprising an upper having a thermoformed outer shell and an inner lining mounted inside the outer shell.  
     BACKGROUND OF THE INVENTION  
      Typical skate boots are fabricated by assembling together previously die-cut pieces of textile material and shaping them over a last. Various pieces of textiles or fabrics are cut to specific patterns, which are then pre-assembled by stitching or gluing or both into a multi-layer construction. The rigidity and flexibility characteristics of the skate boot are defined by the various layers of materials being positioned and layered in specific regions of the pre-assembled component of the skate boot. The accumulation of pieces of material into layers and the mechanical properties of each piece of textile or fabric material define the overall dynamic behavior of the skate boot. Usually, the pre-assembled component further includes rigid components generally made of plastic to increase the rigidity of specific area of the skate boot. The pre-assembled boot generally consists of the back and sides of the skate boot and a toe cap and tongue assembly. The pre-assembled boot has the general configuration of the finished product but has not yet been shaped to the final form of the skate boot.  
      The pre-assembled component is positioned over a last and formed to obtain the shape of the desired finished product. A last is a three-dimensional shape of the inside cavity of a boot. The pre-assembled boot may be mounted upside down onto the last for ease of manipulation and assembly of the remaining components making up the skate boot.  
      An insole is placed on the top part of the upside down last and the pre-assembled boot is stretched over the last and over the insole in order for the pre-assembled boot to conform to the specific shape of the last. The stretched material is then glued and nailed or tacked to the insole to maintain the desired shape.  
      Once the upper part of the skate boot is completed, a rigid outsole is secured to the insole of the boot to complete the skate boot. An ice skate blade holder or an in-line roller chassis is finally mounted to the bottom of the boot to complete the skate.  
      This type of process is extensively used in the shoemaking industry. It generates a good product but has some disadvantages. For instance, the number of parts involved in the multi-layer construction can be staggering; a conventional ice skate for hockey may have up to eighty parts to be assembled and shaped over the last. As a consequence, the manufacturing process is lengthy and complex.  
      There is a need in the industry for a skate boot made of fewer components than the traditionally made skate boot and which is lighter than the traditionally made skate boot.  
      There is also a need for a skate boot, which provides flexibility and durability as well as optimal performance.  
     SUMMARY OF THE INVENTION  
      As embodied and broadly described herein, the invention seeks to provide a lasted skate boot comprising an upper for enclosing a human foot, the foot having a heel, an Achilles tendon having an upper part and a lower part that projects outwardly with relation to the upper part, the lower part merging with the heel, the foot also comprising an ankle with a medial malleolus and a lateral malleolus, a plantar surface, medial and lateral sides and toes; said skate boot comprising an outer shell made of a thermoformable synthetic pre-cut sheet that is thermoformed in a three dimensional shape such that said outer shell comprises: (a) a heel counter for receiving the heel of the foot; (b) medial and lateral quarters for receiving the medial and lateral sides of the foot respectively, said medial and lateral quarters extending forwardly from said heel counter and said ankle portion; and (c) an ankle portion for receiving the ankle, said ankle portion comprising an upper part shaped for following the upper part of the Achilles tendon and a lower part shaped for following the lower part of the Achilles tendon, said lower part projecting outwardly with relation to said upper part and merging with said heel counter.  
      As embodied and broadly described herein, the invention also seeks to provide a method of making a lasted skate boot comprising an upper for enclosing a human foot, the foot having a heel, an Achilles tendon having an upper part and a lower part that projects outwardly with relation to the upper part, the lower part merging with the heel, the foot also comprising 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 pre-cut sheet of thermoformable synthetic material; and (b) thermoforming the sheet of synthetic thermoformable material to form an outer shell comprising (i) a heel counter for receiving the heel of the foot; (ii) an ankle portion for receiving the ankle; and (iii) medial and lateral quarters for receiving the medial and lateral sides of the foot respectively, the medial and lateral quarters extending forwardly from the heel counter and the ankle portion; wherein the ankle portion is thermoformed such that it comprises an upper part and a lower part that projects outwardly with relation to the upper part, the lower part merging with the heel counter, the upper part following the upper part of the Achilles tendon and the lower part following the lower part of the Achilles tendon.  
      Advantageously, the ankle portion of the outer shell comprises medial and lateral sides facing the medial malleolus and the lateral malleolus, the medial and lateral sides having an inner surface and an outer surface, at least one of the medial and lateral sides comprising reinforcing elements, each of the reinforcing elements having a ridge formed on one of the inner or outer surfaces and a groove registering with the ridge, the groove being formed on one of the inner or outer surfaces. The ankle portion may also comprise a lateral depression for receiving the lateral malleolus and a medial depression for receiving the medial malleolus, the lateral depression being below the medial depression. The heel counter may also comprise reinforcing elements having a ridge and a groove registering with the ridge.  
      Other objects and features of the invention will become apparent by reference to the following description and the drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      A detailed description of the preferred embodiments of the present invention is provided herein below, by way of example only, with reference to the accompanying drawings, in which:  
       FIG. 1  is a perspective view illustrating a male-female mold for forming an outer shell according to the invention;  
       FIG. 2  is a perspective view illustrating a second male-female mold for forming the outer shell;  
       FIG. 3  is a perspective view illustrating a third male-female mold for forming the outer shell;  
       FIG. 4  is a perspective view illustrating a fourth male-female mold for forming the outer shell;  
       FIG. 5  is a rear elevational view of the outer shell shown in an unfolded position;  
       FIG. 6  is a cross-sectional view of the outer shell taken at line  6 - 6  of  FIG. 5 ;  
       FIG. 7  is a perspective view of the outer shell shown in a folded position;  
       FIG. 8  is a cross-sectional view of the outer shell taken at line  8 - 8  of  FIG. 7 ;  
       FIG. 9  is a rear elevational view of the outer shell shown in a folded position;  
       FIG. 10  is a perspective view of the outer shell shown in a folded position;  
       FIG. 11  is an exploded perspective view illustrating an ice skate incorporating the outer shell constructed in accordance with the invention;  
       FIG. 12  is a perspective view illustrating the upper constructed in accordance with the invention with a last and an insole;  
       FIG. 13  is a perspective view of an ice skate incorporating the skate boot constructed in accordance with the invention;  
       FIG. 14  is a perspective view of a human foot with the contour of the foot in stippled lines and the bones in plain lines; and  
       FIG. 15  is a front elevational view of the foot of  FIG. 14 . 
    
    
      In the drawings, preferred embodiments of the invention are illustrated by way of examples. It is to be expressly understood that the description and drawings are only for the purpose of illustration and are an aid for understanding. They are not intended to be a definition of the limits of the invention.  
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
      A skate boot manufactured in accordance with the present invention is illustrated generally by reference numeral  10  in  FIG. 13 .  
      Referring to  FIG. 11 , skate boot  10  comprises an upper  12  for enclosing a human foot. Upper  12  comprises an outer shell  14  and an inner lining  16  mounted inside outer shell  14 . Outer shell  14  illustrated in FIGS.  5  to  11  is for use in a skate boot for a right foot.  
      Outer shell  14  is molded of synthetic material. More particularly, outer shell  14  is made by thermo-pressured molding of a suitable thermoforming material initially in uniform thickness sheet form such as a pre-cut sheet having a desired contour, the sheet being 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).  
      Outer shell  14  can be made of a homogenous thermoforming synthetic material or can be made of layers of different thermoforming synthetic materials. For example, outer shell  14  may comprise two layers, the material of the outer layer of shell  14  being more rigid, or more resistant to abrasion, than the material of the inner layer of shell  14 . More specifically, outer layer of shell  14  can be made of a pre-cut sheet of MOSOCA® and inner layer of shell  14  can be made of a pre-cut sheet of polystyrene, both sheets being molded together. A pre-cut sheet of polyethylene or polyurethane may also be used for inner layer of shell  14 . The outer and inner layers may be stitched together before or after the molding operation if desired.  
      Inner lining  16  is made of a soft material and has an inner surface  38  and an outer surface  40 . Inner lining can be a fabric made of 100% nylon fibers. Inner surface  38  is intended to contact the skin of the foot in use. Outer surface  40  of inner lining  16  is secured to outer shell  14  by affixing means such as glue, stitches, nails, adhesives or tacks. It is understood that inner lining  16 , being made of a soft material, is less rigid than outer shell  14  that is molded of synthetic material being sufficiently rigid for supporting the foot.  
      Skate boot  10  also includes a footbed  20 , an insole  22  facing the plantar surface of the foot and an outsole  24  secured to insole  22 . Insole  22  is secured to outer shell  14  with a fastener such as stitches, glue, nails, adhesives or tacks. An ice skate blade holder  26  is secured to outsole  24 . It is understood that an in-line roller chassis may also be secured to outsole  24 . Insole  22  and outsole  24  have apertures for allowing access to a locking mechanism of the ice skate blade with ice skate blade holder  26  (not illustrated).  
      Skate boot  10  also comprises a tongue  28  and a toe box  30  facing the toes of the foot. Tongue  28  extends upwardly and rearwardly from toe box  30  and covers the upper front portions of the foot and the ankle. Preferably, toe box  30  and tongue  28  are pre-assembled prior to installing into outer shell  14 . The frontal edge of tongue  28  is sewn directly to toe box  30 , and then both sides of toe box  30  are secured to outer shell  14  with a fastener such as stitches, glue, nails, adhesives or tacks. Toe box  30  may also be glued, nailed or tacked to outer shell  14 .  
      Skate boot  10  also comprises a band  32  secured to an upper portion of outer shell  14 , band  32  being made of fabric, textile or leather and comprising apertures  34 . Eyelets  36  are punched into band  32 , outer shell  14  and inner lining  16  vis-a-vis apertures  34 . It is understood that the skate boot may comprise lacing loops and/or eyelets  36 . Skate boot  10  may comprise a rigid insert  37  that provides more rigidity in the ankle and heel portions of skate boot  10  and which is sandwiched between outer shell  14  and inner lining  16 . Skate boot  10  may also comprise a protective overlay recovering a portion of upper  12  or a rear cover  39  secured to a rear portion of outer shell  14  (see  FIG. 12 ). Protective overlay and rear cover  39  may be made of fabric, textile or leather.  
      A typical human foot is shown in  FIGS. 14 and 15 . The human foot has a heel H, an Achilles tendon AT having an upper part UP and a lower part LP that projects outwardly with relation to upper part UP, lower part LP merging with heel H.  
      The foot also comprises a plantar surface PS, a medial side MS, a lateral side LS, toes T, and an ankle A with a medial malleolus MM and a lateral malleolus LM, lateral malleolus LM being below than medial malleolus MM.  
      Referring to FIGS.  5  to  10 , outer shell  14  is formed of a heel counter  42  receiving heel H, an ankle portion  44  receiving ankle A and medial and lateral quarters  58 ,  60  receiving medial and lateral sides MS, LS of the foot respectively. Medial and lateral quarters  58 ,  60  extend forwardly from heel counter  42  and ankle portion  44 . Medial quarter  58  comprises inner and outer surfaces  58 IS and  58 OS and lateral quarter  60  comprises inner and outer surfaces  60 IS and  60 OS.  
      Ankle portion  44  comprises an upper part  46  and a lower part  48  that projects outwardly with relation to upper part  46 , lower part  48  merging with heel counter  42 . Ankle portion  44  is formed for following the rear profile of Achilles tendon AT. More specifically, upper part  46  of ankle portion  44  follows upper part UP of Achilles tendon AT and lower part  48  of ankle portion  44  follows lower part LP of Achilles tendon AT. Heel counter  42  is substantially cup shaped for following the contour of heel H.  
      Ankle portion  44  also comprises medial and lateral sides  50 ,  52 . Medial side  50  comprises inner and outer surfaces  50 IS,  50 OS and lateral side  52  comprises inner and outer surfaces  52 IS,  52 OS. Medial and lateral sides  50 ,  52  also comprise medial and lateral depressions  54 ,  56  respectively. Medial depression  54  receives medial malleolus MM and lateral depression  56  receives lateral malleolus LM, lateral depression  56  is located slightly below medial depression  54  for conforming to the morphology of the foot.  
      As shown more particularly in  FIGS. 8 and 9 , medial and lateral sides  50 ,  52  of ankle portion  44  and medial and lateral quarters  58 ,  60  are adapted to conform to the general morphology of the foot. In fact, inner surfaces  50 IS,  52 IS of ankle portion  44  an inner surfaces  58 IS and  60 IS of medial and lateral quarters  58 ,  60  follow the sides of heel H and ankle A, and medial and lateral sides MS, LS of the foot while accounting for statistical variations of the relative position of medial malleolus MM and the lateral malleolus LM.  
      Medial and lateral quarters  58 ,  60  comprise quarter reinforcing elements  62  and medial and lateral sides  50 ,  52  of ankle portion  44  comprise ankle reinforcing elements  68 . Referring to  FIG. 6 , quarter reinforcing element  62  comprises a ridge  64  formed on outer surface  60 OS of lateral quarter  60  and a groove  66  registering with ridge  64 , groove being formed on inner surface  60 IS of lateral quarter  60 . Referring to  FIG. 8 , ankle reinforcing element  68  comprises a ridge  70  formed on outer surface  52 OS of lateral side  52  of ankle portion  44  and a groove  72  registering with ridge  70 , groove  66  being formed on inner surface  52 IS of lateral side  52  of ankle portion.  
      Outer shell  14  illustrated in FIGS.  5  to  13  comprises quarter reinforcing elements  62  that continue with ankle reinforcing elements  68  for forming continuous elongated reinforcing elements on outer shell  14 , these continuous elongated reinforcing elements being also formed on the rear portion of ankle portion  44 . Outer shell  14  also comprises heel reinforcing elements  74  that are formed on heel counter  42 , heel reinforcing elements  74  being continuous with quarter reinforcing elements  62  for forming continuous elongated reinforcing elements on the sides of outer shell  14 .  
      As reinforcing elements  62  and  68 , heel reinforcing elements  74  comprise a ridge formed on the outer surface of heel counter  42  and a groove registering with the ridge, the groove being formed on the interior surface of heel counter  42 .  
      It is understood that quarter and ankle reinforcing elements  62 ,  68  and quarter and heel reinforcing elements  62 ,  74  may be separate or formed together and their design may be selected for obtaining the desired rigidity, stability and flexibility of skate boot  10 . Reinforcing elements  62 ,  68  and  74  may or may not have the same width and height (or depth) but their pattern is identical for the following aspect: a ridge (or projection) formed on the outer or inner surface of outer shell  14  corresponds to a groove (or depression) that registers with the ridge, the groove being formed on the outer or inner surface of outer shell  14  (naturally, a ridge formed on the outer surface of outer shell  14  corresponds to a registered groove formed on the inner surface of outer shell  14 ).  
      It is also understood that the ridge of reinforcing elements  62 ,  68  and  74  may be formed on the interior surfaces of medial and lateral quarters  58 ,  60 , ankle portion  44  and heel counter  42  respectively while the registered groove of reinforcing elements  62 ,  68  and  74  may be formed on the outer surfaces.  
      Reinforcing elements  62 ,  68  and  74  also protect the foot from impacts due to a puck, a ball or a stick since these elements tend to dissipate the impact energy.  
      In order to manufacture outer shell  14 , a pre-cut sheet of thermoformable synthetic material is inserted into the cavity of one of the male-female mold shown in FIGS.  1  to  4 .  
      The male and female portions of the molds define the inner and outer surfaces of outer shell  14  respectively. For instance, the male portion of the molds defines inner surfaces  50 IS,  52 IS of ankle portion  44  and inner surfaces  58 IS,  60 IS of medial and lateral quarters  58 ,  60  whereas the female portion of the molds defines outer surfaces  50 OS,  52 OS of ankle portion  44  an outer surfaces  58 OS,  60 OS of medial and lateral quarters  58 ,  60 .  
      As seen in  FIGS. 2 and 4 , grooves and ridges are provided in the female and male portions of the molds while only grooves are provided in the female portion of the molds illustrated in  FIGS. 1 and 3 . Due to the presence of ridges in the male portions, the deformation of the synthetic material is more important in the region of the reinforcing elements when using the molds illustrated in  FIGS. 2 and 4 . In general, the deformation of the synthetic material is less important when using the molds illustrated in  FIGS. 1 and 2  than the molds illustrated in  FIGS. 3 and 4  since the three-dimensional shape of the latter molds is more prominent than the one of the molds illustrated in  FIGS. 1 and 2 .  
      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.  
      As indicated above, the pre-cut sheet of outer shell  14  may be formed of layers of different thermoforming synthetic materials. It is understood that the pre-cut sheet of outer shell  14  can be molded with the pre-cut sheet of inner lining  16 , instead of securing inner lining  16  to outer shell  14  after the molding operation of outer shell  14 . Naturally, the material of inner lining  16  must be selected from materials that may sustain the thermoforming temperature of outer shell  14 .  
      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.  
      By utilizing different grades of thermoformable synthetic material, different thermoformable synthetic materials or the same material with different density, the designers are able to vary the mechanical properties of outer shell  14 . Similarly, by utilizing different patterns for reinforcing elements  62 ,  68  and  74  (i.e. location, number, width, height (or depth) and orientation), the designers are able to vary the mechanical properties of outer shell  14 . In that sense, using different thermoformable synthetic materials and patterns of reinforcing elements  62 ,  68  and  74 , the designers are thus able to vary the flexibility, rigidity and stability of skate boot  10 .  
      Referring now to  FIG. 12 , outer shell  14  also comprises a lower skirt portion  76  that is foldable to overlap a portion of insole  22 . A last  78  is inserted into the inside cavity of upper  12 . Last  78  enables upper  12  to maintain its shape when skirt portion  76  is folded to give upper  12  its final shape. Last  78  is inserted into upper  12  and insole  22  is positioned underneath last  78  inside skirt portion  76 .  
      Once the assembly is completed, upper  12  is placed upside down into a lasting machine. Glue is first applied to the bottom surface of insole  22  along its periphery. Skirt portion  76  is then folded over last  78  onto the bottom surface of insole  22 , using the lasting machine wipers. Once folded, skirt portion  76  is bonded to insole  22  by the glue that was previously laid on the bottom surface of insole  22 . Skirt portion  76  is further nailed, stitched, or tacked all around insole  22  to provide the necessary mechanical grip to remove the pulling forces and allow the glue to properly set between skirt portion  76  and insole  22 . Once skirt portion  76  is firmly attached to insole  22  and upper  12  has acquired its final shape, a light sanding of the folded skirt portion  76  is performed to partially even the lower surface of upper  12  and provide a flat surface on which outsole  24  can be glued or nailed.  
      The above description of preferred 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.