Patent ID: 8329083

Claim:
A method of making a lasted skate boot for enclosing a human foot when in use, the foot having a heel, an Achilles tendon, 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 male-female mold having male and female sections for defining a mold cavity therebetween, the male section having sides, a rear portion and a bottom portion for defining a three dimensional shape corresponding to the external three dimensional shape of the foot, the female section defining a recess for receiving the male section, the male section comprising a plurality of inner channels for admitting liquid plastic material in the mold cavity; (b) providing a pre-cut sheet made of cloth material laminated to a support made of non-woven fabric; (c) placing the sheet on the male section of the mold such that the non-woven fabric contacts the sides and rear portion of the male section of the mold; (d) closing the male and female sections of the mold; (e) injecting liquid plastic material in the inner channels at a temperature of between 160° C. and 200° C. and at a pressure of between 985 psi and 1015 psi such that the liquid plastic material spreads on the sheet, pushes the sheet against the recess of the female section of the mold, fills the mold cavity and fuses with the non-woven fabric, the non-woven fabric having a thickness selected for creating a barrier in order to prevent the plastic material from reaching the cloth material such that, after cooling, an outer shell comprising a first layer made of non-woven fabric fused with injected plastic material and a second layer made of cloth material is made and wherein the outer shell has a heel portion for surrounding the heel, an ankle portion for surrounding the ankle, and medial and lateral side portions for enclosing the medial and lateral sides of the foot respectively; (f) opening the male and female sections of the mold; and (g) removing the outer shell from the mold.