Skate

Abstract

A skate having a skate boot with a non-lasted boot shell, the shell having a first non-lasted three-dimensional sub-shell and a second non-lasted three-dimensional sub-shell, the second sub-shell being interior to and adjoining the first sub-shell, the first sub-shell comprising a first material having a first density and the second sub-shell comprising a second material having a second density, the second density being less than the first density, the shell being shaped so as to have a heel portion, an ankle portion, a lateral portion, a medial portion, and a sole portion; and a ground-engaging assembly disposed on an underside of the skate. Additional sub-shells are possible. Methods of manufacturing the skate boot shell, including molding and build-up, are also disclosed.

Claims

1. A skate boot configured to receive a foot of a wearer, the skate boot comprising: a shell including a first sub-shell, the first sub-shell including a first material having a first density, the first sub-shell having a monolithic three-dimensional shape defining a first heel portion, a first ankle portion extending from the first heel portion and configured to overlay an ankle of the wearer, a first lateral portion, a first medial portion, and a first sole portion extending between and connected to the first lateral, medial and heel portions; and the shell also including a second sub-shell, the second sub-shell having a three-dimensional shape formed separately from the first sub-shell, the second sub-shell being interior to the first sub-shell, the second sub-shell including a second material having a second density less than the first density, the three-dimensional shape of the second sub-shell defining a second heel portion, a second ankle portion extending from the second heel portion and configured to overlay the ankle of the wearer, a second lateral portion and a second medial portion, the second sub-shell being bonded to the first sub-shell by having the first material directly fused to the second material.

2. A skate boot as recited in claim 1, wherein the first material has a first stiffness and the second material has a second stiffness, the second stiffness being less than the first stiffness.

3. A skate boot as a recited in claim 1, wherein the second material is a foam.

4. A skate boot as recited in claim 1, wherein the first sub-shell has a contoured inner surface and the second sub-shell has a contoured outer surface complimentary with the inner surface of the first sub-shell.

5. A skate boot as recited in claim 1, wherein the first sub-shell is ornamented.

6. A skate boot as recited in claim 1, wherein the first sub-shell has an inner surface and the second sub-shell has an outer surface, the inner surface covering an entirety of the outer surface.

7. A skate boot as recited in claim 1, wherein at least one of the first sub-shell and the second sub-shell is of variable thickness.

8. A skate boot as recited in claim 1, further comprising at least one reinforcing element associated with the skate to reinforce at least part of the skate.

9. A skate boot as recited in claim 1, wherein the first material is a plastic and the second material is a thermoplastic foam.

10. A skate boot as recited in claim 1, further comprising: a toe cap connected to the shell for protecting toes of a wearer of the skate; a tongue connected to the toe cap; a facing connected to the lateral and medial portions of the shell; a liner disposed within the shell.

11. A skate boot as recited in claim 10, wherein the facing is more flexible than the skate shell.

12. A skate boot as a recited in claim 1, wherein the second material is a EPP foam.

13. A skate boot as recited in claim 1, wherein the first material is a plastic or a composite material.

14. A method of manufacturing a skate boot shell of a skate boot for receiving a foot of a wearer, the method comprising: (i) forming a first three-dimensional sub-shell without using a last including forming a monolithic three-dimensional shape including a first heel portion, a first ankle portion extending from the first heel portion and configured to overlay an ankle of the wearer, a first lateral portion, a first medial portion, and a first sole portion extending between and connected to the first lateral, medial and heel portions, the first sub-shell having an inner surface; (ii) forming a second three-dimensional sub-shell without using a last, separately from the first sub-shell, including forming a second heel portion, a second ankle portion extending from the second heel portion and configured to overlay an ankle of the wearer, a second lateral portion, and a second medial portion, the second sub-shell having an outer surface registerable with the inner surface of the first sub-shell; (iii) placing the second sub-shell within an interior of the first sub-shell such that the outer surface of the second sub-shell registers with the inner surface of the first sub-shell; and (iv) securing the second sub-shell to the first sub-shell by directly fusing materials of the first and second sub-shells to each other.

15. A method as recited in claim 14, wherein the second sub-shell is injection molded.

16. A method as recited in claim 14, wherein the second material is EPP foam.

17. A method as recited in claim 14, wherein the first sub-shell is formed of a first material having a first density and the second sub-shell is formed of a second material having a second density, the second density being less than the first density.

18. A method as recited in claim 17, wherein the second material is a foam.

19. A method as recited in claim 18, wherein the first material is a plastic or a composite material.

20. A skate boot configured to receive a foot of a wearer, the skate boot comprising: a shell including a first sub-shell, the first sub-shell including a first material having a first density, the first sub-shell having a monolithic three-dimensional shape defining a first heel portion, a first ankle portion extending from the first heel portion and configured to overlay an ankle of the wearer, a first lateral portion, a first medial portion, and a first sole portion extending between and connected to the first lateral, medial and heel portions; and the shell also including a second sub-shell, the second sub-shell having a three-dimensional shape formed separately from the first sub-shell, the second sub-shell being interior to the first sub-shell with the first sub-shell having an inner surface covering an entirety of an outer surface of the second sub-shell, the second sub-shell including a second material having a second density less than the first density, the three-dimensional shape of the second sub-shell defining a second heel portion, a second ankle portion extending from the second heel portion and configured to overlay the ankle of the wearer, a second lateral portion and a second medial portion, the second sub-shell being bonded to the first sub-shell by a chemical fastener.

21. A skate boot as recited in claim 20, wherein the first material has a first stiffness and the second material has a second stiffness, the second stiffness being less than the first stiffness.

22. A skate boot as a recited in claim 20, wherein the second material is a foam.

23. A skate boot as recited in claim 20, wherein the first sub-shell has a contoured inner surface and the second sub-shell has a contoured outer surface complimentary with the inner surface of the first sub-shell.

24. A skate boot as recited in claim 20, wherein at least one of the first sub-shell and the second sub-shell is of variable thickness.

25. A skate boot as recited in claim 20, further comprising at least one reinforcing element associated with the skate to reinforce at least part of the skate.

26. A skate boot as recited in claim 20, wherein the first material is a plastic and the second material is a thermoplastic foam.

27. A skate boot as a recited in claim 20, wherein the second material is a EPP foam.

28. A skate boot as recited in claim 20, wherein the first material is a plastic or a composite material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For a better understanding of the present invention, as well as other aspects and further features thereof, reference is made to the following description which is to be used in conjunction with the accompanying drawings, where:

(2) FIG. 1 is a right front perspective view of a right skate having a first embodiment of the present invention;

(3) FIG. 2 is a right front perspective exploded view of the skate of FIG. 1;

(4) FIG. 3 is a right front perspective exploded view of the skate boot shell of the embodiment of the present invention incorporated into the skate of FIG. 1;

(5) FIG. 4 is a right front perspective view of the shell of the embodiment of the present invention incorporated into the skate of FIG. 1;

(6) FIG. 5 is a cross-sectional view of the outer sub-shell of the shell of the embodiment of the present invention incorporated into the skate of FIG. 1 taken along the line 5-5 of FIG. 3 and a right side elevational view of the inner sub-shell of the shell of the embodiment of the present invention incorporated into the skate of FIG. 1, when the two are assembled into a shell;

(7) FIG. 6 is a front elevation view of the outer sub-shell of the shell of the embodiment of the present invention incorporated into the skate of FIG. 1;

(8) FIG. 7 is a front elevation view of the shell of the embodiment of the present invention incorporated into the skate of FIG. 1;

(9) FIG. 8 is a top plan view of the outer sub-shell shown in FIG. 6;

(10) FIG. 9 is a top plan view of the shell shown in FIG. 7;

(11) FIG. 10 is a right front perspective view of a shell being a second embodiment of the present invention;

(12) FIG. 11 is a cross-sectional exploded view of the shell of FIG. 10 taken along the line 11-11 in FIG. 10; and

(13) FIG. 12 is a cross-sectional view of the shell of FIG. 10 taken along the line 11-11 in FIG. 10 when the shell has been assembled.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(14) An embodiment of the invention, being an ice skate 100 (for the right foot), is shown in FIG. 1. (Other embodiments of the invention include, but are not limited to, left ice skates, and inline roller skates.) Skate 100 has a skate boot 102 and a skate blade assembly 104. Skate has a skate boot shell 106, which is shown with a cut-away to reveal the sub-shells 120, 122 thereof described in further detail below. Skate boot 102 also has a skate boot toe cap 108, a skate boot tongue 110, a skate boot liner 118, and skate boot facing 112. Skate blade assembly 104 has a skate blade 114 and a skate blade holder 116. The skate boot toe cap 108, skate boot tongue 110, skate boot liner 118, and skate blade assembly 104 and their various components are conventional, and their manufacture, assembly, and use are within the knowledge of one skilled in the art of skate design, and will not be described further herein.

(15) FIG. 2 shows an exploded view of the ice skate 100 of FIG. 1, to allow for a better understanding of the various components thereof. Referring particularly to skate boot shell 106, it will be seen that in this embodiment, skate boot shell 106 has two sub-shells, an outer sub-shell 120 and an inner sub-shell 122. Skate 100 also has an associated reinforcing element 124 (being a conventional molded plastic ankle protector), a conventional lace bite protector 128, and a conventional mid-sole 123 (for securing the skate blade assembly 104 to the skate boot 102). Skate liner 118 also has conventional foam ankle padding 126.

(16) FIG. 3 shows an exploded view of the boot shell 106, showing the two sub-shells, outer sub-shell 120 and inner sub-shell 122. Each of outer sub-shell 120 and inner sub-shell 122 have a three-dimensional shape having a heel portion 120h and 122h (respectively), an ankle portion 120a and 122a (respectively), a lateral portion 120l and 122l (respectively), a medial portion 120m and 122m (respectively), and a sole portion 120s and 122s (respectively). Thus, referring to FIG. 4, the boot shell 106 itself, when assembled, has a three-dimensional shape having a heel portion 106h, an ankle portion 106a, a lateral portion 106l, a medial portion 106m, and a sole portion 106s.

(17) Outer sub-shell 120 is a vacuum-molded three-dimensional structure made of SURLYN®, made via a conventional vacuum molding technique. Outer sub-shell 120 is three-dimensionally shaped (when molded) so as to (when incorporated into boot shell 106 and when boot shell 106 is incorporated into skate 100) conform well to the foot of a wearer during use of the skate 100. Various views of the three-dimensional shape of outer sub-shell 120 can be seen in FIGS. 6 and 8.

(18) Referring to FIG. 5, which shows outer sub-shell 120 in cross-section, the thickness 120t of the outer sub-shell 120 can vary from between about 0.1 mm to about 5 mm. Preferably, the thickness 120t is between about 0.5 mm to about 5 mm, and more preferably between about 1 mm to about 3 mm. The density of outer sub-shell 120 can vary between about 0.75 g/cm.sup.3 and about 1.1 g/cm.sup.3. Preferably, the density is between about 0.85 g/cm.sup.3 and about 1.0 g/cm.sup.3. More preferably, the density is between about 0.9 g/cm.sup.3 to about 1.0 g/cm.sup.3. Most preferably, the density is between about 0.95 g/cm.sup.3 to about 0.98 g/cm.sup.3.

(19) Inner sub-shell 122 is an injection molded three-dimensional structure made of EPP, made via a conventional injection technique (with resin being injected into and then being allowed to expand in the mold). Inner sub-shell 122 is shaped so as to (when incorporated into boot shell 106 and when boot shell 106 is incorporated into skate 100) conform well to the foot of a wearer during use of the skate 100. Various views of the three-dimensional shape of the inner sub-shell 122 can be seen in FIGS. 7 and 9, showing the assembled boot shell 106.

(20) Although not shown, the thickness of the inner sub-shell 122 is generally constant in this embodiment (although it may vary in others). Preferably, the thickness of the inner sub-shell 122 is between about 1 mm to about 15 mm. More preferably, the thickness of the inner sub-shell 122 is between about 2 mm to about 10 mm. Still more preferably, the thickness of the inner sub-shell 122 is between about 4 mm to about 8 mm. Yet more preferably, the thickness of the inner sub-shell 122 is between about 5 mm to about 6 mm. Most preferably, the thickness of the inner sub-shell 122 is about 5.4 mm. The density of inner sub-shell 122 can vary between about 0.016 g/cm.sup.3 (1 lb/ft.sup.3) and about 0.32 g/cm.sup.3 (20 lb/ft.sup.3). Preferably, the density is between about 0.032 g/cm.sup.3 (2 lb/ft.sup.3) and about 0.16 g/cm.sup.3 (10 lb/ft.sup.3). More preferably, the density is between about 0.80 g/cm.sup.3 (5 lb/ft.sup.3) and about 0.96 g/cm.sup.3 (6 lb/ft.sup.3). Most preferably, the density is about 0.83 g/cm.sup.3 (5.2 lb/ft.sup.3).

(21) Referring to FIG. 3, inner sub-shell 122 has an outer surface 122o having a contoured three dimensional shape. Outer sub-shell 120 has an inner surface 120i having a contoured three dimensional shape. The contoured shapes of the outer surface 122o and the inner surface 120i are complimentary such that when the inner sub-shell 122 is placed within the outer sub-shell 120, the surfaces 122o, 120i register well in forming the boot shell 106. Further, as can be seen in the figures, both the outer sub-shell 120 and the inner sub-shell 122 are shaped so as to have ridges 120r, 122r (respectively) on their outer surfaces 120o, 122o (respectively) to provide reinforcement. The ridge 122r on the outer surface 122o of the inner sub-shell 122 is complimentary with a ridge-receiving shape 125 on the inner surface 120i of the outer-shell 120, such that they register when the boot shell is formed; and, together with the ridge 120r of the outer sub-shell, form boot shell reinforcement ridge 106r.

(22) Referring to FIGS. 4, 7 and 9, when the inner sub-shell 122 is placed within the outer sub-shell 120 to form boot shell 106, in this embodiment, the entirety of the outer surface 122o of the inner sub-shell 122 is covered by the inner surface 120i of the outer sub-shell 120.

(23) Boot shell 106 is assembled by first coating the outer surface 122o of inner sub-shell 122 with a conventional adhesive and then placing inner sub-shell 122 within outer sub-shell 120.

(24) Once boot shell 106 is assembled, skate 100 is assembled in a conventional manner with the exception of facing 112 (which is made of EVA). In skate 100, (in contrast with conventional facings) facing 112 is secured to boot shell 106 via stitching 113 only along the bottom portion of the facing. Thus, the majority of the body 117 of facing 112 (including the eyelets 115) neither underlies nor overlies the boot shell 106 and it is not secured to the boot shell. This leaves the majority of the body 117 of facing 112 free to stretch, move, contract, etc. during use of the skate 100, adding to the skate's flexibility.

(25) Referring now to FIGS. 10 and 11, there is shown a second embodiment of the present invention, being skate boot shell 206 (for a right skate—the full skate has been omitted for ease of illustration since it is otherwise conventional), which is similar to the skate boot shell 206 with some exceptions. In this embodiment each of the outer sub-shell 220 and inner sub-shell 222 are formed as two halves. Thus, outer sub-shell 220 has a right half 236 and a left half 234. Similarly inner sub-shell 222 has a right half 232 and a left half 230.

(26) Outer sub-shell 220 has a heel portion 220h, a part of which is located on right half 236 and a part of which is located on left half 234. Outer sub-shell 220 also has an ankle portion 220a, a part of which is located on right half 236 and a part of which is located on left half 234. Outer sub-shell 220 also has a medial portion 220m located on the left half 234 and a lateral portion 220l located on the right half 236. Outer sub-shell 220 also has a sole portion 220s, a part of which is located on right half 236 and a part of which is located on left half 234.

(27) Inner sub-shell 222 has a heel portion 222h, a part of which is located on right half 232 and a part of which is located on left half 230. Inner sub-shell 222 also has an ankle portion 222a, a part of which is located on right half 232 and a part of which is located on left half 230. Inner sub-shell 222 also has a medial portion 222m located on the left half 230 and a lateral portion 222l located on the right half 232. Inner sub-shell 222 also has a sole portion 222s, a part of which is located on right half 232 and a part of which is located on left half 230.

(28) Inner sub-shell 222 has an outer surface 222o (split across its left half 230 and its right half 232). Outer sub-shell 220 has an inner surface 220i (split across its left half 234 and its right half 236). The outer surface 222o of the inner sub-shell 220 is complimentary with the inner surface 220i of the outer sub-shell 220 such that the two register well when the sub-shell halves 230, 232 and 234, 236 are formed into a whole sub-shell 222 and 220 (respectively) and the resultant sub-shells 220, 220 are assembled into boot shell 206.

(29) Outer sub-shell halves 234, 236 are each a vacuum-molded three-dimensional structure made of SURLYN®, made via a conventional vacuum molding technique. Once manufactured, outer sub-shell halves 234, 236 are secured together at surfaces 243 via any suitable conventional technique (e.g. bonding, fastening, stitching etc.) to form joint 244 (in FIG. 12) and thus outer sub-shell 220 (which is otherwise similar to outer sub-shell 120 of the first embodiment, skate 100). Once manufactured, inner sub-shell halves 230, 232 are secured together at surfaces 242 via any suitable conventional technique (e.g. bonding, fastening, stitching, etc.) to form joint 245 (in FIG. 12) and thus inner sub-shell 222 (which is otherwise similar to inner sub-shell 220 of the first embodiment, skate 100).

(30) Boot shell 206 is then assembled as is described above in relation to the first embodiment, skate 100.

(31) Modifications and improvements to the above-described embodiments of the present invention may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. The scope of the present invention is therefore intended to be limited solely by the scope of the appended claims.