U.S. patent application number 11/737606 was filed with the patent office on 2007-08-16 for apparatus, system, and method for unibody skate boot.
This patent application is currently assigned to Kor Hockey, Ltd. Invention is credited to Antonin A. Meibock.
Application Number | 20070186448 11/737606 |
Document ID | / |
Family ID | 32853337 |
Filed Date | 2007-08-16 |
United States Patent
Application |
20070186448 |
Kind Code |
A1 |
Meibock; Antonin A. |
August 16, 2007 |
APPARATUS, SYSTEM, AND METHOD FOR UNIBODY SKATE BOOT
Abstract
Skate boot apparatuses, a skate, and a method are provided. A
base including an upper face configured to receive a wearer's foot
and a lower face configured to structurally support a skate
mechanism is provided. An integral upper support is provided, the
integral upper support extending upwardly from the base to a point
above an ankle of the wearer, the integral support having a varying
rigidity decreasing from a high rigidity near the base to a low
rigidity near the point above the ankle of the wearer.
Inventors: |
Meibock; Antonin A.;
(Alberta, CA) |
Correspondence
Address: |
BLACK LOWE & GRAHAM, PLLC
701 FIFTH AVENUE
SUITE 4800
SEATTLE
WA
98104
US
|
Assignee: |
Kor Hockey, Ltd
Calgary
CA
|
Family ID: |
32853337 |
Appl. No.: |
11/737606 |
Filed: |
April 19, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10729879 |
Dec 5, 2003 |
7219900 |
|
|
11737606 |
Apr 19, 2007 |
|
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60443449 |
Jan 28, 2003 |
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Current U.S.
Class: |
36/89 ;
36/115 |
Current CPC
Class: |
A43B 5/1625 20130101;
A43B 5/049 20130101; A43B 23/07 20130101; A43B 23/087 20130101;
A43B 5/04 20130101; A43B 5/16 20130101; A43B 7/20 20130101; A43C
11/1493 20130101; A43B 5/0427 20130101; A43B 23/086 20130101; A43B
1/0072 20130101 |
Class at
Publication: |
036/089 ;
036/115 |
International
Class: |
A43B 7/20 20060101
A43B007/20; A43B 5/16 20060101 A43B005/16 |
Claims
1. A skate boot apparatus comprising: a base including an upper
face and a lower face configured to interface with a skate
mechanism; an upper structural support integrated with the base and
extending upwardly from the base to a point above a wearer's ankle,
the upper support having an area of a first rigidity above and
adjacent the base and an area of a second rigidity lower than the
first rigidity in a majority of the portion of the upper support
above the area of first rigidity, wherein the upper structural
support includes a plurality of layers of fiber composite material
joined together with a resin; an outer shell secured outside at
least a portion of said upper support; and an inner liner secured
inside said upper support.
2. The apparatus of claim 1, wherein a varying rigidity of the
upper structural support ranging from the first rigidity to the
second rigidity is created by using a varying number of the layers,
wherein sections of the upper structural support having a high
rigidity include a first number of the layers and sections of the
upper structural support having the low rigidity include a second
number of the layers where the first number is greater than the
second number.
3. The apparatus of claim 1, wherein the varying rigidity of the
upper structural support is created by using layers including
layers of varying compositions, each of the varying compositions
having varying rigidities.
4. The apparatus of claim 1, wherein the layers include at least
one hingably coupled layer, the hingably coupled layer being
partially joined with the boot toward the base and being partially
unjoined with the boot away from the base such that the hingably
coupled layer is movable at an upper end configured to receive the
wearer's ankle.
5. The apparatus of claim 1, wherein the layers include at least
one of a long-woven fiber material.
6. The apparatus of claim 5, wherein the long-woven fiber material
includes one of a fiberglass, a carbon-fiber, and an aramid
fiber.
7. The apparatus of claim 1, further comprising an impact-resistant
material layered over the outer layer of composite material.
8. The apparatus of claim 7, wherein the impact-resistant material
includes a polyurethane plastic.
9. The apparatus of claim 1, wherein the varying rigidity of the
upper structural support is created by molding using a varying
thickness wherein sections of the upper structural support having a
high rigidity include a first thickness and sections of the upper
structural support having the low rigidity include a second
thickness where the first thickness is greater than the second
thickness.
10. The apparatus of claim 1, wherein the varying rigidity of the
upper structural support is created by molding using a material of
varying rigidity wherein sections of the upper structural support
having a high rigidity include a first material and sections of the
upper structural support having the low rigidity include a second
material where the first material is more rigid than the second
material.
11. The apparatus of claim 10, wherein at least one of the first
material and the second material includes a short fiber
material.
12. The apparatus of claim 11, wherein a rigidity of the short
fiber material is increasable by increasing a fiber concentration
in the short fiber material.
13. The skate boot of claim 1, wherein said lower face includes at
least two generally planar engagement regions and an arch-shaped
region between said engagement regions.
14. A method for forming a skate boot, the method comprising:
forming a base including: forming the base with an upper face
configured to support a wearer's foot and a lower face configured
to structurally support a skate mechanism; and forming a boot
including: forming an upper support around the base with a
plurality of layers of composite material extending upward
integrally from the base; contouring the upper support of the boot
to surround a wearer's ankle, a wearer's heel, and at least a
portion of a wearer's foot, the upper support having a first
rigidity near the base and at least a second rigidity in a majority
of the portion of the boot above the area of first rigidity, the
second rigidity being lower than the first rigidity; and shaping a
lower surface of the boot beneath the lower face of the base to
receive the skate mechanism.
15. The method of claim 14, further comprising shaping the lower
surface to integrate a plurality of inserts in the boot, the
inserts being configured to releasably engage a plurality of skate
attachment devices to couple the skate mechanism to the boot.
16. The method of claim 15, further comprising molding the base to
at least partially encompass the inserts.
17. The method of claim 14, wherein the base includes a shell and a
core having a lower density than the shell, the method further
comprising shaping the lower surface to include at least one
integral lug extending generally downwardly from the base to engage
the skate mechanism, the core extending into the lug.
18. The method of claim 14, wherein the upper support is formed by
joining a plurality of composite layers.
19. The method of claim 14, wherein a varying rigidity of the boot
ranging from the first rigidity to the second rigidity is created
by using a varying number of the layers, wherein sections of the
boot having a high rigidity include a first number of the layers
and sections of the boot having the low rigidity include a second
number of the layers where the first number is greater than the
second number.
20. The method of claim 19, wherein the varying rigidity of the
boot is created by using layers including layers of varying
compositions, each of the varying compositions having varying
rigidities.
21. The method of claim 19, wherein the layers include at least one
of a long-woven fiber material.
22. The method of claim 21, wherein the long-woven fiber material
includes one of a fiberglass, a carbon-fiber, and an aramid
fiber.
23. The method of claim 19, wherein the varying rigidity of the
boot is created by molding using a varying thickness wherein
sections of the boot having a high rigidity include a first
thickness and sections of the boot having the low rigidity include
a second thickness where the first thickness is greater than the
second thickness.
24. The method of claim 19, wherein the varying rigidity of the
boot is created by molding using a material of varying rigidity
wherein sections of the boot having a high rigidity include a first
material and sections of the boot having the low rigidity include a
second material where the first material is more rigid than the
second material.
25. The method of claim 24, wherein at least one of the first
material and the second material includes a short fiber
material.
26. The method of claim 25, wherein a rigidity of the short fiber
material is increasable by increasing a fiber concentration in the
short fiber material.
27. The method of claim 14, further comprising extending the upper
support generally over a metatarsal of the wearer's foot.
28. The method of claim 14, wherein the upper support is configured
to receive a toe cap, the upper support being configured to at
least partially extend over a trailing edge of the toe cap.
29. The method of claim 14, wherein the upper face of the base
includes a recess for receiving an edge of a toe cap.
30. The method of claim 14, further comprising shaping a mid region
of a lower surface of the boot beneath the lower face of the base
in an arch shape and a planar region adjacent the mid region.
31. A skate boot apparatus comprising: a base including an upper
face configured to receive a wearer's foot and a lower face
configured to structurally support a skate mechanism, wherein the
base includes a core section between the upper face and the lower
face, the upper and lower faces being connected around the sides of
the core, the faces and sides forming a resin-impregnated, fiber
composite shell around the core, the core having a lower density
than the shell; an upper structural support integrated with the
base and extending upwardly from the base to a point above a
wearer's ankle, the upper support having an area of a first
rigidity above and adjacent the base and at least a second rigidity
lower than the first rigidity in a majority of the portion of the
upper support above the area of first rigidity; an outer shell
secured outside at least a portion of said upper support; and an
inner liner secured inside said upper support.
32. The apparatus of claim 31, wherein the shell is molded around
the core.
33. The apparatus of claim 31, wherein core section includes a
rigid foam material encased by the shell on all sides.
34. The apparatus of claim 31, wherein core section includes a
plurality of recesses to accommodate inserts coupled with the base,
the inserts having protrusions extending into an interior of the
boot, the inserts abutting a least a portion of the shell.
35. The apparatus of claim 31, wherein the core section is formed
separately from the boot and received into a core section recess in
the boot.
36. The apparatus of claim 35, wherein the core section is custom
formed to accommodate the wearer's foot.
37. The apparatus of claim 35, wherein the core section is bonded
to the upper surface of the base of the boot.
Description
PRIORITY CLAIM
[0001] This invention is a continuation application of U.S. patent
application Ser. No. 10/729,879, filed Dec. 5, 2003 under Attorney
Docket No. KORH-1-1001, which claims priority to U.S. Provisional
Application No. 60/443,449, filed Jan. 28, 2003.
FIELD OF THE INVENTION
[0002] This invention relates generally to skates and, more
specifically, to skate boot construction.
BACKGROUND OF THE INVENTION
[0003] Design of skate boots, particularly for hockey skates, has
changed little over the course of the last century. In the early
twentieth century, future Hall of Fame hockey star Joe Hall
realized that his hockey skates were not as responsive or
supportive as he would have wanted them to be. Mr. Hall approached
a neighbor, a shoemaker from Brandon, Manitoba, named George
Tackaberry, to try to develop improved hockey skates. Mr.
Tackaberry developed the concept of a custom leather boot featuring
a reinforced toe and heel to provide the skater with better support
and control. These were the first legendary "Tacks" skates, which
have since become the de facto standard for all hockey skates.
[0004] However, since Mr. Tackaberry's development of his skates,
little progress has been made. This is unfortunate in light of the
increasing needs of skaters. Figure skating, speed skating, and ice
hockey, have become increasingly popular. As hockey becomes more
popular, better, faster, stronger and larger athletes are playing
hockey, and these athletes seek increasingly better equipment to
attain every possible advantage in competition. As a result, more
responsive and supportive skates are desired.
[0005] FIG. 1 shows a conventional skate 100 which, in this
example, is a hockey skate. A conventional skate 100 generally
includes three sections: a skate mechanism 102, an upper 104, and a
base 106 coupling the skate mechanism 102 to the upper 104. The
skate mechanism 102, in this case, includes a blade 110, a skate
frame 112 configured to support the blade 110 with a plurality of
pylons 113, and a mounting bracket 114 configured to join the skate
mechanism 102 to the base 106. Alternatively, in an in-line,
wheeled skate (not shown), the skate mechanism includes the wheels,
a frame configured to support the wheels, and a bracket configured
to join the mechanism to the base.
[0006] The base 106, which is analogous to the sole of a shoe, is
joined with the mounting bracket 114 using rivets or similar
fasteners (not shown). The upper 104, which is analogous to the
upper of a shoe, in most skates is formed from a combination of
fabric and leather and nailed, stitched, and/or glued to a last
board (not shown in FIG. 1), just as the upper of a shoe is
attached to its last board. Alternatively, the upper 104 is molded
from plastic and glued or molded to the last board. Edges of the
upper 104 are attached around edges of an underside of the last
board. The last board is coupled to the base 106 to complete the
boot.
[0007] Conventional skate designs, such as the skate 100, result in
a number of shortcomings. One such shortcoming results from
attachment of the skate mechanism 102 to the base 106 and
subsequent attachment of the base 106 to the upper 104. The
conventional joining of these separate sections 102, 104, and 106
results in a potentially undesirable degree of play between the
wearer's foot and the skate mechanism 102 as the upper 104 flexes
around the wearer's foot (not shown), the base 106 flexes against
the upper 104, and the mounting bracket 114 of the skate mechanism
102 flexes against the base 106. Although some speed skates
incorporate a linear array inserts into their bases, such a linear
array does not provide a desirable degree of support for lateral
movement. As a result of the joining of these separate structures,
the responsiveness of the skate 100 to movements of the wearer is
diminished.
[0008] FIG. 2 shows a cutaway view 200 of a conventional skate 100
and visually highlights the layers interposed between the wearer
and the skate mechanism 102. The cutaway view 200 shows how the
upper 104 is fastened to the last board 210 only around the edges
of the last board 210. Limited attachment of the upper 104 to the
last board 210 adds to unwanted flexure between the upper 104 and
the last board 210, which can result in attenuation of the wearer's
movements to the skate mechanism 102. A contoured footbed 220
supports the foot of the user. The footbed 220 may be joined to the
last board 210, but the two are nonetheless separate and may result
in some further attenuation between the movements made by the
wearer and the response of the skate mechanism 102. However,
without the footbed 220, the wearer's foot could rub uncomfortably
over attachments between the base 106 and the skate bracket 112.
Generally, comfort and responsiveness are traded off in
conventional skate design.
[0009] Another shortcoming results from a tradeoff between comfort
and responsiveness. The upper 104 of a newly manufactured skate
100, like the upper of a new manufactured shoe, may be rigid and
uncomfortable, but softens and conforms over time to better fit the
wearer's ankle and foot. The initial rigidity may be somewhat
uncomfortable to the wearer, although it simultaneously may afford
greater responsiveness between the wearer's foot and the skate.
After a break-in period--which may be a lengthy and unpleasant
process--lessens the rigidity of the upper 104, the upper 104 may
be more comfortable, but may be correspondingly less responsive to
the movements of the wearer. Unfortunately, the more thoroughly
broken-in the skate 100 becomes, the more pliable the entire skate
100 becomes. Thus, over time the skate 100 may become more
comfortable, but it also may become less responsive. Conventional
molded uppers formed from plastic do not break-in with time, thus
the material used generally is partially pliable or semi-rigid to
provide a tradeoff between comfort and control.
[0010] Thus, there are unmet needs in the art for a skate that
optimally combines comfort and responsiveness, reduces or
eliminates the break-in period, and betters maintains structural
integrity over time.
SUMMARY OF THE INVENTION
[0011] Embodiments of the present invention provide a skate boot, a
skate using the improved unibody boot, and a method for making the
skate boot. The boot provides an integrated base and upper directly
couplable to a skate mechanism, resulting in a more rigid,
supportive, and responsive skate. The upper of the skate is molded
of at least a partially rigid material to comfortably yet securely
conform to a shape of a wearer's foot and ankle to better transfer
the wearer's movements to the skate. Contouring of the upper also
reduces a break-in period over which the upper becomes more
comfortable to wear.
[0012] More particularly, the present invention comprises skate
boot apparatuses, a skate, and a method. A base including an upper
face configured to receive a wearer's foot and a lower face
configured to structurally support a skate mechanism is provided.
An integral upper support is provided, the integral upper support
extending upwardly from the base to a point above an ankle of the
wearer, the integral support having a varying rigidity decreasing
from a high rigidity near the base to a low rigidity near the point
above the ankle of the wearer.
[0013] In accordance with further aspects of the invention, a
plurality of inserts is included in the boot. In one embodiment of
the present invention, the inserts are arrayed around
circumferential edges of the base. The inserts are configured to
engage a plurality of skate attachment devices to couple the skate
mechanism to the boot. The inserts are integrated with the base and
configured to engage the skate attachment devices through the
shaped lower surface of the unibody boot. In one embodiment, the
base is molded to at least partially encompass the inserts.
[0014] In accordance with another aspect of the present invention,
at least one of the inserts includes an inwardly threaded female
connector configured to receive one of the skate attachment
devices, the skate attachment device including an outwardly
threaded male connector. Alternatively, at least one of the inserts
includes an outwardly threaded male connector configured to engage
one of the skate attachment devices, the skate attachment device
including an inwardly threaded female connector.
[0015] In accordance with other aspects of the present invention,
at least one integral lug extends generally downwardly from the
base to engage the skate mechanism. The integral lug includes at
least one attachment point extending through the integral lug in a
direction generally parallel to the lower face of the base, the
attachment point being configured to receive a skate attachment
device. In one embodiment of the present invention, the integral
lug is configured to interleavably engage a recess in a skate
mechanism.
[0016] Further, the base may include a core section. The core
section may include a rigid foam material. The core section
suitably is fixably molded within the boot or injection molded into
a recess formed within the boot. The core section may include a
rigid foam material. The core section may include a plurality of
recesses to accommodate inserts coupled with the base, the inserts
having protrusions extending into an interior of the boot.
Alternatively, the core section is formed separately from the boot
and received into a core section recess formed in the boot. The
core section may be custom formed to accommodate the wearer's foot.
The core section suitably is bonded to the upper surface of the
base of the boot.
[0017] In accordance with other aspects of the present invention,
the boot includes a range of rigidities including a first rigidity
proximate to the shaped lower surface and a second rigidity away
from the shaped lower surface, the first rigidity being greater
than the second rigidity. The boot may be formed by at least one of
joining a plurality of layers or by molding.
[0018] A varying rigidity of the boot ranging from the first
rigidity to the second rigidity is created by using a varying
number of the layers. Sections of the boot having a high rigidity
include a first number of the layers and sections of the boot
having the low rigidity include a second number of the layers where
the first number is greater than the second number. Also, the
varying rigidity of the boot suitably is created by using layers
including layers of varying compositions, each of the varying
compositions having varying rigidities.
[0019] Also in accordance with aspects of the present invention,
the layers may include at least one hingably coupled layer, the
hingably coupled layer being partially joined with the boot toward
the base and being partially unjoined with the boot away from the
base such that the hingably coupled layer is movable at an upper
end configured to receive the wearer's ankle.
[0020] According to other aspects of the present invention, the
layers include at least one of a long-woven fiber material. The
long-woven fiber material may include one of a fiberglass, a
carbon-fiber, and Kevlar. Also, at least one of the layers may
include an impact-resistant material, such as a polyurethane
plastic. The layer of impact-resistant material suitably may be an
outermost layer of the boot. The layer may be transparent, and
disposed to at least partially protect a graphical design disposed
beneath an outer surface of the layer of impact-resistant material.
The graphical design may be sublimated on a non-outward-facing side
of the layer.
[0021] In accordance with other aspects of the present invention,
the varying rigidity of the boot is created by molding using a
varying thickness wherein sections of the boot having a high
rigidity include a first thickness and sections of the boot having
the low rigidity include a second thickness where the first
thickness is greater than the second thickness. Also, the varying
rigidity of the boot is created by molding using a material of
varying rigidity wherein sections of the boot having a high
rigidity include a first material and sections of the boot having
the low rigidity include a second material where the first material
is more rigid than the second material. Suitably, at least one of
the first material and the second material includes a short fiber
material. The rigidity of the short fiber material is increasable
by increasing a fiber concentration in the short fiber
material.
[0022] In accordance with still further aspects of the present
invention, the upper support is configured to extend generally over
a metatarsal of the wearer's foot. The upper support may be
configured to receive a toe cap, with the upper support being
configured to at least partially extend over a trailing edge of the
toe cap. The upper face of the base may include a recess for
receiving an edge of a toe cap.
[0023] Lastly, in accordance with other aspects of the present
invention, at least one of the base and the upper support include a
ventilation opening extending through the upper support.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The preferred and alternative embodiments of the present
invention are described in detail below with reference to the
following drawings.
[0025] FIG. 1 is a side elevational view of a conventional hockey
skate;
[0026] FIG. 2 is a side cutaway elevational view of the
conventional hockey skate of FIG. 1;
[0027] FIG. 3 is a side elevational view of a skate boot according
to an embodiment of the present invention;
[0028] FIG. 4 is a side cutaway view of the boot;
[0029] FIG. 5 is a side cutaway view of a boot including a
separately formed core section;
[0030] FIG. 6 is a side elevational view of the boot to show
arrangement of a hingably-attached layer incorporated in the boot
structure;
[0031] FIG. 7 is a rear elevational view of the boot;
[0032] FIG. 8 is a bottom partial cutaway view of the boot using
integrated inserts to engage a skate mechanism;
[0033] FIG. 9 shows a side elevational view of the boot
incorporating an integrated lug to engage a skate mechanism;
[0034] FIG. 10A shows a rear elevational view of the skate
mechanism coupled to one configuration of a boot having an
integrated lug;
[0035] FIG. 10B shows a rear elevational view of the skate
mechanism coupled to another configuration of a boot having an
integrated lug;
[0036] FIG. 11 is a side elevational view of a skate using the
boot; and
[0037] FIG. 12 is a side cutaway view of the skate of FIG. 11.
DETAILED DESCRIPTION OF THE INVENTION
[0038] By way of overview, the present invention comprises skate
boot apparatuses, a skate, and a method. A base including an upper
face configured to receive a wearer's foot and a lower face
configured to structurally support a skate mechanism is provided.
An integral upper support is provided, the integral upper support
extending upwardly from the base to a point above an ankle of the
wearer, the integral support having a varying rigidity decreasing
from a high rigidity near the base to a low rigidity near the point
above the ankle of the wearer.
[0039] FIG. 3 is a side elevational view of a boot 300 according to
an embodiment of the present invention. As will be further
described below, the boot 300 may be constructed a variety of
different ways. Using any one of these ways to construct the boot
300, generally the resulting boot 300 effectively is a one-piece
shell to provide structural rigidity to allow more improved control
and responsiveness of a skate using the boot 300.
[0040] The boot 300 includes a base 302. In the embodiment shown in
FIG. 3, the base 302 includes an upper face 304 formed to engage
and support a foot of a wearer (not shown) and a lower face 306
configured to support a skate mechanism. The base 302 is integrally
encompassed within the boot 300. Thus, because the base 302 is
incorporated within the boot 300, the lack of structural rigidity
resulting from having a separate base 106 (FIGS. 1 and 2) coupled
to the last board 210 (FIG. 2) are avoided in embodiments of the
present invention.
[0041] The boot 300 further includes a contoured upper 310. As will
be further described in connection with FIGS. 5 and 6, the
contoured upper 310 is formed to conform to an anatomical shape of
a wearer's foot and ankle. In one presently preferred embodiment,
the upper 310 is formed to cover a heel, an ankle, and the
metatarsal region of a wearer's foot. By forming the upper 310 to
conform to the shape of a wearer's foot and ankle, gaps between the
wearer's body and the boot are reduced or eliminated. Thus, the
boot 300 provides more complete support to the foot and ankle of
the wearer. As a further result of the contouring of the upper 310,
movements of the wearer's body are more rapidly, directly, and
forcefully received by the boot 300, thus rendering the skate (not
shown) to be more responsive to the wearer's movements. Contouring
of the upper 310 also reduces a break-in period over which the
upper 310 becomes more comfortable for the wearer.
[0042] Although rigidity is desirable, it will be appreciated that,
in a preferred embodiment of the present invention, some
flexibility also is desirable. At a base end 320 of the upper 310,
a high degree of rigidity is desired to both support the skate
mechanism (not shown) and buttress a base of the wearer's foot
where rigid support is desired. On the other hand, at an upper,
receiving end 350 of the upper 310 where the ankle of the wearer
passes into the upper 310, the upper 310 desirably has some
flexibility so that the upper 310 will not dig, cut into, or grate
the ankle of the wearer. Some flexibility also is desired at the
upper, receiving end 350 of the upper 310 to facilitate closing and
securing of the upper 310 to the wearer's foot and ankle. Thus,
some flexibility is built into the boot at the upper, receiving end
350. In addition, in a preferred embodiment of the present
invention, intermediate degrees of flexibility are built into the
upper 310 at a first intermediate layer 340 and a second
intermediate layer 330 between the base end 320 of the upper 310
and the upper, receiving end 350 of the upper 310.
[0043] Incorporation of the varying rigidity across different zones
320, 330, 340, and 350 of the upper 310 suitably is accomplished in
a variety of ways. In one presently preferred embodiment, layers of
one or more thicknesses and/or compositions are cut to size and
layered over a form and heated to meld the layers together. The
layers can be chosen for their physical properties.
Long-woven-fiber materials, such as fiberglass or Kevlar, may be
selected for more rigid layers. Further, polyurethane materials may
be included to provide impact resistance which may be highly
desirable for a hockey skate to protect the wearer from injury.
[0044] A polyurethane layer suitably may be an outermost layer of
the boot. The outermost layer may be transparent. Thus, the
polyurethane layer suitably provides both impact resistance and a
graphical design. The graphical design may be disposed on the boot
300 before an outermost layer is applied, or the graphical design
may be included in the outermost layer or printed or sublimated on
a non-facing side of the layer to protect the graphical design. The
transparent layer allows the graphical design and/or the
composition of the layers below to show through.
[0045] To achieve varying thicknesses, a highest number of layers
are deployed at the base end 320 and a fewest number of layers is
deployed at the upper, receiving end 350 of the upper. In other
words, a first layer may be created and formed around a mold
extending from the base 302 through uppermost edges of the upper,
receiving end 350. A second layer may be created and formed around
the first layer extending from the base through uppermost edges of
the first intermediate layer 340. Similarly, a third layer may be
created and formed around the second layer extending from the base
through uppermost edges of a second intermediate layer 330.
Finally, a fourth layer may be created and formed around the third
layer extending from the base through uppermost edges of the base
end 320. Once the layers are joined together, the result is an
upper 310 having varying thicknesses--and commensurate varying
rigidities--from the base end 320 through an upper, receiving end
350.
[0046] It will be appreciated that the upper 310 can be formed
using a number of variations. One variation may include using
layers of varying thicknesses. For example, a thin layer may be
used as the first layer extending through the upper, receiving end
350 to provide a high degree of flexibility at that point. Thicker
layers may then be used for the second, third, and fourth layers to
lend added rigidity toward the base end 320. Further, successively
thicker layers may be used to further increase rigidity toward the
base end 320 of the upper. Alternatively, the upper 310 and the
boot 300 could be molded, such as by multi-point injection molded,
using a mold having a varying thickness with greater thicknesses
toward the base end 320 and lesser thicknesses toward the upper,
receiving end 350 to achieve a similar result. Also, different
materials could be incorporated in the molding, using more rigid
materials for portions of the boot 300 for which higher rigidity is
desired. For example, a short fiber material could be used, with
materials having a higher concentration of fibers and, thus, a
higher rigidity, in portions where higher rigidity is desired.
Other materials could be used for parts of the boot 300 where less
rigidity is desired.
[0047] A lower surface 360 of the boot 310 can be similarly formed.
Layers of fiberglass can be wrapped around a lower surface 306
beneath the base 302. Layers also may be placed over the upper
surface 304 of the base 302 in what will form a lower interior
section of the boot 300 for supporting a bottom of the wearer's
foot. Multiple layers suitably may be used, recognizing that the
lower surface 360 of the boot 300 appropriately has a high rigidity
for receiving and supporting the skate mechanism (not shown).
Again, the heating or comparable treatment of the layers causes the
boot 300 to form a sturdy, appropriately rigid unified whole. As
previously described, layers forming the lower surface 360 also may
be molded rather than formed of layers.
[0048] FIG. 4 is a side cutaway view of the boot 300. As shown in
FIG. 4, the upper 310 has a greater cross-sectional thickness at
the base end 320 and a thinner cross-sectional thickness at the
upper receiving end 350. The base 302 is encased within layers or
other materials forming the boot and thus is integrated into the
boot 300. One or more layers extending across the lower surface 360
of the boot 300 encompass the base 302 from beneath while one or
more layers extending over the upper surface 304 of the base 302
encompass the base 302 from above. Again, the result of the layered
and joined or molded construction results in a single, unified boot
300.
[0049] It will be appreciated that the base 302 suitably may be
formed of built up layers of the same material used to form the
upper and encompass the base 302. Similarly, the base 302 may be
molded as part of a uniform molding process. It is a design choice
whether a different material appropriately is used for the base 302
to address design concerns such as weight, rigidity, shock
absorption, foot cushioning, or feasibility of manufacture.
[0050] In one presently preferred embodiment, the base 302 includes
a core section 303 formed from a rigid foam material to balance
these concerns, as well as to accommodate integrating skate
attachment devices into the boot 300 as is described below in
connection with FIG. 6. Forming the base 302 using a core section
303 surrounded by rigid layers creates a torsion box which
significantly adds to the rigidity of the base 302. The core
section 303 may be previously formed with the base 302 then formed
around the core section 303. Alternatively, the core section 303
suitably may be injection molded into a recess left in the base
302.
[0051] As shown in FIG. 5, the core section 305 also may be a
separately formed and inserted into the boot. It may be desirable
to form a custom-molded core section 305, custom-fit to a
particular wearer. The core section 305 could be formed and then
inserted into a core section recess in the base 302 left to
accommodate the core section. Providing a recess shaped to receive
the core section 305 prevents the core section 305 from sliding
relative to the base 302 to ensure that undesired movement between
the core section 305 and the base 302 does not result in
attenuation of responsiveness to movements of the wearer's foot.
Alternatively, even if the core section 305 is not custom molded,
the core section 305 may be molded to accommodate protrusions (not
shown) resulting from inserts incorporated in the base 302.
[0052] FIG. 4 also shows a toe cap recess 371 configured to receive
a toe cap (not shown). In one embodiment, the toe cap might be
shaped to engage and be coupled with the upper surface 304 of the
base 302. Alternatively, the toe cap may rest against and be
coupled with a front edge of the base 302. In one presently
preferred embodiment, the toe cap and the boot 300 are formed such
that the upper 310 of the boot 300 overlaps a trailing edge of the
toe cap. The overlapping construction ensures rigidity of the
completed boot and toe cap construction, with the overlapping
construction providing further protection for the wearer's
foot.
[0053] FIG. 4 also shows a plurality of ventilation openings 372,
374, and 376 extending through the boot 300. One or more arch
ventilation openings 372 may extend through an arch section of the
boot 300. Heel ventilation openings 374 may extend through the heel
of the boot 300. Upper ventilation openings 376 may extend through
the upper of the boot 300. It will be appreciated that the openings
372, 374, and 376, will not only allow for ventilation of heat, but
also for evaporation of perspiration. It also will be appreciated
that a lining (not shown in FIG. 4) suitably permeably cover the
openings 372, 374, and 376 to cushion surfaces of the openings 372,
374, and 376 without impermeably sealing the openings.
[0054] FIG. 6 is a side elevational view of a boot 380 showing a
variation of the construction. The boot 380 includes a hingably
coupled layer 382. The hingably coupled layer 382 is joined to an
underlying surface 384 using the same techniques used to join other
layers as previously described. However, the hingably-attached
layer 382 is only partially attached to an underlying surface 384
at an attached portion 386, leaving an unattached portion 388
engaging an upper portion of the wearer's leg (not shown). If the
hingably coupled layer 382 includes a suitably flexible material,
the unattached portion 388 of hingably coupled layer 382 can flex
between the wearer's leg and the attached portion 386. Thus, the
unattached portion 388 acts as a relatively flexible cuff to
provide additional support to the wearer while restricting the
wearer's movements less than a fully attached layer potentially
could restrict the wearer's movements.
[0055] FIG. 7 is a rear elevational exterior view of the boot 300.
As can be appreciated from FIG. 7, the boot 300 is formed to
contour to the anatomy of the wearer's foot and ankle. For example,
the boot 300, at its base end 320, is appropriate wide to
accommodate a width of the wearer's foot (not shown). However,
extending upward from the base end 320, it can be seen that the
boot 300 includes a heel contour 710 shaped to accommodate and
conform to a shape of the wearer's heel. Extending upward from the
heel contour 710 is an ankle contour 720. The ankle contour 720
narrows from the heel contour to follow a narrowed shape along a
back of the wearer's ankle. Also, each side of the boot 300
includes an ankle joint pocket 730 to accommodate protrusions
situated where the wearer's ankle joint extends outwardly to the
sides between the wearer's foot and ankle. Sculpting of the boot
300 thus conforms to the anatomy of the wearer to provide support,
comfort, and responsiveness.
[0056] FIG. 7 also shows how the lower surface 360 is configured to
engage a mounting bracket of a skate mechanism (not shown). The
lower surface 360 includes a flattened heel receiving surface 750
configured to securely engage a corresponding flattened surface on
the mounting bracket of the skate mechanism. In addition, the lower
surface 360 includes a plurality of openings 760 for receiving
attachment devices (not shown) for coupling the boot 300 to the
skate mechanism (not shown). Skate attachment devices, in the
nature of fasteners such as bolts, screws, scrivets, rivets, or
other attachment devices are received through the openings where
they are engaged by inserts (not shown) integrated within the boot
300, as will be further described in connection with FIG. 8.
[0057] FIG. 8 is a bottom partial cutaway view of the boot 300.
FIG. 8 shows the lower surface 360 of the boot including the
flattened heel receiving surface 750 and a corresponding flattened
front-foot receiving surface 810 for engaging corresponding
flattened surfaces on a skate mechanism (not shown). The flattened
heel receiving surface 750 and the flattened front-foot engaging
surface 810 flank the arch support 370 configured to conform to and
provide support to an arch of the wearer's foot.
[0058] Inside the flattened receiving surfaces 750 and 810 of the
foot are mounted inserts 820 for engaging and attaching a skate
mechanism to the boot. In one presently preferred embodiment shown,
the inserts 820 include inwardly-threaded, female connectors each
of which is configured to receive a corresponding outwardly
threaded male connector (not shown) extending through the skate
mechanism. Engagement of the male connectors couples the skate
mechanism to the boot 300. In one presently preferred embodiment,
the inserts are encompassed within the base 302 (FIGS. 3 and 4)
integrated within the boot 300. A molded base can be molded around
the inserts 820 to rigidly secure the inserts 820 within the
boot.
[0059] Rigidly integrating the inserts 820 within the boot 300
advantageously increases the responsiveness of a skate by helping
to translate movements of the wearer to the skate mechanism with
less attenuation. Disposing inserts 820 around a perimeter of the
base 302 provides structural support for lateral movement that is
not available in conventional skates. It will be appreciated that
other suitable means for integrating inserts 820 into he boot
suitably are used. Different couplings could be used instead of
inwardly-threaded female connectors. For example, outwardly
threaded male connectors could be encompassed in the base and
configured to engage inwardly-threaded female connectors associated
with the skate bracket. Alternatively, the inserts 820 suitably may
include rigid sleeves mounted either perpendicularly or in parallel
with the lower surface 360 of the boot and configured to receive
attaching devices having their own coupling devices at either end.
Also, it will be appreciated that the inserts 820 could be molded
into a lower surface 360 of the boot 300, particularly if the boot
itself is molded. The inserts 820 suitably are held in place by an
appropriate die during the molding process.
[0060] FIG. 9 shows a side elevational view of an alternative
embodiment of a boot 900 including one or more integrated
attachment lugs 910. The integrated attachment lug 910 is
integrated into the boot 900. The lugs 910 can be molded as part of
a molded boot 900. Alternatively, lug cores (not shown) may be
situated on or as part of the base, and one or more layers built up
around the lug core.
[0061] The lugs 910 provide a rigid attachment mechanism to engage
a skate mechanism. As will be further described below, the lugs 910
may provide structural support to the skate mechanism. The lugs 910
may include attachment points 920, which are openings through which
attachment devices (not shown) join the skate mechanism to the boot
900. As can be seen in FIG. 6A, the attachment points 920 of the
lugs 910 allow the skate mechanism to be coupled with the boot 900
using attachment devices extending parallel to a bottom surface of
the base instead of penetrating into the base perpendicularly to
the base.
[0062] FIG. 10A shows a rear elevational view of the boot 900 being
coupled with a skate mechanism 1000. The skate mechanism includes a
recess 670 configured to receive the interleavably lugs 910. The
lugs 910 and side portions 1010 of the skate mechanism defining a
recess 1020, when coupled together, form a skate bracket to provide
a rigid support for the skate, thereby providing lateral stability
for the wearer. It will be appreciated that preferably there would
be no appreciable gap between the lugs 910 and the skate mechanism
for optimal rigidity. Nonetheless, some gaps are shown in FIG. 10A
for clarity of explanation.
[0063] The skate mechanism 1000 is joined to the lugs 910 using an
attachment device 1030 extending through an opening in the side
portions 1010 and through the attachment points. The attachment
device 1030 suitably includes a bolt and nut, a rivet, or another
attachment device configured to couple the side portions 1010 to
the lugs 910.
[0064] FIG. 10B shows a rear elevational view of the boot having,
instead of a recess 1030 being formed in the skate mechanism 1000,
a plurality of lugs 910 could be formed on opposing sides of the
base with a space between the lugs 910 defining a recess 1050
configured to interleavably receive a skate mechanism 1060. In
either configuration, the lugs 910 and the skate mechanism 1000 or
1060 are interleavably engaged in a generalized tongue-and-groove
arrangement and secured by one or more attachment devices 1030.
[0065] FIG. 11 is a side elevational view of a skate 1100 using an
embodiment of the boot 300 according to the present invention. In
one presently preferred embodiment, a skate upper 1110 is bonded to
upper surfaces of the upper 310 of the boot 300 using adhesives,
thermal bonding, and/or other suitable techniques. A lower surface
360 of the boot 300 engaging the skate mechanism 1120 remains
uncovered. The skate upper 1110 includes a lace-receiving system
1112, a tongue 1114, an ankle support 1116, and a toebox 1118. In
one presently preferred embodiment of the present invention, the
upper 310 of the boot 300 is largely covered by the skate upper
1110. However, some portion of the upper 310 above the lower
surface 360 of the boot 300 may remain uncovered.
[0066] The skate mechanism 1120, which includes a blade 1122, a
skate bracket 1124 configured to support the blade 1122, and a base
1126. The base 1126 is coupled to the lower surface 360 of the boot
310. Attachment devices 1130 extend through the base 1126 into the
lower surface 360 and the base 302 (FIGS. 3 and 4) of the boot 300
where they engage the inserts (not shown). In the embodiment shown,
the attachment devices are outwardly-threaded male connectors
configured to engage inwardly-threaded female connectors integrated
into the boot 300.
[0067] FIG. 11 also shows a graphic design 1190 disposed on the
boot 300. An outer surface of the boot 300 may include a graphic
design 1190 disposed as part of or beneath an outer layer 1194 of
the boot 300 as previously described. The outer layer 1192 of the
boot 300 may include a transparent material. The transparent
material may include a polyurethane material, such that the outer
layer 1192 suitably may be configured to provide impact resistance
as previously described. The graphic design 1190 may be disposed on
a layer of the boot 300 beneath the outer layer 1192 where the
transparent layer 1192 protects the graphic 1190. The graphic 1190
also suitably is integrated into the outer layer 1192 or sublimated
onto the transparent outer layer 1192. The transparent outer layer
1192 allows the underlying construction to show through.
[0068] FIG. 12 is a side cutaway view of the skate 1100 using the
boot 300. In addition to an upper 310 of the skate boot 300 being
partially covered by the skate upper 710 on an exterior of the boot
300, an interior 1200 of the boot is covered by a liner 1210. The
liner 1210, formed of a soft lining material, lines the interior
surface 1200 of the boot 300 to provide cushioning and comfort to
the wearer. For further comfort, cushioning, and support, an insole
1220 is disposed on a bottom surface of the interior 1200 of the
boot 300.
[0069] FIG. 12 illustrates how the skate mechanism 1120 is secured
to the lower surface 360 of the boot 300. The male attachment
devices 1130 extend through the base 1126 of the skate mechanism
through the lower surface 360 of the boot 300 into the base 302 of
the boot 300. Inserts 620 integrally secured within the base 12
receive and engage the attachment devices 1130, coupling the skate
mechanism 1120 to the boot.
[0070] While the preferred embodiment of the invention has been
illustrated and described, as noted above, many changes can be made
without departing from the spirit and scope of the invention.
Accordingly, the scope of the invention is not limited by the
disclosure of the preferred embodiment. Instead, the invention
should be determined entirely by reference to the claims that
follow.
* * * * *