U.S. patent application number 11/655131 was filed with the patent office on 2008-07-24 for skate boot.
Invention is credited to Gaetan Champagne, Tai-Heng Chen, Ming-Shou Chien, Wern-Shiamg Jou.
Application Number | 20080172906 11/655131 |
Document ID | / |
Family ID | 39639865 |
Filed Date | 2008-07-24 |
United States Patent
Application |
20080172906 |
Kind Code |
A1 |
Jou; Wern-Shiamg ; et
al. |
July 24, 2008 |
Skate boot
Abstract
A lasted skate boot for enclosing and supporting a human foot,
the boot comprising: an outer shell comprising a heel portion for
surrounding the heel, an ankle portion for surrounding the ankle,
medial and lateral side portions for enclosing the medial and
lateral sides of the foot respectively, the outer shell comprising
cloth material laminated to a support made of a non-woven fabric,
and wherein the outer shell further comprises plastic material
fused with the non-woven fabric; an inner lining made of a soft
material and mounted in the outer shell; a toe box for enclosing
the toes, the toe box being affixed to the medial and lateral side
portions; and a tongue for facing the upper frontal portion of the
foot, the tongue extending upwardly and rearwardly from the toe
box.
Inventors: |
Jou; Wern-Shiamg;
(Kaohsiung, TW) ; Chien; Ming-Shou; (Yangmei
Township, TW) ; Chen; Tai-Heng; (Taipei, TW) ;
Champagne; Gaetan; (Saint-Colomban, CA) |
Correspondence
Address: |
Ralph A. Dowell of DOWELL & DOWELL P.C.
2111 Eisenhower Ave, Suite 406
Alexandria
VA
22314
US
|
Family ID: |
39639865 |
Appl. No.: |
11/655131 |
Filed: |
January 19, 2007 |
Current U.S.
Class: |
36/115 ;
12/147R |
Current CPC
Class: |
A43B 23/081 20130101;
A43B 5/1666 20130101; B29D 35/0009 20130101; B29D 35/126
20130101 |
Class at
Publication: |
36/115 ;
12/147.R |
International
Class: |
A43B 5/16 20060101
A43B005/16; A43D 999/00 20060101 A43D999/00 |
Claims
1. A lasted skate boot for enclosing and supporting 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, an upper frontal portion and toes, said
boot comprising: (a) an outer shell comprising a heel portion for
surrounding the heel, an ankle portion for surrounding the ankle,
medial and lateral side portions for enclosing the medial and
lateral sides of the foot respectively, said outer shell comprising
cloth material laminated to a support made of a non-woven fabric,
and wherein the outer shell further comprises plastic material
fused with the non-woven fabric; (b) an inner lining made of a soft
material and mounted in said outer shell; (c) a toe box for
enclosing the toes, said toe box being affixed to said medial and
lateral side portions; and (d) a tongue for facing the upper
frontal portion of the foot, said tongue extending upwardly and
rearwardly from said toe box.
2. A lasted skate boot as defined in claim 1, further comprising an
insole for facing the plantar surface of the foot.
3. A lasted skate boot as defined in claim 2, wherein each of said
medial and lateral side portions comprises a skirt projecting
downwardly from its lower edge.
4. A lasted skate boot as defined in claim 3, wherein said skirt
overlaps a portion of said insole and is affixed to said
insole.
5. A lasted skate boot as defined in claim 1, wherein said heel
portion is substantially cup shaped for following the contour of
the heel of the foot.
6. A lasted skate boot as defined in claim 1, wherein said inner
lining comprises a surface intended for contact with the heel,
ankle and lateral and medial sides of the foot.
7. A skate boot as defined in claim 1, further comprising a footbed
mounted inside said outer shell, said footbed comprising an upper
surface for receiving the plantar surface of the foot and a wall
projecting upwardly from said upper surface, said wall partially
cupping the heel and extending up to a medial line of the foot.
8. A skate boot as defined in claim 1, wherein said outer shell
further comprises a tendon guard for facing at least partially a
rear portion of the Achilles tendon.
9. A skate boot as defined in claim 4, further comprising an
outsole affixed to a bottom surface of said insole.
10. An ice skate comprising a skate boot as defined in claim 9,
said ice skate comprising an ice skate blade holder mounted on said
outsole.
11. An ice skate comprising a skate boot as defined in claim 9,
said ice skate comprising an ice skate blade holder mounted to a
bottom surface of said insole.
12. 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, said 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.degree. C. and 200.degree. 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 to form, after cooling, an outer
shell comprising 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.
13. A method as defined in claim 12, wherein the sheet further
partially extends over the bottom portion of the male section such
that the outer shell further comprises medial and lateral skirts
after step (e).
14. A method as defined in claim 13, further comprising positioning
an insole, a toe box and the outer shell over a last; and affixing
the medial and lateral skirts to the insole.
15. A method as defined in claim 14 further comprising affixing a
rigid outsole to a bottom portion of said insole.
16. A method as defined in claim 15 further comprising affixing an
ice blade holder to a bottom surface of said rigid outsole.
17. A method as defined in claim 16 further comprising affixing a
layer of material to an external surface of the outer shell.
18. A method as defined in claim 12 further comprising affixing an
inner lining to an inner surface of the outer shell.
19. A method as defined in claim 18 further comprising placing a
padding element between the inner lining and the inner surface of
the outer shell.
20. A method as defined in claim 14, wherein the sheet further
comprises an upper portion facing an upper part of the rear portion
of the male section of the mold such that the outer shell further
comprises a tendon guard for facing the Achilles tendon after step
(e).
21. A method as defined in claim 12, wherein the liquid plastic
material is selected from the group comprising surlyn, ethylene
vinyl acetate, thermoplastic polyurethane, nylon66, hytrel,
polypropylene and polyethylene.
22. A method as defined in claim 21, wherein the cloth material is
selected from the group of polyester, nylon, carbon fibers,
synthetic fibers and fiberglass.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a lasted skate boot with an
outer shell comprising cloth material laminated to a support made
of a non-woven fabric, and wherein the outer shell further
comprises plastic material fused with the non-woven fabric. The
invention also relates to a method of making a lasted skate boot
comprising such outer shell.
BACKGROUND OF THE INVENTION
[0002] The construction of sporting boots used for sporting
activities such as ice skating, roller skating, hiking, trekking
and cross-country skiing has become quite complex over recent
years. Existing sporting boots often include multiple different
components, and multiple different materials in order to provide
the sporting boot with the performance and aesthetic requirements
imposed by consumers. As such, over recent years different
manufacturing processes have been developed and new materials have
been used.
[0003] U.S. Pat. No. 3,807,062 discloses a boot having an inner
layer formed of a rigid material for providing rigidity at selected
locations such as the sole, heel and ankle portion of the foot; and
an outer layer, which is molded over the inner layer. The boot is
thus reinforced at selected area while other areas are more
flexible.
[0004] U.S. Pat. No. 4,509,276 discloses a skate boot made of a
lower exterior molded rigid plastic portion and intermediate and
upper portions made of pliable material to allow forward flexure
and torsional flexibility in the ankle area.
[0005] U.S. Pat. No. 4,777,741 discloses an article of footwear
such as a shoe or skate, which comprises a molded outer shell and a
semi-rigid molded tongue portion to close the footwear.
[0006] U.S. Pat. No. 5,339,544 discloses a footwear comprising a
first component made of a single piece of molded synthetic material
having a rear upper portion which extend from an insole, and a
second component made of soft material having a front upper portion
and a lining. The two components are connected together with the
lining of the second component inserted inside the rear portion of
the first component.
[0007] U.S. Pat. No. 6,499,233 discloses a footwear comprising a
structural molded inner shell for supporting and enclosing the foot
and an outer skin bonded onto the outer sides of the inner
shell.
[0008] These designs effectively reduce the number of components
utilized in the construction of footwear or skate. However, the
appearance of some of these designs is not always appealing.
[0009] Thus there is a need in the industry for a skate boot having
fewer components, providing good foot support and has an exterior
look which may be made more appealing to the consumer.
SUMMARY OF THE INVENTION
[0010] As embodied and broadly described therein, the present
invention provides a lasted skate boot for enclosing and supporting
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, an upper frontal portion
and toes, said boot comprising: (a) an outer shell comprising a
heel portion for surrounding the heel, an ankle portion for
surrounding the ankle, medial and lateral side portions for
enclosing the medial and lateral sides of the foot respectively,
said outer shell comprising cloth material laminated to a support
made of a non-woven fabric, and wherein the outer shell further
comprises plastic material fused with the non-woven fabric; (b) an
inner lining made of a soft material and mounted in said outer
shell; (c) a toe box for enclosing the toes, said toe box being
affixed to said medial and lateral side portions; and (d) a tongue
for facing the upper frontal portion of the foot, said tongue
extending upwardly and rearwardly from said toe box.
[0011] The invention also provides a method of making a lasted
skate boot for enclosing a human foot when in use, the foot having
a heel, an ankle with a medial malleolus and a lateral malleolus, a
plantar surface, medial and lateral sides and toes, said 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 a cloth
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.degree. C. and 200.degree. 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 to form, after cooling, an outer
shell comprising 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.
[0012] These and other aspects and features of the present
invention will now become apparent to those of ordinary skill in
the art upon review of the following description of specific
embodiments of the invention in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A detailed description of examples of embodiments of the
present invention is provided hereinbelow with reference to the
following drawings, in which:
[0014] FIG. 1 is a side view of a human foot with the integument of
the foot shown in stippled lines and the bones shown in solid
lines;
[0015] FIG. 2 is a front view of the human foot of FIG. 1;
[0016] FIG. 3 is a perspective view of an ice skate comprising an
outer shell in accordance with a the present invention;
[0017] FIG. 4 is an exploded view of the ice skate of FIG. 3
[0018] FIG. 5 is a perspective view of male and female sections of
a mold for making the outer shell;
[0019] FIG. 6 is side view of the male and female sections of the
mold of FIG. 5, where the sheet used for making the outer shell is
shown;
[0020] FIG. 7 is side view of the male and female sections of the
mold of FIG. 5 with the sheet placed over the male section of the
mold;
[0021] FIG. 8 is a cross-sectional view of the male and female
sections, once closed and with the sheet in the mold cavity;
and
[0022] FIG. 9 is a perspective view of the outer shell.
[0023] In the drawings, embodiments of the invention are
illustrated by way of example. It is to be expressly understood
that the description and drawings are only for the purposes of
illustration and as an aid to understanding, and are not intended
to be a definition of the limits of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0024] To facilitate the description, any reference numerals
designating an element in one figure will designate the same
element if used in any other figures. In describing the
embodiments, specific terminology is resorted to for the sake of
clarity but the invention is not intended to be limited to the
specific terms so selected, and it is understood that each specific
term comprises all equivalents.
[0025] Shown in FIGS. 1 and 2 is a typical human foot F that
includes toes T, a plantar surface PS, a medial side MS and a
lateral side LS. In addition, the human foot includes a heel H, an
Achilles tendon AT and an ankle A having a lateral malleolus LM and
a medial malleolus MM, the lateral malleolus LM being at a lower
position than the medial malleolus MM.
[0026] Shown in FIGS. 3 and 4 is an ice skate 1 that comprises a
skate boot 10 suitable for enclosing a right human foot F. The ice
skate 1 has an outer shell 12, a toe cap 14, a tongue 24, a padding
element 26 (optional component), an inner lining 22, a footbed 28,
an insole 30, an outsole 32, an ice skate blade holder 16 and a
blade 18.
[0027] The method of making the outer shell 12 will now be
described in more detail below with respect to FIGS. 5 to 9. FIGS.
5 to 8 show a mold 34 for making the outer shell 12. The mold 34 is
a male-female mold having a male section 36 and a female section 38
for defining a mold cavity therebetween.
[0028] As best seen in FIGS. 5 to 7, the male section 36 has medial
and lateral sides 40, 42, a rear portion 44 and a bottom portion 46
for defining a three dimensional shape corresponding to the
external three dimensional shape of the foot F. The rear portion 44
may further comprise an upper portion 48 corresponding to the shape
of the Achilles tendon AT. The female section 38 has a recess 50
for receiving the male section 36. As seen in FIG. 7, the male
section 36 comprises a plurality of inner channels 52 for admitting
liquid plastic material in the mold cavity.
[0029] In order to make the outer shell 12, a pre-cut sheet 100
made of cloth material (e.g. polyester, nylon, carbon fibers,
synthetic fibers or fiberglass) laminated to a support made of
non-woven fabric. As it is well known in the art, non-woven fabric
is manufactured by putting small fibers together in the form of a
sheet and then binding them either with an adhesive or by
interlocking them with serrated needles such that the inter-fiber
friction results in a strong fabric. The sheet 100 is after placed
on the male section 36 of the mold such that the non-woven fabric
contacts the sides and rear portions 40, 42, 44 of the male section
36 of the mold.
[0030] The male and female sections 36, 38 of the mold are then
closed and liquid plastic material is injected in the inner
channels 52 at a temperature of between 160.degree. C. and
200.degree. 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 100 against the recess 50 of the female section of the
mold, fills the mold cavity and fuses with the non-woven fabric to
form the outer shell 12. It is understood that non-woven fabric has
to be of a certain thickness depending on the type of cloth used in
order to create a barrier to prevent the plastic from going through
the cloth during the injection process, while the plastic is in its
liquid form. For example, for a cloth made of polyester TH3076/600D
SILVER, a non-woven fabric having a thickness of 0.8 mm is used.
There is a number of plastic materials that are suitable and can be
used such as but not limited to: surlyn, ethylene vinyl acetate
(EVA), thermoplastic polyurethane (TPU), nylon66, hytrel,
polypropylene, polyethylene.
[0031] After cooling the male and female sections 36, 38 of the
mold are opened and the outer shell 12 is finally removed from the
mold. The excess material around the perimeter of the outer shell
12 may be trimmed after.
[0032] It is understood that the plastic material enters in a
liquid form in the mold, fuses with the non-woven material, and
after about 10 seconds, the plastic is in a solid form such that
the outer shell is made and the mold is open. The cycle time of the
injection may be between 60 seconds and 90 seconds. For example, it
may take about 20 seconds to put the sheet in the mold, about 45
seconds to close the mold and inject the liquid plastic, about 10
seconds for cooling, and about 15 seconds to open the mold and
remove the outer shell.
[0033] As shown in FIG. 9, the outer shell 12 comprises a heel
portion 54 for receiving the heel H, an ankle portion 56 for
receiving the ankle A and medial and lateral side portions 58, 60
for facing the medial and lateral sides MS, LS respectively. These
portions 54, 56, 58, 60 form a foot receiving cavity that conforms
to the general shape of the foot F. The medial and lateral side
portions 58, 60 extend forwardly from the heel portion 54. The heel
portion 54 may be substantially cup shaped for following the
contour of the heel H. The outer shell 12 has an inner surface 62
facing the foot F when in use, and an outer surface 64. Because the
outer surface 64 is made of plastic fused with the non-woven fabric
of the sheet 100, the outer shell 12 offers a good resistance to
wear, abrasion, cuts, impacts and moisture.
[0034] The outer shell 12 may also comprise a tendon guard portion
66 for covering the Achilles tendon AT. As seen in FIG. 6, the
sheet 100 has then a portion 102 extending over the upper portion
48 of the male section 36 of the mold. It is understood that the
portion 102 may be integrally formed with the sheet 100 (as shown
in FIG. 6) or can be a separate sheet stitched to the sheet 100.
The separate sheet may be made of a different material than that of
the outer shell 12. In some cases, a foxing portion 104 made of
flexible TPU or PVC material may be affixed to the sheet 100 prior
to placing the sheet 100 in the mold.
[0035] The ankle portion 56 may comprise a medial cup-shaped
depression for receiving the medial malleolus MM and a lateral
cup-shaped depression for receiving the lateral malleolus LM, the
lateral depression being located slightly lower than the medial
depression, for conforming to the morphology of the foot F.
[0036] The medial and lateral side portions 58, 60 of the outer
shell 12 may comprise respective medial and lateral skirts 68, 70
that are integrally formed therewith and extend downwardly
therefrom. It is understood that the sheet 100 has then a portion
106 extending over the bottom portion 46 of the male section 36 of
the mold.
[0037] Once the outer shell 12 has been obtained after the
injection process, the inner lining 22 may then be glued or sewed
to the inner surface 62 of outer shell 12. The inner lining 22 is
made of a layer of soft material such as a sheet of polyester
fabric or synthetic leather or fabric made from 100% nylon fibers,
which are laminated with a 1.5 to 2 mm layer of foam. The inner
lining 22 comprises an inner surface that is adapted to contact the
skin of the foot F in use. The padding element 26 can also be added
between the inner surface 62 of the outer shell 12 and the inner
lining 22.
[0038] As shown in FIG. 4, two narrow bands 72 are secured to the
upper portion of each of the side portions 58, 60. The narrow bands
72 are made of fabric, textile, soft PVC materials, synthetic
leather or leather. In an alternative embodiment, a single
continuous band that covers the upper portion of each of side
portions 58, 60 and wraps around the rear of the ankle portion 56
can be used instead of two distinct bands 72.
[0039] Apertures 74 are then punched through the narrow bands 72,
the outer shell 12 and the inner lining 22. Once punched, the
apertures 74 are reinforced by metallic rivets (eyelets) 76 or any
suitable means as is well known in the art of footwear
construction.
[0040] The tongue 24 and toe cap 14 are then affixed to the outer
shell 12. In a non-limiting embodiment, the toe cap 14 and the
tongue 24 are pre-assembled prior to installation to outer shell
12. The tongue 24 is affixed to the toe cap 14 and extends upwardly
and rearwardly from the toe cap 14 for covering the forefoot of the
foot F. The frontal edge of tongue 24 can be sewn directly to toe
cap 14 or can be fixed in an alternative manner known in the art.
The toe cap 14 may be secured to the outer shell 12 by sewing both
sides of toe cap 14 to each ends of the side portions 68, 70.
[0041] A last is afterwards inserted into the inside cavity of the
outer shell 12 in order to complete the construction of the boot.
The last enables the outer shell 12 to maintain its shape when the
skirts 68, 70 are affixed to the insole 32. A light sanding of the
skirt 68, 70 and the insole 32 60 may be performed to partially
even the lower surface of the boot and provide a flat surface on
which the outsole 32 can be mounted. The blade holder 16 is then
mounted on the outsole 32.
[0042] The footbed 28 can be inserted into the outer shell 12 in
order to sit upon the insole 30. The footbed 28 has an upper
surface 78 for receiving the plantar surface PS of the foot F, and
a padding wall 80 that projects upwardly from the upper surface for
partially cupping the heel H and extending up to a medial line of
the foot F.
[0043] The above description of the embodiments should not be
interpreted in a limiting manner since other variations,
modifications and refinements are possible within the spirit and
scope of the present invention. The scope of the invention is
defined in the appended claims and their equivalents.
* * * * *