METHOD OF MAKING A LASTED SKATE BOOT

• US 20100275393A1
• Filed: 07/12/2010
• Published: 11/04/2010
• Est. Priority Date: 01/19/2007
• Status: Active Grant

• Current Assignee: Bauer Hockey, LLC
• Original Assignee: Nike Bauer Hockey Inc. (Nike, Inc.)
• Inventors: CHEN, Tai-Heng, CHAMPAGNE, Gaétan, JOU, Wern-Shiarng, CHIEN, Ming-Shou
• Granted Patent: US 8,329,083 B2
• Time in Patent Office: Days
• US Class Current: 12/146L
• CPC Class Codes: A43B 23/081 Toe stiffeners
• CPC Class Codes: A43B 5/1666 characterised by the upper
• CPC Class Codes: B29D 35/0009 by injection moulding; Apparatus therefor
• CPC Class Codes: B29D 35/126 Uppers

Abstract

A method of making a lasted skate boot 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 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.

Claims

1. 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°

C. and 200°

C. and at a pressure of between 985 psi and 1015 psi such that the liquid plastic material spreads on the sheet, pushes the sheet against the recess of the female section of the mold, fills the mold cavity and fuses with the non-woven fabric 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.

2. A method as defined in claim 1, 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).

3. A method as defined in claim 2, 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.

4. A method as defined in claim 3, further comprising affixing a rigid outsole to a bottom portion of said insole.

5. A method as defined in claim 4, further comprising affixing an ice blade holder to a bottom surface of said rigid outsole.

6. A method as defined in claim 5, further comprising affixing a layer of material to an external surface of the outer shell.

7. A method as defined in claim 1, further comprising affixing an inner lining to an inner surface of the outer shell.

8. A method as defined in claim 7, further comprising placing a padding element between the inner lining and the inner surface of the outer shell.

9. A method as defined in claim 3, 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).

10. A method as defined in claim 1, wherein the liquid plastic material is selected from the group comprising surlyn, ethylene vinyl acetate, thermoplastic polyurethane, nylon66, hytrel, polypropylene and polyethylene.

11. A method as defined in claim 1, wherein the cloth material is selected from the group of polyester, nylon, carbon fibers, synthetic fibers and fiberglass.