CN112469554A - Skates or other shoes - Google Patents

Abstract

A skate (e.g., a skate shoe) for a skater (e.g., a hockey player). The skate includes a skate boot for receiving the skater's foot and a skating device (e.g., blade and 5-blade holder) disposed beneath the skate boot to engage a skating surface (e.g., ice). At least a portion of the skate boot and optionally at least a portion of one or more other components (e.g., the skate device) can be constructed of one or more materials (e.g., foam) that are molded by flow molding in a molding apparatus during a molding process (e.g., injection molding or casting). This may allow the skate (or other 0-shoe) to have useful performance characteristics (e.g., weight reduction, fit and comfort, etc.) while being more cost effective to manufacture. Other articles of footwear are also provided.

Description

Skates or other shoes

Cross Reference to Related Applications

For purposes of the united states, this application is a partial continuation of international application PCT/CA2017/050155 filed on 9.2.2017, claiming priority from U.S. provisional patent application 62/292,998 filed on 9.2.2016, all of which are incorporated herein by reference.

Technical Field

The present invention relates generally to footwear, including, for example, skates (e.g., ice skates) for hockey and/or other activities.

Background

Skaters use skates for a variety of sports, such as ice hockey, roller hockey, and the like. The skate includes a skate boot which typically includes a plurality of components that are assembled together to form the skate boot. This may include a housing, toe cap, tongue, tendon protection, etc.

For example, a method of manufacturing the shell of a conventional skate boot includes thermoforming layers of different synthetic materials and then assembling the layers to form the shell. However, such conventional skates can sometimes be too bulky, uncomfortable, unprotected in certain areas, and/or unsuitable for the skater's foot. In addition, such conventional skates can be costly to manufacture.

Similar considerations may exist for other types of footwear (e.g., ski boots, motorcycle boots, work boots, etc.).

For these and/or other reasons, improvements in skates and other footwear are desired.

Disclosure of Invention

In accordance with aspects of the present invention, a skate (e.g., a skate shoe) for a skater is provided. The skate includes a skate boot for receiving the skater's foot and a skating device (e.g., blade and blade holder) positioned beneath the skate boot to engage a skating surface. At least a portion of the skate boot and optionally at least a portion of one or more other components (e.g., the skate device) is constructed of one or more materials (e.g., foam) that are molded during a molding process (e.g., injection molding or casting) by flowing in a molding apparatus. This may allow the skate to have useful performance characteristics (e.g., weight reduction, fit and comfort, etc.) while being more cost effective to manufacture. Other articles of footwear are also provided.

According to one aspect of the present invention, there is provided a skate boot for a skate, the skate comprising a skate device disposed beneath the skate boot to engage a skating surface, the skate boot defining a chamber for receiving a user's foot, the skate boot including a body including a medial side portion for facing a medial side of the user's foot, a lateral side portion for facing a lateral side of the user's foot, a heel portion for receiving the user's heel, and an ankle portion for receiving the user's ankle, wherein: the medial, lateral, heel and ankle portions of the body are molded together and integral with one another; and the body comprises a plurality of layers comprising a plurality of different and flow molded materials.

According to another aspect of the invention there is provided a method of manufacturing a skate boot for a skate, the skate including a skate device disposed beneath the skate boot to engage a skating surface, the skate boot defining a chamber for receiving a user's foot, the method comprising: providing a molding apparatus; and molding a body of the skate boot using a molding apparatus, the body including a medial side portion facing a medial side of the user's foot, a lateral side portion facing a lateral side of the user's foot, a heel portion to receive the heel of the user's foot, and an ankle portion to receive the ankle of the user, wherein: the medial, lateral, heel and ankle portions of the body are molded together and integral with one another; and molding includes flowing different multiple materials in the molding apparatus to form the multi-layered body.

According to another aspect of the present invention, there is provided an article of footwear for receiving a user's foot, the article of footwear comprising a body including a medial side portion for facing a medial side of the user's foot, a lateral side portion for facing a lateral side of the user's foot, a heel portion for receiving the user's heel, and an ankle portion for receiving the user's ankle, wherein: the medial, lateral, heel and ankle portions of the body are molded together and integral with one another; and the body comprises a plurality of layers comprising a plurality of different and flow molded materials.

According to another aspect of the present invention, there is provided a skate boot for a skate, the skate including a skate device disposed beneath the skate boot to engage a skating surface, the skate boot defining a chamber for receiving a user's foot, the skate boot including a body including a medial portion for facing a medial side of the user's foot, a lateral portion for facing a lateral side of the user's foot, a heel portion for receiving the user's heel, and an ankle portion for receiving the user's ankle, wherein: the medial, lateral, heel and ankle portions of the body are molded together and integral with one another; and the body comprises a plurality of injection molded layers comprising a plurality of different materials.

According to another aspect of the invention there is provided a method of manufacturing a skate boot for a skate, the skate including a skate device disposed beneath the skate boot to engage a skating surface, the skate boot defining a chamber for receiving a user's foot, the method comprising: providing injection molding equipment; and injection molding a body of the skate boot using an injection molding apparatus, the body including a medial side portion facing a medial side of a foot of the user, a lateral side portion facing a lateral side of the foot of the user, a heel portion to receive a heel of the user, and an ankle portion to receive an ankle of the user, wherein: the medial, lateral, heel and ankle portions of the body are molded together and integral with one another; and the body comprises a plurality of injection molded layers comprising a plurality of different materials.

According to another aspect of the present invention there is provided a skate boot for a skate, the skate including a skate device disposed beneath the skate boot to engage a skating surface, the skate boot defining a chamber for receiving a user's foot, the skate boot comprising: a body including a medial side portion facing a medial side of a user's foot, a lateral side portion facing a lateral side of the user's foot, a heel portion to receive a heel of the user, and an ankle portion to receive an ankle of the user; a tendon protection device protruding upward from the main body; and a cutting guard comprising a cut-resistant material extending over the body and movable relative to the tendon protection device.

According to another aspect of the present invention, there is provided a last for molding a body of an ice skate. The skate includes a skate device disposed beneath the skate boot to engage a skating surface. The skate boot is configured to receive a user's foot. The last is configured to mold the body of the skate such that the body of the skate includes a medial side portion that faces the medial side of the user's foot, a lateral side portion that faces the lateral side of the user's foot, a heel portion that receives the heel of the user's foot, and an ankle portion that receives the ankle of the user. The last is of repeatable construction to facilitate stripping of the body of the skate from the last so that the last can be varied between a moulding configuration for moulding the body of the skate on the last and a stripping configuration for stripping the body of the skate from the last.

According to another aspect of the invention, a method of making a skate boot for a skate that includes a skate device positioned beneath the skate boot to engage a skating surface is provided. The skate boot is configured to receive a user's foot. The method comprises the following steps: providing a last that is changeable between a molded configuration and a demolded configuration; molding the body of the skate on a last in a molded configuration such that the body of the skate includes a medial side portion that faces the medial side of the user's foot, a lateral side portion that faces the lateral side of the user's foot, a heel portion that receives the user's heel, and an ankle portion that receives the user's ankle; changing the last from the moulded configuration to a release configuration to facilitate removal of the body of the skate from the last; and demolding the body of the skate from the last in a demolding configuration.

According to another aspect of the present invention, a last for molding a body of an article of footwear that receives a foot of a user is provided. The last is configured to mold a body of an article of footwear such that the body of the article of footwear includes a medial side portion that faces a medial side of a user's foot, a lateral side portion that faces a lateral side of the user's foot, a heel portion that receives a heel of the user's foot, and an ankle portion that receives an ankle of the user. The last is reconfigurable to facilitate demolding of the body of the footwear article from the last so that the last can be changed between a molded configuration for molding the body of the skate on the last and a demolded configuration for demolding the body of the skate from the last.

According to another aspect of the invention, a method of manufacturing an article of footwear for receiving a foot of a user is provided. The method comprises the following steps: providing a last that is changeable between a molded configuration and a demolded configuration; molding a body of an article of footwear over a last in a molded configuration such that the body of the article of footwear includes a medial side portion facing a medial side of a user's foot, a lateral side portion facing a lateral side of the user's foot, a heel portion to accommodate a heel of the user's foot, and an ankle portion to accommodate the ankle of the user; changing the last from the molded configuration to a demolded configuration to facilitate removal of the body of the article of footwear from the last; and demolding the body of the article of footwear from the last in a demolding configuration.

According to another aspect of the invention, a resilient female mold member for molding a skate boot body of an ice skate is provided. The skate includes a skate device disposed beneath the skate boot to engage a skating surface. The skate boot is configured to receive a user's foot. The resilient female mould member is configured as part of a female mould and is arranged adjacent a last used for moulding the body of the skate. The resilient female mould member includes an inner surface which is preformed to define a cavity between the resilient female mould member and the last to receive a polymeric material to mould at least a portion of the body of the skate such that the inner surface of the resilient female mould member forms an outer surface of that portion of the body of the skate.

According to another aspect of the present invention, a method of making a skate boot for a skate is provided. The skate includes a skate device disposed beneath the skate boot to engage a skating surface. The skate boot is configured to receive a user's foot. The method includes providing a last and a negative mold for molding the body of the skate. The female mould comprises a resilient female mould member comprising an inner surface which is preformed to define a cavity between the resilient female mould member and the last. The method comprises flowing a polymeric material in a cavity to mould at least a portion of the body of the skate such that the inner surface of the resilient female mould member forms the outer surface of that portion of the body of the skate.

According to another aspect of the invention there is provided a resilient female mould member for moulding a body of an article of footwear. The article of footwear is configured to receive a foot of a user. The resilient female mold member is configured as part of a female mold and is disposed adjacent a last used to mold a body of an article of footwear. The resilient female mold member includes an inner surface that is preformed to define a cavity between the resilient female mold member and the last to receive a polymeric material to mold at least a portion of the body of the article of footwear such that the inner surface of the resilient female mold member forms an outer surface of the portion of the body of the article of footwear.

According to another aspect of the invention, a method of manufacturing an article of footwear for receiving a foot of a user is provided. The method comprises the following steps: a negative mold and last for molding a body of an article of footwear are provided. The female mould comprises a resilient female mould member comprising an inner surface which is preformed to define a cavity between the resilient female mould member and the last. The method includes flowing a polymeric material in the cavity to mold at least a portion of the body of the article of footwear such that an inner surface of the resilient female mold member forms an outer surface of the portion of the article of footwear body.

According to another aspect of the present invention, a method of manufacturing a skate boot for a skate is provided. The skate includes a skate device disposed beneath the skate boot to engage a skating surface. The skate boot is configured to receive a user's foot. The method comprises the following steps: placing the sheet in a mould for moulding the body of the skate; and flowing the material in the mold to mold at least a portion of the body of the skate. The sheet conforms to the portion of the body of the skate.

According to another aspect of the present invention, a skate boot for a skate is provided. The skate includes a skate device disposed beneath the skate boot to engage a skating surface. The skate boot is configured to receive a user's foot. The skate includes a body, the body including: a layer of material molded by flow; and a sheet provided during molding of the material layer and conforming thereto.

According to another aspect of the invention, a method of manufacturing an article of footwear for receiving a foot of a user is provided. The method comprises the following steps: placing the sheet in a mold for molding a body of an article of footwear; and flowing the material in the mold to mold at least a portion of the body of the article of footwear. The sheet conforms to the portion of the body of the article of footwear.

According to another aspect of the invention, an article of footwear for receiving a foot of a user is provided. The article of footwear includes a body comprising: a layer of material molded by flow; and a sheet provided during molding of the material layer and conforming thereto.

According to another aspect of the present invention, a skate boot for a skate is provided. The skate includes a skate device disposed beneath the skate boot to engage a skating surface. The skate boot is configured to receive a user's foot. The skate boot includes a body including a medial side portion that faces a medial side of a user's foot, a lateral side portion that faces a lateral side of the user's foot, a heel portion that receives a heel of the user's foot, and an ankle portion that receives an ankle of the user. The medial, lateral, heel and ankle portions of the body are molded together and integral with one another by the flow of material in a mold. The bodies do not have parting lines opposite each other.

According to another aspect of the invention, an article of footwear for receiving a foot of a user is provided. The article of footwear includes a body including a medial side portion that faces a medial side of a user's foot, a lateral side portion that faces a lateral side of the user's foot, a heel portion that receives a heel of the user's foot, and an ankle portion that receives an ankle of the user. The medial, lateral, heel and ankle portions of the body are molded together and integral with one another by the flow of material in a mold. The bodies do not have parting lines opposite each other.

These and other aspects of the invention will become apparent to those skilled in the art from the following description of the embodiments of the invention, which is to be read in connection with the accompanying drawings.

Drawings

The detailed description of embodiments of the present invention is provided below, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is an example of a skate for a skater in accordance with one embodiment of the present invention;

FIG. 2 is an exploded view of the skate;

FIG. 3 is a perspective view of the skate boot shell of the skate;

fig. 4 to 7 are a side view, a front view, a top view and a bottom view, respectively, of the housing of fig. 3;

FIG. 8 is a cross-sectional view of the housing taken along line 8-8 of FIG. 5;

FIGS. 9 and 10 are cross-sectional views of the housing taken along lines 9-9 and 10-10 of FIG. 4;

FIG. 11 is a block diagram showing a molding process for implementing the molding apparatus to form the shell of the skate boot;

FIG. 12 is a cross-sectional view of the housing showing a plurality of sub-housings of the housing, including inner, intermediate and outer sub-housings of the housing;

fig. 13 is an example of a last molding apparatus for forming a shell;

fig. 14 is a cross-sectional view of a last and a first female mold for producing a shell inner sub-shell;

FIG. 15 is a cross-sectional view of the last and second negative mold used to produce the middle sub-shell of the shell;

fig. 16 is a cross-sectional view of a last and a third female mold for producing a shell outer sub-shell;

FIGS. 17 and 18 are perspective cross-sectional views of the housing of FIG. 3 taken at different points along the length of the housing;

FIG. 19 is a cross-sectional view of the shell in one embodiment, wherein the shell includes design elements and reinforcements disposed between the middle and outer sub-shells;

FIGS. 20A and 20B are side views of the housing of the embodiment wherein the reinforcement includes ribs;

fig. 21A and 21B are side views of the shell in the example where the reinforcement comprises a reinforcement sheet;

FIG. 21C is a side view of a housing according to an embodiment, wherein the reinforcement includes a single fiber;

FIG. 22 is a conceptual illustration of material components flowing into a mold cavity to produce a synthetic polymeric material;

FIG. 23 is a perspective view of one embodiment in which the housing includes a cover layer;

FIG. 24 is a perspective view of the tongue of the skate;

FIG. 25 is a side view of a blade of the skate apparatus;

FIGS. 26A to 29 show different examples of embodiments in which the blade is secured to the blade holder of the skating device of the skate;

FIG. 30 is a side view of the housing in an embodiment wherein a limited portion of the cartridge is integrally molded with the housing;

FIGS. 31 and 32 are cross-sectional views of examples of securing a limited portion of a cartridge integrally molded with another portion of the housing and cartridge;

FIG. 33 is a cross-sectional view of a cartridge in an embodiment wherein the cartridge includes a blade detachment mechanism;

FIG. 34 is a side view of the blade of the skate;

FIG. 35 is a cross-sectional view of the blade taken along line 35-35 of FIG. 34;

FIG. 36 is a side elevational view of a skate with the toe cap, tongue, tendon guard, footbed and a pair of lace members integrally molded with the housing in one embodiment;

FIG. 37 is a side view of a skate with the shell of the skate being molded separately (i.e., separate from the skate's toe, tongue, tendon guard, footbed, and lace members) in one embodiment;

FIG. 38 is a side view of a skate with any one of the toe cap, tongue, tendon guard, footbed, and lace members integrally molded with the shell of the skate in one embodiment;

FIG. 39 is a cross-sectional view of the shell of the skate in one embodiment, wherein the shell is a one-piece shell (i.e., no subshells);

FIG. 40 is a cross-sectional view of a skate housing in one embodiment, wherein the housing includes a subshell;

41A, 41B, and 41C are cross-sectional views of the shell in an embodiment wherein at least one sub-shell includes an opening in a sole region of the shell;

figures 42, 43A and 43B are sectional views of the shell in an embodiment in which the footbed of the skate is integrally formed with the shell of the skate;

FIGS. 44A and 44B are cross-sectional views of the shell in an embodiment wherein the outer sub-shell of the shell and/or the inner sub-shell of the shell includes an opening in the sole region of the shell;

FIG. 45 is a cross-sectional view of the shell in an embodiment wherein the footbed of the skate is integrally formed with the shell and is in contact with an outer sub-shell of the shell;

FIG. 46 is a cross-sectional view of the shell in an embodiment wherein the footbed of the skate is an insert disposed between the stator shells of the shell;

FIGS. 47A and 47B are cross-sectional views of the housing in an embodiment in which a limited portion of the cartridge is integrally molded with the housing;

FIG. 48 is a sectional view of the shell in an embodiment in which the footbed of the skate is integrally formed with the shell;

FIG. 49 is a cross-sectional view of the housing in one embodiment, wherein the housing includes inner, middle and outer sub-housings and is molded separately from the cartridge;

FIG. 50 is a cross-sectional view of the housing in one embodiment, wherein the housing includes four sub-housings;

FIG. 51 is a cross-sectional view of the housing in an embodiment with the cartridge molded separately from the housing and affixed to the housing;

FIG. 52 is a cross-sectional view of the housing in an embodiment in which the cartridge is integrally molded with the housing with the middle sub-housing comprising the cartridge exposed;

FIG. 53 is a cross-sectional view of the housing in an embodiment in which the cartridge is integrally molded with the housing and a given sub-housing surrounds the cartridge rather than the housing;

FIG. 54 is an exploded view of the skate in one embodiment wherein the housing is molded separately from the blade carriage and other components of the skate, particularly the toe cap, tongue, tendon guard, footbed, and lace member of the skate;

FIG. 55 is a perspective view of a blade cartridge formed separately from the shell of a skate in one embodiment;

FIG. 56 is a top view of a cross section of the shell taken along an ankle portion of the shell;

figures 57A and 57B show top cross-sectional views of the ankle portion of the shell according to an embodiment in which the skate boot includes a stiffener including an extension;

fig. 58 and 59 show the following embodiments: wherein the extension connects a medial ankle side of the ankle portion to a lateral ankle side of the ankle portion forward of the ankle portion of the shell;

fig. 60 and 61 show the following examples: wherein the extension comprises a plurality of free ends that are movable relative to one another and converge toward one another;

fig. 62 shows an example of a variation: wherein the extension is located rearward of the ankle portion of the shell;

fig. 63 and 64 show the following examples: the reinforcement including two extensions, one of which is located rearward of the ankle portion of the shell;

FIG. 65 is an example of a variation: wherein the rear portion of the ankle portion includes an opening;

FIG. 66 is a perspective view of a skate housing in accordance with a variation wherein the reinforcement includes a lace member of the skate;

fig. 67 and 68 show different examples of housings according to the variant of fig. 66;

fig. 69 shows an example of a housing according to the variant of fig. 66: wherein the skate boot includes an extension;

FIG. 70 is a side view of the skate of FIG. 63;

fig. 71A and 71B show a side view and a front view of a skate according to another embodiment;

FIG. 72 shows an example of a test for determining the stiffness of a portion of a subcase;

FIG. 73 shows an example of an embodiment: wherein an outermost one of the sub-housings constitutes an outer surface of the housing and an outer surface of the cartridge;

FIG. 74 shows an example of a variation: wherein the cartridge is free of an opening extending from its exterior side to its interior side;

fig. 75 to 77 show an example of a variation: wherein the housing and/or cartridge comprises one or more inserts onto which the sub-housings are molded;

fig. 78A to 78C show other examples of the variation of fig. 75: wherein the insert forms a part of the housing;

fig. 79 shows an example of a variation: wherein one or more of the sub-shells comprise a filling portion composed of different materials;

FIGS. 80A to 80F show other examples of the variation of FIG. 79;

fig. 81 and 82 show an example of a variation: wherein a sheet is used in the moulding of the housing;

fig. 83 shows an example of a variation: wherein the skate includes a cutting guard;

FIG. 84 illustrates an example of a variation of the cutting guard of FIG. 83;

FIG. 85 shows a top view of a portion of the cutting guard of FIG. 83;

fig. 86A to 86D show an example of a variation: wherein the housing and/or cartridge and/or other components integrally formed with the housing are molded as separate components and then assembled together;

fig. 87 shows an example of a variation: wherein the cartridge includes an insert for receiving a blade;

fig. 88 shows an example of a variation: wherein the cartridge comprises a void;

fig. 89 shows an example of the variation: wherein the housing and/or blade holder and/or other components integrally formed with the housing include an opening configured to alter performance of the skate;

FIG. 90 shows an example of an embodiment: wherein the material of the given stator housing comprises a polymeric substance and an expansion agent;

FIG. 91: an example of the bulking agent of figure 90 is shown;

fig. 92 and 93 illustrate examples of lasts that form the shell in other embodiments;

fig. 94 to 105 show an example of a last for forming a shell in another embodiment;

fig. 106 to 110 show an example of a last for forming a shell in another embodiment;

fig. 111 to 115 show an example of a footwear last forming a shell in another embodiment;

fig. 116 and 117 show an example of a last for forming a shell in another embodiment;

fig. 118 and 119 show an example of a last for forming a shell in another embodiment;

fig. 120 to 122 show an example of an elastic female mold member in another embodiment;

fig. 123 shows an example of a variation: wherein the shoe is a ski boot;

FIG. 124 shows an example of a variation: wherein the shoe is a work shoe; and

figures 125 and 126 are side and front views of the right foot of the skater with the outer skin of the foot shown in phantom and the bones shown in solid lines.

In the drawings, embodiments of the invention are shown by way of example. It is to be expressly understood that the description and drawings are only for the purpose of illustration and as an aid to understanding, and are not intended as a definition of the limits of the invention.

Detailed Description

FIG. 1 shows an example of a wearer's shoe 10 in accordance with an embodiment of the present invention. In this example, shoe 10 is a skate for a skater to skate on a skating surface 12. In this embodiment, skate 10 is a hockey skate for a hockey player playing hockey. In this example, skate 10 is a skate shoe, the hockey ball played is ice hockey, and skating surface 12 is ice.

Skate 10 includes a skate boot 22 for receiving a player's foot 11 and a skate apparatus 28 disposed beneath the skate boot 22 to engage the skating surface 12. In this embodiment, the skate 28 includes a blade 26 for contacting the ice 12 and a blade holder 24 positioned between the skate shoe 22 and the blade 26. Skate 10 has a longitudinal direction, a transverse direction and a height direction.

In this embodiment, skate 10 includes at least a portion of a skate boot 22 and possibly at least a portion of one or more other components (e.g., blade holder 24) constructed of one or more materials (e.g., foam) that are molded by flowing in a molding apparatus during a molding process (e.g., injection molding or casting), as discussed further below. This may allow skate 10 to have useful performance characteristics (e.g., weight reduction, fit and comfort, etc.) while being more cost effective to manufacture.

The skate boot 22 defines a cavity 54 for receiving the player's foot 11. With additional reference to fig. 125 and 126, the player's foot 11 includes toes T, ball B, arch ARC, plantar surface PS, top surface TS, medial side MS, and lateral side LS. The top surface TS of the player 'S foot 11 is continuous with the lower portion of the player' S tibia S. In addition, the player has a heel HL, an achilles tendon AT, and an ankle a having a medial malleolus MM and a lateral malleolus LM located lower than the medial malleolus MM. The Achilles tendon AT has an upper portion UP and a lower portion LP that projects outwardly relative to the upper portion UP and merges with the heel HL. The forefoot of the player includes the toes T and forefoot B, the rearfoot of the player includes the heel HL, and the midfoot of the player is between the forefoot and rearfoot.

The skate 22 includes a forward portion 56 for receiving a player's toes T, a rearward portion 58 for receiving a player's heel HL and AT least a portion of the achilles tendon AT and ankle A, and an intermediate portion 60 located between the forward portion 56 and the rearward portion 58.

More specifically, in this embodiment, the skate 22 includes a shell 30, a toe cap 32, a tongue 34, a tendon guard 35, a liner 36, and a shoeA bed 38 and an insole 40. The skate 22 also includes lace members 44₁、44₂And an eyelet 46₁-46_ESaid eyelet 46₁-46_EExtend through (e.g., perforate) lace member 44 relative to aperture 48₁、44₂ Shell 30 and liner 36 to accommodate a shoe lace for attachment to skate 10. In some embodiments, the skate boot 22 may not include any lace members, and the eyelets 46_I-46_EMay extend directly through the shell 30 and liner 36 via the aperture 48.

Shell 30 is the body of skate boot 22 that imparts strength and structural integrity to skate 10 to support the foot 11 of the player. More specifically, in this embodiment, as shown in FIG. 3, the shell 30 includes a heel portion 62 for receiving a player's heel, an ankle portion 64 for receiving a player's ankle, medial and lateral portions 66, 68 that face the medial and lateral sides, respectively, of the player's foot 11, and a sole portion 69 that faces the plantar surface PS of the player's foot 11. Accordingly, shell 30 includes quarter portion 75, quarter portion 75 including a medial quarter portion 77, a lateral quarter portion 79, and a heel counter 81. The medial and lateral portions 66, 68 include upper edges 70, 72, and in this embodiment, the upper edges 70, 72 constitute the upper edges of the lace members 44. 44₂(i.e., lace members 44)₁、44₂Integral with the housing, as will be described later). The heel portion 62 may be formed in a substantially cup-shape to conform to the contour of the player's heel HL. Ankle portion 64 includes medial and lateral ankle sides 74, 76. The medial ankle side 74 has a medial concavity 78 for receiving the medial ankle of the player and the lateral ankle side 76 has a lateral concavity 80 for receiving the lateral ankle of the player. Lateral recess 80 is located slightly lower than medial recess 78 to conform to the topography of player's foot 11. Ankle portion 64 also includes a rear portion 82, and rear portion 82 faces lower portion LP of player Achilles tendon AT.

In this embodiment, with additional reference to fig. 11, the housing 30 includes one or more materials that are molded into the shape of the housing 30 by flow molding in a molding apparatus 150 during a molding process (e.g., injection molding or casting). More specifically, in this embodiment, the housingThe body 30 includes a plurality of materials M which are molded into the shape of the housing 30 by flow molding in the molding apparatus 150 in a molding process₁-M_N. Material M₁-M_NDifferent from each other, e.g., having different chemical properties and/or exhibiting substantially different values of one or more material properties (e.g., density, elastic modulus, hardness, etc.). In this example, material M₁-M_NArranged such that the housing 30 comprises a plurality of layers 85₁-85_LThe layers being made of corresponding materials M₁-M_NAnd (4) preparing. In this sense, the housing 30 may be referred to in this case as a "multi-layer" housing, with the layer 85 of the housing 30 being₁-85_LMay be referred to as a "sub-housing". This may allow skate 10 to have useful performance characteristics (e.g., weight reduction, fit and comfort, etc.) while being more cost effective to manufacture.

Material M₁-M_NMay be implemented in any suitable manner. In this embodiment, material M₁-M_NAre each a polymeric material. For example, in this embodiment, the polymeric material M₁-M_NIs a Polyurethane (PU). Any other suitable polymer (e.g., polypropylene, Ethylene Vinyl Acetate (EVA), nylon, polyester, vinyl, polyvinyl chloride, polycarbonate, polyethylene, ionomer resins (e.g.,

) Styrene-butadiene copolymers (e.g.,

) Etc.), a self-reinforced polypropylene composite (e.g.,

) Or any other thermoplastic or thermoset polymer).

In the example of this embodiment, the material M₁-M_NAre foams. In this case, the polymeric material M₁-M_NEach of which is a PU foam. This foamed appearance may allow the shell 30 to be relatively light while providing strength. For example, in some embodiments, the density of each polymeric material may be no more than 40 kilograms per cubic meter, in some cases no more than 30 kilograms per cubic meter, in some cases no more than 20 kilograms per cubic meter, in some cases no more than 15 kilograms per cubic meter, in some cases no more than 10 kilograms per cubic meter, and in some cases even lower. In other embodiment examples, polymeric material M₁-M_NOne or more of which may not be a foam.

In this embodiment, the sub-housing 85 of the housing 30₁-85_LMaterial M of₁-M_NWhich forms at least a portion of heel portion 62, ankle portion 64, medial and lateral portions 66, 68, and sole portion 69 of shell 30. More specifically, in this embodiment, the material M₁-M_NMaking up at least a majority (i.e., most or all) of the heel portion 62, ankle portion 64, medial and lateral portions 66, 68, and sole portion 69 of the shell 30. In this example, material M₁-M_NThe entire heel portion 62, ankle portion 64, medial and lateral portions 66, 68, and sole portion 69 of the shell 30 are formed.

From polymeric materials M₁-M_NFormed sub-housing 85₁-85_LMay have different properties for different purposes.

For example, in some cases, polymeric material M_xMay be compared with the polymeric material M_yIs harder so as to comprise the polymeric material M_xContains a polymeric material M_yThe sub-housing of (a) is harder. For example, comprising polymeric material M_xAnd the sub-shell comprises a polymer material M_yThe ratio of the stiffnesses of the subshells of (a) may be at least 1.5, in some cases at least 2, in some cases at least 2.5, in some cases 3, in some cases 4, in some cases even more.

In some cases, a given one of the sub-housings 85₁-85_LMay be configured to be larger than the other sub-housing 85₁-85_LIs harder. For example, to provide a given sub-shell with a higher stiffness than another, polymeric material M₁-M_NMay vary. For example, polymeric material M_xMay be greater than the hardness of the polymeric material M_yThe hardness of (2). For example, in some cases, polymeric material M_xHardness and polymeric material M_yMay be at least 1.5, in some cases at least 2, in some cases at least 2.5, in some cases at least 3, in some cases at least 4, in some cases at least 5, in some cases even more.

In order to observe the sub-housing 85_xAs shown in fig. 72, a sub-housing 85_xMay be in contact with the sub-housing 85_xIs separated (e.g., by cutting, or otherwise removed from the sub-housing 85)_xRemoving the portion, or producing the portion without producing the sub-housing 85_xThe remainder of the section) and a three-point bending test may be performed on the section to subject it to a load tending to bend the section in a particular manner (along a defined direction of the section if the section is anisotropic), to observe the stiffness of the section and measure a parameter representative of the stiffness of the section. For example, in some embodiments, the three-point bending test may be based on conditions defined in standard tests (e.g., ISO 178 (2010)).

For example, to view the sub-housing 85_xCan be performed to make the sub-housing 85 a three-point bending test_xSubjected to a load tending to bend the sub-housing 85x until the sub-housing 85_xTo a predetermined deflection and in the sub-housing 85_xThe bending load is measured at the predetermined deflection. Sub-housing 85_xMay be selected to correspond to the sub-housing 85_xIn the sub-housing 85_xA designated point (e.g., sub-housing 85)_xPoint of the inner surface of (a) of the substrate. For example, in some embodiments, the sub-housing 85_xMay be between 3% and 5%. Sub-housing 85_xCan be used to calculate the bending load at the sub-housing 85_xBending stress at the specified point of (a). Sub-shell85_xThe bending stress at the designated point of (a) may be calculated as σ My/l, where M is the bending load induced about the sub-housing 85_xY is the moment from the sub-housing 85_xTo the sub-housing 85_xI is with respect to the sub-housing 85_xOf the area of the neutral axis of (a). Sub-housing 85_xCan be regarded as the sub-housing 85_xBending stress at a predetermined strain (i.e., at a predetermined deflection). Alternatively, the sub-housing 85_xCan be used as the sub-housing 85_xBending load at a predetermined deflection.

Sub-housing 85₁-85_LMay be related to the modulus of elasticity (i.e., young's modulus) of the polymer material with which it is associated. For example, to provide a given sub-housing with greater rigidity than another sub-housing, the polymeric material M₁-M_NMay vary. For example, in some embodiments, polymeric material M_xMay be greater than the modulus of elasticity of the polymeric material M_yThe modulus of elasticity of (a). For example, in some cases, polymeric material M_xElastic modulus of (D) and polymeric material M_yThe ratio of the elastic moduli of (a) may be at least 1.5, in some cases at least 2, in some cases at least 2.5, in some cases at least 3, in some cases at least 4, in some cases at least 5, in some cases even more. In other embodiments, the ratio may have any other suitable value.

In some cases, a given one of the sub-housings 85₁-85_LMay be configured to be larger than the other sub-housing 85₁-85_LThe density is higher. For example, to provide a given sub-housing with a greater density than another sub-housing, the polymeric material M₁-M_NMay vary. For example, in some embodiments, polymeric material M_xMay be greater than the density of the polymeric material M_yThe density of (c). For example, in some cases, material M_xDensity and material M of_yMay be at least 1.1, in some cases at least 1.5, in some cases at least 2, in some cases at leastIn some cases at least 2.5, in some cases at least 3, in some cases even higher, at a certain value.

In this embodiment, as shown in FIG. 12, the sub-housing 85₁-85_LIncluding an inner sub-housing 85₁ Middle sub-housing 85₂And an outer sub-housing 85₃. Inner sub-housing 85₁Is "internal" in that it is the sub-housing 85₁-85_LThe innermost one. That is, inner sub-housing 85 is worn by the athlete wearing skate 10₁Closest to the foot 11 of the player. In a similar manner, the outer sub-housing 85₃Is "external" in that it is the sub-housing 85₁-85_LThe outermost one of them. That is, the outer sub-shell 85 is worn by the athlete wearing the skate 10₃Furthest from the foot 11 of the player. Intermediate sub-housing 85₂Disposed inside and outside the sub-housing 85₁、85₃In the meantime.

Inner, middle and outer sub-housings 85₁、85₂、85₃Comprising the respective polymeric material M₁、M₂、M₃. In this embodiment, the polymeric material M₁、M₂、M₃Having different material properties that impart the inner, intermediate and outer sub-housings 85₁、85₂、85₃Different characteristics. As a result, in some cases, the sub-housing 85₁、85₂、85₃A given one of the possible sub-housings 85₁、85₂、85₃The other of which is more impact resistant, the sub-housing 85₁、85₂、85₃A given one of the possible sub-housings 85₁、85₂、85₃Is more resistant to wear, and/or the sub-housing 85₁、85₂、85₃A given one of the possible sub-housings 85₁、85₂、85₃The other is denser.

For example, inner, middle and outer sub-housings 85₁、85₂、85₃The density of each of which may vary. For example, in the embodimentIn the illustrated embodiment, the inner, middle and outer sub-housings 85₁、85₂、85₃Is increased inwardly so that the inner sub-housing 85 is made to be₁Is denser than the intermediate sub-housing 85₂Density of, intermediate sub-housing 85₂Is denser than the outer sub-housing 85₃The density of (c). For example, the inner sub-housing 85₁May be about 30kg/m³And a middle sub-housing 85₂May be about 20kg/m³Outer sub-housing 85₃May be about 10kg/m³. In other embodiments, the inner, middle and outer sub-housings 85₁、85₂、85₃May have any other suitable value. In other embodiments, the inner, middle and outer sub-housings 85₁、85₂、85₃May be increased outwardly so that the outer sub-housing 85₃Is a sub-shell 85₁-85_LThe highest density. In other embodiments, the inner, middle and outer sub-housings 85₁、85₂、85₃The density of (b) may not be arranged in the order of increasing or decreasing density.

Further, in this embodiment, the inner, intermediate and outer sub-housings 85₁、85₂、85₃May vary. For example, in this embodiment, the inner sub-housing 85₁Is more rigid than the intermediate sub-housing 85₂And an outer sub-housing 85₃A respective stiffness of each.

Further, in this embodiment, the inner, intermediate and outer sub-housings 85₁、85₂、85₃May vary in thickness. For example, in this embodiment, the intermediate sub-housing 85₂Is thicker than the inner and outer sub-housings 85₁、85₃The respective thickness of each of them. For example, in some cases, the inner, middle and outer sub-housings 85₁、85₂、85₃Each of which has a thickness of 0.1mm to 25mm, and in some cases 0.5mm to 10 mm. For example, inner, middle and outer sub-housings 85₁、85₂、85₃Each of which isThe thickness of the seed may be no more than 30mm, in some cases no more than 25mm, in some cases no more than 15mm, in some cases no more than 10mm, in some cases no more than 5mm, in some cases no more than 1mm, in some cases no more than 0.5mm, in some cases no more than 0.1mm, and in some cases even less.

In order to provide the inner, intermediate and outer sub-housings 85 with different characteristics₁、85₂、85₃Inner, middle and outer sub-housings 85₁、85₂、85₃Of polymeric material M₁、M₂、M₃Different types of polymeric materials may be included. For example, in this example, the polymeric material M₁Comprising a generally soft and dense foam, a polymeric material M₂Comprising a specific polymeric material M₁Is more rigid than the foam of the polymeric material M and is more rigid than the polymeric material M₁Of a lower density structural foam, and a polymeric material M₃Is a material other than foam. For example, the outer sub-housing 85₃Of the polymer material M₃May consist of a transparent polymer coating.

In other embodiments, the sub-housing 85₁-85_LMay be constructed in a variety of other ways. For example, in other embodiments, the housing 30 may include a different number of sub-housings or no sub-housings. For example, in some embodiments, as shown in fig. 39, the housing 30 may be a single housing and therefore not include any sub-housings. In other embodiments, as shown in FIG. 40, the housing 30 may include two sub-housings 85₁-85_L。

Further, as shown in fig. 41A to 41C, when the housing 30 includes two sub-housings, particularly, the inner and outer sub-housings 85_INT、85_EXTWhen, if the outer sub-housing 85 is used_EXTIs denser than the inner sub-housing 85_INTGiven a sub-housing 85_INT、85_EXTThere may be an opening along at least a portion of sole portion 69 of shell 30 (e.g., along a majority of sole portion 69 of shell 30), which may be referred to as a gap. For example, as shown in FIG. 41A, in some embodimentsMiddle, outer sub-housing 85_EXTA gap G may be included at sole portion 69 of shell 30, such that inner and outer sub-shells 85_INT、85_EXTDo not overlap one another at sole portion 69 of shell 30 (i.e., inner sub-shell 85)_INTMay be the only subshell present at sole portion 69 of shell 30). As shown in fig. 41B, the outer sub-housing 85_EXTIn embodiments having a gap at sole portion 69 of shell 30, inner sub-shell 85INT may face outward at sole portion 69 of shell 30 toward outer sub-shell 85_EXTProtrude and fill the outer sub-housing 85_EXTSo that the inner sub-housing 85 is_INTIs greater at the sole portion 69 of the shell 30. As another example, as shown in FIG. 41C, the inner sub-housing 85_INTIn embodiments having a gap at sole portion 69 of shell 30, outer sub-shell 85_EXTMay face inwardly toward inner sub-shell 85 at sole portion 69 of shell 30_INTProtrudes and fills the inner sub-housing 85_INTSo that the outer sub-housing 85 is_EXTIs greater at the sole portion 69 of the shell 30. As shown in FIG. 42, the footbed 38 may be integrally formed with the shell 30 so as to at least partially cover the inner surface of the innermost sub-shell (in this case, the inner sub-shell 85)_INT) And covers sole portion 69 of shell 30. In other cases, the footbed 38 may be inserted separately after the molding process of the shell 30 is completed.

In some embodiments, as shown in FIGS. 44A and 44B, when the housing 30 includes three sub-housings, particularly inner, middle and outer sub-housings 85₁、85₂、85₃And an outer sub-housing 85₃Is denser than the intermediate sub-housing 85₂At density of (2), the outer sub-housing 85₃ A gap 61 may be included at sole portion 69 of shell 30, and an intermediate sub-shell 85₂May protrude into outer sub-shell 85 at sole portion 69 of shell 30₃In order to fill the outer sub-housing 85₃Of the gap 61. In such an embodiment, the intermediate sub-housing 85₂May have a greater thickness at sole portion 69 of shell 30.

In some embodiments, as shown in FIG. 50, a sub-housing 85 of the housing 30₁-85_LMay include four sub-housings 85₁、85₂、85₃、85₄。

In this embodiment, of polymeric material M₁-M_NFormed sub-housing 85₁-85_LAre integral with one another such that they comprise a unitary, one-piece construction. That is, from polymeric material M₁-M_NFormed sub-housing 85₁-85_LAre integrally connected to each other such that the housing 30 is a one-piece housing. In the example of this embodiment, this is achieved by means of the polymeric material M in the moulding device 150 during the moulding process₁-M_NChemical bonding of (2) the sub-shell 85₁-85_LAre realized in combination with each other.

During the molding process, the polymeric material M will be formed by the flow into the molding apparatus 150₁-M_NFormed sub-housing 85₁-85_LMolded into the shape of the housing 30. In this embodiment, the molding process includes polymerizing the polymeric material M₁-M_NFlows (i.e., in liquid or other fluid form) within the molding apparatus 150 to form the sub-housings 85 within the molding apparatus 150₁-85_LThereby forming the housing 30 and, once molding thereof is completed, retrieving the housing 30 from the molding apparatus 150.

In this embodiment, the molding process of casing 30 is injection molding, and molding apparatus 150 includes a male mold 152 (also commonly referred to as a "last"), with which male mold 152 all of polymeric material M is molded₁-M_NMolding to shape as shown in fig. 13. That is, in this example, last 152 is a single last, all of subshells 85 of shell 30₁-85_LAre formed from the single last. Molding apparatus 150 also includes a plurality of female molds 154₁-154_NEach female mold 154 is configured to receive last 152 at a different stage of the molding process. In this embodiment, each female mold 154 includes first and second portions 155, 157 that are secured together to receive last 152.

Reference will now be made in more detail to figures 14 to 16Described for molding a sub-housing 85 comprising an inner, middle and outer portion₁、85₂、85₃Examples of the method of the housing 30.

Referring additionally to FIG. 14, to mold the inner sub-housing 85₁With last 152 secured to first female mold 154₁To last 152 and first female mold 154₁Forming a mold cavity 156. The mold cavity 156 has the desired inner sub-shell 85₁The shape of (2). Mold cavity 156 is then passed through first female mold 154₁Injection port, runner and gate system (not shown) of (a) injecting the desired polymeric material M₁And allowed to cure. Once the polymeric material M is polymerized₁Has been cured for a sufficient time to form the inner sub-shell 85₁Opening the first female mold 154₁(i.e., separating first and second portions 155, 157 thereof from one another) and removed from molding apparatus 150 while last 152 remains on molding apparatus 150, inner sub-housing 85₁Still remaining thereon.

At this stage, with additional reference to FIG. 15, to form the intermediate sub-housing 85₂A second female mold 154 is formed₂Mounted on the molding apparatus 150. Last 152 is secured to second female mold 154₂Inside to inside the sub-housing 85₁(in some cases at least a portion of last 152) and a second female mold 154₂Forming a mold cavity 158. The mold cavity 158 has the desired intermediate sub-housing 85₂The shape of (2). Mold cavity 158 is then passed through second female mold 154₂Injection port, runner and gate system (not shown) of (a) injecting the desired polymeric material M₂And allowed to cure. Once the polymeric material M is polymerized₂Cured for a sufficient time to form the intermediate sub-housing 85₂Opening second female mold 154₂(i.e., separating first and second portions 155, 157 thereof from one another) and removed from molding apparatus 150 while last 152 remains on molding apparatus 150, inner sub-housing 85₁And a middle sub-housing 85₂Still remaining thereon.

With additional reference to FIG. 16, to form the outer sub-housing 85₃A third female mold 154 is placed₃Mounted on the molding apparatus 150. Last 152 is secured to third female mold 154₃In order to be inSpacer housing 85₂Form a mold cavity 160 (in some cases at least a portion of last 152, and in some cases, inner sub-shell 85) therebetween₁At least a portion of) and a third female mold 154₃. The mold cavity 160 has the desired outer sub-housing 85₃The shape of (2). Mold cavity 160 is then passed through third female mold 154₃Injection port, runner and gate system (not shown) of (a) injecting the desired polymeric material M₃And allowed to cure.

Once the polymeric material M is polymerized₃Cured for a time sufficient to form the outer sub-shell 85₃The housing 30, including its now formed inner, intermediate and outer sub-housings 85₁、85₂、85₃Demolded from last 152 (i.e., removed from last 152). This can be achieved in a number of ways.

For example, in some embodiments, inner, intermediate and outer sub-housings 85 are formed₁、85₂、85₃Of polymeric material M₁、M₂、M₃May be sufficiently resilient to allow an operator of the molding apparatus 150 to pass through the inner, intermediate and outer sub-housings 85₁、85₂、85₃Bending to remove shell 30 from last 152. In some cases, when the inner, middle and outer sub-housings 85 are used₁、85₂、85₃Can be removed from one last 152 when at least one given sub-shell in (b) is not fully cured, such that the shell 30 has some elasticity, otherwise, if the inner, middle and outer sub-shells 85 are not fully cured₁、85₂、85₃Is fully cured, it does not have this elasticity.

Moreover, in some embodiments, with additional reference to fig. 92-119, last 152 may be repeatedly configured to facilitate demolding (i.e., removing) shell 30 from last 152. That is, the configuration (e.g., shape) of last 152 may vary between a configuration of "molded" shell 30 that molds shell 30 onto last 152 and a "demolded" configuration that demolds shell 30 from last 152. Last 152 has a demolded configuration that is different than the molded configuration of last 152, and it is noted that in the demolded configuration of last 152, shell 30 demolds are easier than in the molded configuration of last 152 (e.g., removal of shell 30 from last 152 in its demolded configuration requires less force to be exerted on shell 30 than in its molded configuration, or removal of shell 30 from last 152 in its demolded configuration is easy, while preventing removal of shell 30 from last 152 in its molded configuration without damaging shell 30). For example, last 152 may be shrunk (i.e., reduced in size) in its demolded configuration relative to its molded configuration. Accordingly, removal of shell 30 from last 152 may be facilitated by holding shell 30 away from last 152 and/or holding and moving at least a portion of last 152 away from shell 30.

This is particularly useful for molding shell 30 over last 152, such that shell 30 has undercut 51₁-51₆I.e., a recess (e.g., dimple) or other recessed portion, which would otherwise complicate demolding of housing 30. For example, in this embodiment, the undercut 51₁、51₂Are medial and lateral recesses 78, 80 for receiving the medial and lateral malleoli MM, LM of the athlete, the undercut 51₃、51₄Is a concave part 83₁、83₂Recesses 831, 832 are defined by the curvature of heel portion 62 in the longitudinal and height directions of skate 10 and the curvature of heel portion 62 in the transverse direction of skate 10, such that heel portion 62 is substantially cup-shaped, undercut 51₅、51₆Is a recess 86₁、86₂Defined by the curvature of medial portion 66 and the curvature of lateral portion 68 in the longitudinal and height directions of skate 10 adjacent the player's forefoot. The housing 30 may have any other suitable undercut, such as undercut 51 in other embodiments₁-51₆。

In addition, this may facilitate demolding of shell 30 from last 152 without deforming shell 30. That is, once molding is completed, the shape of the shell 30 can be maintained during and at the time of demolding. In this example, this may be useful because the housing 30 is rigid (e.g., to avoid compressing the housing 30, etc.).

For example, in some embodiments, from its molded configuration to its demolded configuration, the volume occupied by last 152 may decrease such that the volume occupied by last 152 in its demolded configuration is less than the volume occupied by last 152 in its molded configuration.

In some embodiments, as shown in fig. 92, last 152 includes a cavity 163 for containing a fluid 167 to vary the volume occupied by last 152 by expanding and contracting last 152. For example, in some cases, last 152 may be an expandable last that may be expanded and contracted by controlling the fluid pressure within last 152. For example, expandable last 152 may be filled with fluid 167, which fluid 167 is air (or any other fluid) to expand expandable last 152 to a "molded" size to perform the molding process, and then the air is evacuated to contract expandable last 152 to a "demolded" size that is less than the molded size, and at which demolding of shell 30 from last 152 may be performed. Fluid 167 can be a liquid (e.g., water, oil, etc.) or any other suitable fluid.

As a variation, in some embodiments, as shown in FIG. 93, cavity 163 of last 152 may contain particles 169₁-169_PSuch as beads, particles, sand, or other grit, configured to change the rigidity of last 152 in response to the flow (i.e., into or out of) of fluid 167 relative to cavity 163 of last 152. For example, as fluid 167 flows out of chamber 167 (e.g., by vacuum), particles 169₁-169_PMay be hardened (i.e., increase the rigidity of last 152).

As another example, in some embodiments, as shown in Figs. 94-105, last 152 may include a plurality of last members 175₁-175_MThese last members 175₁-175_MAre movable relative to each other to change between their moulded and their demoulded configurations. Last member 175₁-175_MMay be considered a "module" of the last such that last 152 is a "modular" last. Last member 175₁-175_MIs shaped such that last member 175 is last member 175₁-175_MCollectively forming last member 152 into the shape thereof for molding in configuration thereofThe housing 30 is molded.

In this embodiment, last member 175 changes between its molded and demolded configurations as last 152 changes₁-175_MWhile remaining connected to each other. Last 152 includes a control system 187 to control last member 175₁-175_MMovement relative to each other. The control system 187 includes a linkage including a link 183 and an actuation mechanism 191₁-183_CConnecting rod 183₁-183_CConnecting adjacent last members 175₁-175_MSuch that they are movable relative to each other, the actuating mechanism 191 comprising a plurality of actuators 193₁-193₄Operable to position last member 175₁-175_MBetween the molded configuration of last 152 and the demolded configuration of last 152.

Adjacent last member 175₁-175_MMay be translated and/or rotated relative to one last member to change last member 152 between its molded configuration and its demolded configuration. That is, adjacent last member 175₁-175_M Last member 152 may be moved relative to one last member by translation, rotation, or a combination of translation and rotation to change between its molded configuration and its demolded configuration. For example, in this embodiment, linkage 181 includes a mechanism for positioning adjacent last members 175₁-175_MTranslation guides 193 translating relative to each other₁-193₄And for adjacent last members 175₁-175_M Pivot 197 that pivot relative to each other.

In this embodiment, last member 175₁Is a front central last member to form a portion of the front region of shell 30, including a central portion of toe cap 32 and a front central portion of sole portion 69 integrally formed with shell 30; last member 175₃Is a rear central last member to form a portion of a rear central region of shell 30, including a central portion of heel portion 62, a central portion of ankle portion 64, and a rear central portion of sole portion 69; shoe lastMember 175₂Is disposed at front central last member 175₁And a rear central last member 175₃Intermediate central last member therebetween to form an intermediate central portion of sole portion 69; and last member 175₄、175₄Are medial and lateral last members to form medial and lateral portions of heel portion 62, medial and lateral portions of ankle portion 64, medial and lateral portions of sole portion 69, medial and lateral portions of toe cap 32 integrally formed with shell 30, and medial and lateral portions 66, 68 of shell 30.

More specifically, in this embodiment, last member 175₁-175_MMovable relative to each other to change last 152 from its molded configuration to its demolded configuration by: (1) via translation guide 195₁、195₂Relative to front central last member 175₁And a rear central last member 175₃Translating intermediate central last member 175 upward₂(ii) a (2) Via relative to translation guide 195₁Inclined translation guide 195₂With intermediate central last member 1752 leading toward front central last member 175₁Translate forward such that front central last member 175₁And a rear central last member 175₃Closer to each other and rear central last member 175₃A heel portion 62 exiting the shell 30; (3) via translation guide 195₂Relative to front central last member 175₁Translating rear central last member 175 upward₃(ii) a (4) Front central last member 175₁Rear central last member 175₃And intermediate central last member 175₂Pivot together about pivots 197 such that front central last member 175₁Away from a central portion of the toe cap 32 integrally formed with the shell 30; and (5) medial and lateral last members 175₄、175₄Laterally translate toward one another to move away from medial and lateral portions of heel portion 62, medial and lateral portions of ankle portion 64, medial and lateral portions of sole portion 69, medial and lateral portions of toe cap 32 integrally formed with shell 30, and medial and lateral portions 66, 68 of shell 30,thereby leaving the entire shell 30 removable from last 152. Thus, the shell 30 can be molded and easily demolded, even with the undercut 51₁-51₆The same is true without deforming it during demoulding.

In one variation, in some embodiments, as shown in fig. 106-110, last member 175₁、175₂Movable relative to each other to change last 152 from its molded configuration to its demolded configuration by: (1) relative to last member 175₁Last member 175 that rotates to form heel portion 62 of shell 30₂To clear the heel portion 62 of the shell 30; and then rotate last member 175 together₁And last member 175₂To remove them from the housing 30.

In some embodiments, each last member 175 of last 152₁-175_MCan be moved relative to each other by disconnecting and separating them from each other. For example, one or more last members 175 of last 152 may be removed₁-175_MTo facilitate removal of shell 30 from last 152. In such embodiments, adjacent last members 175 are connected₁-175_MOne or more links 183₁-183_CAllowing these adjacent last members to be connected to one another in the molded configuration of last member 152 and disconnected and separated from one another in the demolded configuration of last member 152.

Last member 175₁-175_MAny suitable material may be included. In this embodiment, last member 175₁-175_MIs rigid. For example, last member 175₁-175_MMay be made of metal, rigid plastic, wood or any other suitable material.

In one variation, in some embodiments, as shown in fig. 111-115, last 152 includes base 199 and last member 175₃ Base 199 includes last members 175 movable relative to one another₁、175₂Last member 175₃Is a removable cover 179, i.e., a sheath, that covers the base 199 and is removable from the base 199. Tong (Chinese character of 'tong')By using a different sheath similar to sheath 179, sheath 179 can allow for the molding of differently sized or shaped housings 30 over 152, preventing polymeric material M from being polymerized during injection molding₁Leakage, and/or reduction or elimination of internal parting lines on the housing 30.

In this embodiment, the sheath 179 is resilient to facilitate its placement on the base 199 of the last 152 and subsequent removal thereof during molding, but is sufficiently strong to maintain its desired shape during molding of the shell 30. For example, in some embodiments, the sheath 179 can include an elastomeric material, such as silicone rubber or any other polymeric material having a suitable elasticity. For example, in some embodiments, the elastomeric material of the sheath 179 can have a hardness of 10 shore a to 99 shore a, or any other suitable value. This may create a sealing effect to prevent the polymeric material M from forming₁Leaks during the injection molding process. In addition, the sheath 179 can have a smooth outer surface that can reduce or eliminate internal parting lines on the shell 30.

Thus, in this embodiment, sheath 179 is placed over base 199 of last 152 for molding shell 30. The elasticity of the sheath 179 assists in this regard. Then, in order to demold shell 30, last member 175 is made₂Relative to last member 175₁And the sheath 179 moves to clear the front region of the sheath 179. In this example, last member 175₁Including cavity 171, and last member 175₂Can be rotated into cavity 171 to effectively move to last member 175₁Of the inner part of (a). Last member 175 is then placed₁And last member 175 located in cavity 171₂Moving up out of the sheath 179. The housing 30 may be removed by deforming the sheath 179 to extract the housing 30 therefrom. Alternatively, in some cases, sheath 179 may remain in housing 30 to become part of the skate boot 22 of skate 10.

In other embodiments, sheath 179 of last 152 may be implemented in various other ways.

For example, in some embodiments, the sheath 179 can include a reinforcement (e.g., a fabric layer (e.g., mesh), a thin metal layer, a plastic film, etc.) within its elastomeric material to reinforce it (e.g., prevent tearing).

As another example, in some embodiments, the sheath 179 can be injection molded using a thermoplastic material, such as polypropylene, polyethylene (e.g., high density polyethylene), or any other suitable material (e.g., having low surface adhesion).

As another example, in some embodiments, as shown in FIGS. 116 and 117, the thickness of the sheath 179 can be varied to define the undercut 51 of the housing 30₁-51₆While facilitating demolding of shell 30 from last 152. For example, in this embodiment, the sheath 179 is thicker at the location of the medial and lateral recesses 78, 80 of the housing 30 for accommodating the medial and lateral malleoli MM, LM of the player, the recess 83 defined by the curvature of the heel portion 62 in the longitudinal and height directions of the skate 10 and the curvature of the heel portion 62 in the transverse direction of the skate 10₁、83₂And a recess 86 defined by the curvature of the medial side portion 66 and the curvature of the lateral side portion 68 in the longitudinal and height directions of the skate 10 adjacent the player's forefoot₁、86₂. Further, in this embodiment, last member 175₁Shaped (e.g., straight or tapered downward) to be vertically movable during demolding, and to vertically move last member 175₁Thereafter, last member 175₂Is removable from the housing 30.

As another example, in some embodiments, the sheath 179 can be a film that is placed (e.g., wrapped) over the base 199 of the last 152.

As another example, in other embodiments, sheath 179 may be an air-impermeable sock that may be pulled over last 152 and removed from last 152.

In other embodiments, last member 175 is controlled₁-175_MThe control systems 187 for movement relative to each other may be implemented in any other suitable manner.

For example, in some embodiments, as shown in fig. 118 and 119, control system 187 may be configured to control last member 175₁、175₂Is moved so thatThe last 152 can be expanded to its molded configuration and contracted to its demolded configuration. In this embodiment, last member 175₁、175₂Connecting rod 183 therebetween₁-183_CIncluding central member 186 and arms 189₁-189_AArm 189₁-189_AExtends from central member 186 to last member 175₁、175₂Such that movement of the central member 186 in a given direction (e.g., downward) causes the arms 189₁-189_AThe member 175₁、175₂Push apart from each other to deploy last member 152 for molding shell 30, and movement of central member 186 in the opposite direction (e.g., upward) causes arms 189₁-189_AThe member 175₁、175₂Pulling toward one another to retract last 152 for demolding shell 30.

In other embodiments, last member 175₁-175_MMay be implemented in any other suitable manner. For example, in various embodiments, last member 175₁-175_MMay have any other suitable shape, may have any other suitable number of last members (e.g., two, three, four, six, seven, etc. last members), and last members 175₁-175_MMay be moved relative to one another in any other manner, etc. Moreover, in various embodiments, last member 175 of the various embodiments contemplated herein₁-175_MMay be combined in some embodiments.

Referring additionally to fig. 120-122, in some embodiments, a given one of the female dies 154₁-154₃May include a resilient female mold member 410, the female mold member 410 including an inner surface 414, the inner surface 414 constituting a given one of the female molds 154₁-154₃And is preformed to define a given one of the mold cavities 156, 158, wherein a given one of the polymeric materials M is present₁-M₃Is injection molded to mold a given one of the sub-housings 85₁-85₃So that the inner surface 414 produces a given one of the sub-housings 85₁-85₃Of the outer surface of (a). The resilient female mold member 410, also referred to as a "film," is configured to avoid forming at least one parting line on the shell 30 that would otherwise result from the female mold 154 in the absence of the film 410₁-154₃The portions 155, 157 of a given one result in the formation of a parting line.

For example, in this embodiment, film 410 is part of female mold 154 such that its inner surface 414 is preformed to define mold cavity 156 between itself and last 152, polymeric material M being injected in mold cavity 156₁To mold the sub-housing 85₁Such that the inner surface 414 forms the sub-housing 85₁Of the outer surface of (a).

Prior to placing the film 410 in the molding apparatus 150, the inner surface 414 of the film 410 is pre-formed such that it is shaped to define the mold cavity 156, thereby molding the sub-housing 85₁And produces a sub-housing 85₁Of the outer surface of (a). For example, the film 410 may be preformed in a separate mold in a previous operation.

When closing and opening the female mold 154₁While the film 410 is in the female mold 154₁Is elastic during movement and covers the female mould 154₁One or more spaces in which the portions 155, 157 move relative to each other. This may avoid the formation of one or more parting lines because the film 410 covers where the one or more parting lines were originally located.

In this embodiment, the film 410 extends continuously to form the female mold 154₁And forms at least a majority (i.e., most or all) of the inner surface of the sub-housing 85₁At least a majority of the outer surface of (a). More specifically, in this embodiment, membrane 410 includes medial and lateral portions 420, 422, an ankle portion 424, a heel portion 426, and a sole portion 428 that are integrally formed as a one-piece structure and continuous with one another. In this example, the membrane 410 is elastic and seamless (i.e., without any seams) at the rear of the heel portion 426 and the ankle portion 424, while the medial and lateral portions 420, 422 and the medial and lateral portions of the sole portion 428 may be separated from and movable relative to each other to allow the membrane 410 to close and open the female mold 154₁While in the female mold 154₁OfBending during the movement of the segments 155, 157.

Thus, in this embodiment, the membrane 410 is configured such that the sub-housing 85₁There may be no parting lines opposing each other (i.e., at the sub-housing 85)₁The opposite side of) the substrate. For example, in this embodiment, the sub-housing 85₁May have a parting line 263 (in this example, parting line 263 is located in the sub-housing 85₁Toe portion of) but without any parting line opposite parting line 263, i.e., at sub-housing 85₁The parting line is the sub-housing 85 due to the presence of the membrane 410 in this example₁The heel portion and the rear of the ankle portion).

In this embodiment, the membrane 410 may comprise an elastomeric material, such as silicone rubber, any other rubber, or any other polymeric material having suitable elasticity. For example, in some embodiments, the elastomeric material of membrane 410 may have a hardness of 10 shore a to 99 shore a, or any other suitable value.

In other embodiments, the membrane 410 of the molding device 150 may be implemented in a variety of other ways.

For example, in other embodiments, the membrane 410 may be elastic and seamless in other areas, and separable and movable elsewhere to allow the membrane 410 to close and open the female mold 154₁While in the female mold 154₁Is bent during the movement of the portions 155, 157. For example, in some embodiments, the membrane 410 may be elastic and seamless at the sole portion 428, while the medial and lateral portions of the ankle portion 424, the medial and lateral portions of the heel portion 426, and the medial and lateral portions 420, 422 may be separated from and movable relative to one another to allow the membrane 410 to close and open the negative mold 154₁While in the female mold 154₁Are bent during the movement of the portions 155, 157. In other embodiments, membrane 410 may be elastic and free of seams at the front, while the medial and lateral portions of ankle portion 424 of sole portion 428, the medial and lateral portions of heel portion 426, and the medial and lateral portions 420, 422 may be separated from and movable relative to each other to be in the area of the heel portionClosing and opening the female mold 154₁While allowing the film 410 to rest on the female mold 154₁Are bent during the movement of the portions 155, 157.

As another example, in some embodiments, the membrane 410 may include a reinforcement (e.g., a fabric layer (e.g., a mesh), a thin metal layer, a plastic film, etc.) within its elastomeric material to reinforce it (e.g., prevent tearing).

As another example, in some embodiments, the film 410 may be injection molded using a thermoplastic material such as polypropylene, polyethylene (e.g., high density polyethylene), or any other suitable material (e.g., having low surface adhesion).

As another example, in some embodiments, the membrane 410 may be incorporated into a material (e.g., polyurethane, epoxy or other polymeric material; aluminum, steel or other metallic material; cement; etc.) that is more rigid and stronger than it.

Although the molding process has been described as being performed on a single molding apparatus 150, in some embodiments, the molding process may utilize multiple molding apparatuses (e.g., molding stations), with each apparatus including a different female mold 154. In such an embodiment, at least one sub-housing 85 is still mounted₁Can be moved from one molding station to the next without removing the negative molds mounted on the various molding apparatuses. In some embodiments, the molding stations may be distributed horizontally (e.g., linearly and/or arranged in a carousel or other rotating or curvilinear fashion). In other embodiments, the molding stations may be distributed vertically, e.g., stacked vertically on top of each other, which may be more spatially efficient.

Referring additionally to fig. 19 and 20, in some embodiments, the housing 30 may include some sub-housings 85 disposed on the housing 30₁-85_LIn between, e.g. in the middle and outer sub-housings 85₂、85₃In the meantime. The reinforcement 115 is produced separately from the shell 30 and is configured to reinforce selected areas of the shell 30 (e.g., the inner and/or outer portions 66, 68 of the shell 30), for example, to make it stiffer or stiffer (e.g., to increase resistance to deflection or impact)). For the purpose of providing a middle and outer sub-housing 85₂、85₃Includes a reinforcing member 115 forming an intermediate sub-housing 85₂And then forming the outer sub-housing 85₃Previously, the reinforcement 115 was secured to the intermediate sub-housing 85₂Of the outer surface of (a). For example, the reinforcement 115 may be mechanically secured (e.g., stapled, stitched, etc.), glued (e.g., by an adhesive), ultrasonically bonded, or secured to the intermediate sub-housing 85in any other suitable manner₂Of the outer surface of (a).

The reinforcement 115 may be configured in any suitable manner. For example, as shown in fig. 20A, the reinforcement 115 may include a plurality of ribs 117₁-117_R(or a single rib 117)_i). When the reinforcing member 115 is fixed to the intermediate sub-housing 85₂When up, it is from the middle sub-housing 85₂Is projected outwardly. In addition, the rib 117₁-117_RMay extend over the housing 30 and/or the cartridge 24. As shown in FIG. 20B, in some embodiments, the ribs 117₁-117_RMay extend from the housing 30 to the cartridge 24. That is, the ribs 117₁-117_RWith a vertical extent spanning the cartridge 24 and the housing 30. In other examples, the ribs 117₁-117_RMay span blade holder 24, housing 30, and lace members 44₁、44₂. Further, in some cases, the ribs 117₁-117_RMay not all be disposed between the same sub-housings. For example, in some cases, the first ribs 117_iCan be provided in the middle and outer sub-housings 85₂、85₃And the second rib 117_jDisposed within and intermediate sub-housing 85₁、85₂In the meantime.

Alternatively, as shown in FIG. 21, the reinforcement 115 may include a middle sub-housing 85 similarly secured to₂For example glued thereto. In this embodiment, the reinforcing sheet 119 includes a rigidity and/or hardness ratio intermediate sub-housing 85₂Of polymeric material M₂Larger materials. For example, the reinforcement panel 119 may include a composite material including a thermoset material, a thermoplastic material, carbon fibers, and/or glass fibers. For example, the composite material may be a fiber-matrix composite material that includes a matrix having fibers embedded therein. The matrix may comprise any suitable polymeric resin, such as a thermoset polymeric material (e.g., polyester, vinyl ester, vinyl ether, polyurethane, epoxy, cyanate ester, etc.), a thermoplastic polymeric material (e.g., polyethylene, polypropylene, acrylic, polyetheretherketone, polyethylene terephthalate, polyvinyl chloride, polymethyl methacrylate, polycarbonate, acrylonitrile butadiene styrene, nylon, polyimide, polysulfone, polyamide-imide, self-reinforced polyphenylene oxide, etc.), or a thermoset-thermoplastic hybrid polymeric material. The fibers may be made of any suitable material, such as carbon fibers, polymer fibers, such as aramid fibers, boron fibers, glass fibers, ceramic fibers, and the like.

Further, in some embodiments, the reinforcing sheet 119 may comprise a fabric or textile material. For example, the reinforcing sheet 119 may comprise a fabric mesh, such as a nylon mesh or any other suitable fabric material. For example, the sub-housing 85 may be surrounded by a reinforcing plate 119_xI.e. the reinforcing plate 119 is provided at the sub-housing 85_xTo cover the sub-housing 85_xAt least a majority (i.e., a majority or all) of the outer surface of (a). In addition, the reinforcing plate 119 may be stacked on the sub-housing 85 to cover it_xUpper subsequent sub-housing 85_yAt least a majority of the inner surface. Thus, the reinforcement tab 119 may extend from the outer portion 66 to the inner portion 68 of the housing 30. In other cases, reinforcing sheet 119 may be disposed at a limited portion of shell 30 (e.g., only ankle portion 64 of shell 30).

In another example, as shown in fig. 21C, the reinforcement 115 may include a single fiber 111 rather than a woven mesh. The single fiber 111 is configured to exert tension on the shell 30 and/or other components of the skate boot 22. In particular, the tension of the single fiber 111 is transmitted to the housing 30, and thus its performance can be controlled.

In some embodiments, the sub-housing 85 of the housing 30₁-85_LMay include a plurality of reinforcements 115. For example, the rib 117_iCan be disposed in selected areas of the housing 30The stiffener 119 may be disposed in another selected area of the housing 30.

Further, in some embodiments, instead of or in addition to the reinforcement 115, the shell 30 may include trim pieces 121 (which may be referred to as design elements) that are disposed at certain sub-shells 85 of the shell 30₁-85_LAs shown in fig. 19, for example, are arranged in the middle and outer sub-housings 85₂、85₃In the meantime. The design element 121 constitutes an aesthetic element produced separately from the casing 30 and may be included in the casing 30 to achieve its aesthetic appearance. For example, the design element 121 may comprise a sheet of material with: one or more alphanumeric characters that may form text (e.g., words, information, etc.); one or more symbols (e.g., a logo, emblem, badge, etc.); one or more shapes or patterns; and/or one or more real or imaginary objects (e.g., a human, an animal, a vehicle, an imaginary or fictional human, or any other real or imaginary thing). In forming the intermediate sub-housing 85₂Thereafter and after forming the outer sub-housing 85₃Previously, the design element 121 was fixed to the intermediate sub-housing 85₂Of the outer surface of (a). For example, the design elements 121 may be mechanically secured (e.g., stapled, stitched, etc.), glued (e.g., by an adhesive), ultrasonically bonded, or secured to the intermediate sub-housing 85in any other suitable manner₂Of the outer surface of (a). Although a single design element 121 is depicted in fig. 19, the housing 30 may include a plurality of such design elements, which may be spaced apart from one another. Furthermore, in some cases, the reinforcement 115, which is spaced apart from the trim piece 121 depicted in fig. 19, may itself serve as a trim in addition to its reinforcing function.

Once the stiffener 115 (or stiffeners 115) and/or design element 121 (or design elements 121) have been secured to the intermediate sub-housing 85₂The molding process is performed as described above. Notably, the next sub-housing (in this case the outer sub-housing 85)₃) Formed to cover the reinforcement 115 and/or design element 121, thereby confining the reinforcement 115 and/or design element 121 to the middleHousing 85₂And an outer sub-housing 85₃In the meantime. In some embodiments, the outer sub-housing 85₃May be transparent (i.e., translucent) and may therefore allow passage through the outer sub-housing 85₃The reinforcement 115 and/or design elements 121 are shown. This may be particularly useful for display design elements 121, but may also be useful for displaying reinforcements 115 for aesthetic purposes.

In this embodiment, the molding process used to form the housing 30 is low pressure injection molding. That is, the sub-housing 85 is constituted₁-85_LOf polymeric material M₁-M_NIs injected under relatively low pressure into each mold 154_iIn the formed mold cavity. In addition, the molding process for forming the housing 30 may be characterized as a co-injection molding process, as the polymeric material M₁-M_NAre injected into the same mold.

In this embodiment, no external heat is applied to the polymeric material M of the housing 30₁-M_N. In contrast, in this embodiment, as shown in fig. 22, in order to form the sub-housing 85_iGiven a polymeric material M_xWhen combined, chemically react to release heat. In other words, two or more components react exothermically when combined. For example, in one example, material M_xIs a polyurethane and includes components 125, 127 that chemically react when combined. Components 125, 127 may be polyols and isocyanates. The exothermic chemical reaction characteristic of the molding process of shell 30 is in contrast to conventional methods involving thermoforming to form skate boots shells, which apply heat to a sheet of thermoformable material in a mold by thermoforming such that the sheet of thermoformable material takes the shape of the mold.

In other embodiments, the molding process of the housing 30 may be performed in any suitable manner. For example, in some embodiments, higher pressure injection molding may be used. As another example, in some embodiments, two or more lasts may be used, such as last 152 (e.g., different lasts for molding respective sub-housings 85)₁-85_L). Further, the last 152 may be configured differently than the last shown in fig. 13. For example, last 152 may not include a projection for forming hole 48, but rather one or more female molds 154₁-154_NSuch protrusions for forming the holes 48 may be included. In other cases, the protrusions on last 152 used to form holes 48 may be retractable. As another example, in some embodiments, the molding process of housing 30 may be casting, wherein polymeric material M is polymerized₁-M_NAre poured into one or more molds.

The skate boot 22 can include a covering layer 102 on the outer surface 65 of the shell 30 for aesthetic or functional purposes.

Referring additionally to FIG. 23, in this embodiment, the cover layer 102 includes a plurality of cover elements 104₁-104_o. Which may be provided at any suitable portion of the housing 30. For example, in some cases, the cover element 104₁-104_oMay be a graphic (e.g., a logo), brand name, pattern, word, etc. Although the cover member 104₁-104_oThe aesthetic appearance of skate 10 can be improved, but in some cases, some cover elements 104₁-104_oMay also be used for functional purposes. For example, in some cases, the cover element 104₁-104_oMay be configured to minimize wear of at least a portion of the outer surface 65 of the housing 30. For example, the cover member 104_xMay be located near the bottom of the inside and/or outside of the shell 30 to prevent contact between the skate surface 12 and the shell 30 of the skate boot 22. This helps reduce excessive wear on skate 10.

The cover layer 102 may be secured to the outer surface 65 of the housing 30 in a variety of ways. For example, each cover element 104₁-104_oMay be mechanically secured to the outer surface 65 of the housing 30 (e.g., by stitching, staples, etc.), bonded thereto by an adhesive, or ultrasonically bonded. Covering element 104₁-104_oMay be secured to the outer surface 65 of the housing 30 in any other suitable manner.

The lining 36 of the skate boot 22 is secured to the inner surface of the shell 30,and includes an inner surface 96 for facing, in use, the heel HL and medial and lateral sides MS, LS of the player's foot 11 and ankle a. The liner 36 may be made of a soft material (e.g., made of)

Fabric made of fibers or any other suitable fabric). The footbed 38 is mounted within the interior of the housing 30 and includes an upper surface 106 for receiving the plantar surface PS of the player's foot 11 and a wall 108 projecting upwardly from the upper surface 106 to partially cover the heel HL and extend to the midline of the player's foot 11. The insole 40 has an upper surface 25 intended to face the plantar surface PS of the player's foot 11 and a lower surface 23 to which the shell 30 can be fixed.

In some embodiments, the skate boot 22 may not include a liner 36. For example, the inner sub-shell 85 of the shell 30 of the skate 22₁May already be used as a liner and therefore the addition of liner 36 may be superfluous. In other cases, the liner 36 may be inserted during the molding process using the molding apparatus 150. For example, in forming the first sub-housing (i.e., the inner sub-housing 85)₁) Previously, the textile material may first be placed on last 152, for example as a preformed "sock", inner sub-shell 85₁Formed on the sock.

The toe cap 32 of the skate boot 22 is configured to face and protect the toes T of the athlete's foot 11. As will be described in greater detail below, in this example, at least a portion (i.e., part or all) of the toe cap 32 is integrally formed with the shell 30. As shown in fig. 6, 8 and 9, the toe cap 32 includes a bottom portion 116 for at least partially covering the front of the lower surface 23 of the insole 40, a lateral portion 118 for facing the little toe of the player's foot 11, a medial portion 120 for facing the big toe of the player's foot 11, an end 122 between the lateral portion 118 and the medial portion 120, an upper portion 124 for facing the top of the toes T of the player's foot 11, and a top extension 126 for securing the tongue 34 to the toe cap 32. The top extension 126 of the toe cap 32 may be secured (e.g., glued and/or sewn) to a distal portion of the tongue 34 to secure the tongue 34 to the toe cap 32.

The toe cap 32 canA synthetic material 105 is included that imparts stiffness to the toe cap 32. In various embodiments, for example, the composite material 105 of the toe cap 32 may comprise a nylon, polycarbonate material (e.g.,

) Polyurethane, thermoplastic, thermoset resin, reinforced thermoplastic, reinforced thermoset resin, polyethylene, polypropylene, high density polyethylene, or any other suitable material. In some cases, the composite material 105 of the toe cap 32 may be a composite material including thermoset materials, thermoplastic materials, carbon fibers, and/or glass fibers. For example, the composite material may be a fiber-matrix composite material that includes a matrix in which fibers are embedded. The matrix may comprise any suitable polymeric resin, such as a thermoset polymeric material (e.g., polyester, vinyl ester, vinyl ether, polyurethane, epoxy, cyanate ester, etc.), a thermoplastic polymeric material (e.g., polyethylene, polyurethane, polypropylene, acrylic, polyetheretherketone, polyethylene terephthalate, polyvinyl chloride, polymethyl methacrylate, polycarbonate, acrylonitrile butadiene styrene, nylon, polyimide, polysulfone, polyamide-imide, self-reinforced polyphenylene oxide, etc.), or a hybrid thermoset-thermoplastic polymeric material. The fibers may be made of any suitable material, such as carbon fibers, polymer fibers, such as aramid fibers, boron fibers, glass fibers, ceramic fibers, and the like.

A tongue 34 extends upwardly and rearwardly from the toe box 32 for covering a top surface TS of the player's foot 11. In this embodiment, with additional reference to FIG. 24, the tongue 34 includes a core 140 defining a section of the tongue 34 of increased stiffness, a cushioning member (not shown) for absorbing impact against the tongue 34, a perimeter member 144 for at least partially defining a perimeter 145 of the tongue 34, and a covering member 146 configured to at least partially define a front surface of the tongue 34. Tongue 34 defines a lateral portion 147 that covers a lateral portion of player's foot 11 and a medial portion 149 that covers a medial portion of player's foot 11. The tongue 34 also defines a distal portion 151 for securing to the toe cap 32 (e.g., by stitching) and a proximal portion 153 closest to the player' S tibia S.

The tendon protection device 35 extends upward from a rear portion 82 of the ankle portion 64 of the housing 30 to protect the player's achilles tendon. As will be described in more detail below, in this embodiment, at least a portion (i.e., part or all) of the tendon protection device 35 is integrally formed with the shell 30 of the skate boot 22. In other embodiments, the tendon protection device 35 may be a separate component from the housing 30 such that the tendon protection device 35 is fastened to the housing 30 by mechanical fasteners (e.g., by stitching, stapling, screws, etc.) or in any other suitable manner.

In other embodiments, the skate boot 22 can be configured in any other suitable manner. For example, in other embodiments, various components of the skate boot 22 mentioned above may be configured or omitted differently, and/or the skate boot 22 may include any other components that may be made of any other suitable material and/or using any other suitable process.

As shown in FIG. 25, the blade 26 includes an ice-contacting material 220, the ice-contacting material 220 including an ice-contacting surface 222 for sliding over an ice surface as the athlete skys. In this embodiment, the ice-contacting material 220 is a metallic material (e.g., stainless steel). In other embodiments, ice-contacting material 220 may be any other suitable material.

As shown in fig. 4, 5 and 7, the blade holder 24 includes a lower portion 162 and an upper portion 166, the lower portion 162 including a blade retention base 164 that retains the blade 26, and the upper portion 166 including a support 168 that extends upwardly from the blade retention base 164 toward the skate 22 to interconnect the blade holder 24 and the skate 22. The front portion 170 of the cartridge 24 and the rear portion 172 of the cartridge 24 define a longitudinal axis 174 of the cartridge 24. The front portion 170 of the cartridge 24 comprises the forward-most point 176 of the cartridge 24 and extends, in use, under the player's forefoot, while the rear portion 172 of the cartridge 24 comprises the rearward-most point 178 of the cartridge 24 and extends, in use, under the player's rearfoot. The middle portion 180 of the cartridge 24 is located between the front 170 and rear 172 portions of the cartridge 24 and extends, in use, along the underside of the player's midfoot. The cartridge 24 includes an inner side 182 and an outer side 184 opposite one another.

The blade retention base 164 is elongated in the longitudinal direction of the blade holder 24 and is configured to retain the blade 26 such that the blade 26 extends along a bottom 186 of the blade retention base 164 to contact the ice surface 12. To this end, the blade holding base 164 includes a blade holding portion 188 that faces and holds the blade 26. In this embodiment, as shown in fig. 26A, the blade holding portion 188 includes a recess 190, and an upper portion of the blade 26 is disposed in the recess 190.

Blade holder 24 may hold blades 26 in any suitable manner. For example, in this embodiment, the blade 26 may be permanently secured to the blade holder 24 (i.e., not intended to be detached and removed from the blade holder 24). For example, as shown in fig. 27, a blade 26 and a blade retention base 164 of a blade holder 24 may be mechanically interlocked by an interlocking portion 234 of one of the blade retention base 164 and the blade 26, the interlocking portion 234 extending into an interlocking void 236 of the other of the blade retention base 164 and the blade 26. For example, in some cases, blade 26 may be positioned in a mold used to mold blade holder 24 such that interlocking portions 234 of blade retention base 164 flow into interlocking voids 236 of blade 26 (i.e., blade holder 24 is overmolded onto blade 26) during the molding process. In some embodiments, as shown in fig. 26 and 28, blade holder 24 may use adhesive 226 and/or one or more fasteners 228 to hold blade 26. For example, in some embodiments, as shown in fig. 26, recess 190 of cartridge 24 may receive the upper portion of blade 26 held by adhesive 226. The adhesive 226 may be an epoxy-based adhesive, a polyurethane-based adhesive, or any suitable adhesive. In some embodiments, instead of or in addition to using an adhesive, as shown in fig. 29, the recess 190 of the blade holder 24 may receive an upper portion of the blade 26 that is held by one or more fasteners 228. Each fastener 228 may be a rivet, screw, bolt, or any other suitable mechanical fastener. In some embodiments, blade holder 24 may hold blade 26 by a press fit. For example, as shown in fig. 26B, the recess 190 of the blade holder 24 may be configured (e.g., sized) to press fit with the blade 26. More specifically, in the example of this embodiment, the blade 26 includes an elastomeric coating 237, the elastomeric coating 237 including an elastomeric material (e.g., polyurethane, rubber, or any other suitable elastomeric material) that forms at least a portion of an outer surface of the blade 26. The elastomeric coating 237 has a greater coefficient of friction than the ice-contacting material 220 of the blade 26 when interacting with the blade holder 24, thereby improving retention of the blade holder 24 to the blade 26 in a press fit. Alternatively or additionally, in some embodiments, as shown in fig. 28, the blade retention portion 188 of the blade holder 24 may extend into a recess 230 in an upper portion of the blade 26 to retain the blade 26 with an adhesive 226 and/or one or more fasteners 228. For example, in some cases, the blade retention portion 188 of the blade holder 24 may include a protrusion 232 that extends into a recess 230 of the blade 26.

In this embodiment, the blade retention base 164 includes a plurality of apertures 208 distributed longitudinally along the blade holder 24 and extending from the inner side 182 to the outer side 184 of the blade holder 24₁-208₄. In this example, the corresponding hole 208₁-208₄Are different in size. In other embodiments, the aperture 208₁-208₄May have any other suitable configuration or may be omitted.

In other embodiments, the blade retention base 164 may be configured in any other suitable manner.

The support 168 is configured to support the skate boot 22 above the blade retention base 164 and to transfer forces to and from the blade retention base 164 during skating. In this embodiment, the support 168 includes a front strut 210 and a rear strut 212, the front strut 210 and the rear strut 212 extending upwardly from the blade retaining base 164 toward the skate 22. The front strut 210 extends toward the front 56 of the skate 22 and the rear strut 212 extends toward the rear 58 of the skate 22. Blade retention base 164 extends from front post 210 to rear post 212. More specifically, in this embodiment, the blade retention base 164 includes a bridge 214 interconnecting the front and rear struts 210, 212.

In this embodiment, at least a portion (i.e., part or all) of the blade holder 24 is integrally formed with the shell 30 of the skate 22. That is, at least a portion of the blade holder 24 and the housing 30 of the skate boot 22 are formed as a unitary, one-piece structure. Accordingly, the blade holder 24 includes a portion 215 integrally formed with the housing 30 of the skate 22 such that the portion 215 of the blade holder 34 and the housing 30 of the skate 22 are integrally formed together in the molding apparatus 150 during the molding process.

In this embodiment, portion 215 of the blade holder 24 includes a sub-housing 85 of the housing 30 of one or more skate boots 22₁-85_LOf polymeric material M₁-M_N. For example, in this example, portion 215 of cartridge 24 includes middle and outer sub-housings 85₂、85₃And therefore includes a polymeric material M associated therewith₂、M₃. In particular, in this example, the majority of the cartridge 24 is made up of an intermediate sub-housing 85₂Of polymeric material M₂Constructed such that blade holder 24 is constructed primarily of structural foam material. Alternatively, portion 215 of cartridge 24 may comprise one or more different materials.

In this embodiment, at least a majority (i.e., most or all) of the cartridge 24 may be integrally formed with the housing 30. That is, portion 215 of cartridge 24 may be a substantial portion or the entirety of cartridge 24. In this embodiment, the cartridge 24 is integrally formed with the housing 30 in its entirety.

Thus, in this embodiment, cartridge 24 is formed with housing 30 in a molding apparatus 150 having a last 152. In particular, cartridge 24 is initially in the middle sub-housing 85 of housing 30₂And through the outer sub-housing 85 of the housing 30₃Is completed. That is, in this embodiment, as shown in fig. 73, the intermediate sub-housing 85₂Is the innermost sub-housing of the tool holder 24, while the outer sub-housing 85₃Is the outermost sub-housing of cartridge 24.

Further, in this embodiment, the blade 26 is included in a given mold 154_iAttaching the blade 26 to the blade holder 24 during the molding process such that the blade holder 24 overmolds the blade 26 during the molding process. For example, the mold 154_iMay be specially designed to form the intermediate sub-housing 85₂The blade 26 is retained during the previous molding process.

In this embodiment, one or more other components (e.g., toe cap 32, tendon protector 35, lace members 44)₁、44₂ Tongue 34, footbed 38, etc.) may be integrally molded with housing 30 in molding apparatus 150 during a molding process. These one or more other components of the shell 30 and the skate boot 22 can thus comprise a unitary, one-piece construction.

For example, in this embodiment, the toe cap 32, the tendon protection device 35, and the lace member 44₁、44₂Is integrally molded with the housing 30 in a molding apparatus 150 during a molding process.

For example, in this embodiment, the toe cap 32 includes a portion 217 that is integrally formed with the shell 30 such that the toe cap 32 portion 217 of the skate 22 and the shell 30 of the skate 22 are integrally formed together in the molding apparatus 150 during the molding process. Thus, the portion 217 of the toe cap 32 of the skate 22 can include the sub-housing 85 of the housing 30 of the skate boot 22₁-85_LOf one or more polymeric materials M₁-M_N。

In this embodiment, the portion 217 of the toe cap 32 comprises the sub-shell 85 of the shell 30 of the skate 22₁-85_LOf one or more polymeric materials M₁-M_N. For example, in this example, the portion 217 of the toe cap 32 includes the inner, middle and outer subshells 85₁、85₂、85₃And therefore comprises a polymeric material M associated therewith₁、M₂、M₃. Optionally, the portion 217 of the toe cap 32 may comprise one or more different materials.

Furthermore, in this embodiment the tendon protection 35 comprises a portion 219 which is integrally formed with the shell 30, so that during the moulding process the portion 219 of the tendon protection 35 of the skate boot 22 and the shell 30 of the skate boot 22 are integrally formed together in the moulding apparatus 150. Thus, the portion 219 of the tendon protector 35 of the skate 22 can include the sub-shell 85 of the shell 30 of the skate 22₁-85_LOf one or more polymeric materials M₁-M_N. For example, in this example, the portion 219 of the tendon protection device 35 comprises only the outer sub-housing 85₃And therefore includes the polymeric material M associated therewith₃. Alternatively, the portion 219 of the tendon protection device 35 may comprise one or more different materials. For example, in some embodiments, the portion 219 of the tendon protection device 219 may also include the inner sub-housing 85₁And/or the middle sub-housing 85₂Such that the portion 219 of the tendon protection device 35 also comprises a polymeric material M associated therewith₁And/or polymeric material M₂。

Further, in this embodiment, each lace member 44₁、44₂Includes a portion 221 formed integrally with the shell 30 so that each lace member 44 of the skate 22_i、44₂Is integrally formed with the housing 30 of skate 22 in molding apparatus 150 during the molding process. Thus, each lace member 44 of the skate 22_iMay comprise the sub-shell 85 of the shell 30 of the skate 22₁-85_LOf one or more polymeric materials M₁-M_N. For example, in this example, lace members 44_iIncludes only the outer sub-housing 85₃And therefore comprises a polymeric material M associated therewith₃. Alternatively, lace members 44_i Portion 221 may comprise one or more different materials. For example, in some embodiments, lace members 44_iMay also include an inner sub-housing 85₁And/or the middle sub-housing 85₂So that the lace members 44_iAlso included in part 221 is a polymeric material M associated therewith₁And/or polymeric material M₂. Further, in this embodiment, extends through lace members 44₁、44₂By a last 152 and associated female die 154 during the molding process_iFor example, a bump.

In other embodiments, skate 10 can be implemented in any other suitable manner.

For example, in some embodiments, as shown in fig. 30-32, only the limited features 225 of the cartridge 24 may be integrally formed with the housing 30. For example, in some embodiments, the feature 225 of the cartridge 24 may include a tab 227 that protrudes from an underside of the housing 30 to which another feature 229 of the cartridge 24 may be secured. As shown in fig. 31 and 32, the tab 227 of the component 225 of the cartridge 24 may be secured to another component 229 of the cartridge 24 by an adhesive 231 applied between the two parts 225, 229, or in some cases by a mechanical fastener (such as a nut and bolt assembly 233) that passes through the components 225, 229 to secure them together. In other embodiments, the components 225, 229 of the cartridge 24 may be secured to one another in any other suitable manner. In other embodiments, the major components of cartridge 24 may be integrally molded with housing 30. For example, in some cases, at least a majority of cartridge 24 may be molded with housing 30. In some cases, substantially the entirety of cartridge 24 may be integrally molded with housing 30.

For example, in some embodiments, cartridge 24 may hold blades 26 in any other suitable manner. For example, in other embodiments, as shown in fig. 33, cartridge 24 includes a blade detachment mechanism 192 such that blade 26 may be selectively detached and removed from cartridge 24, as well as attached to cartridge 24 (e.g., when blade 26 has worn or otherwise needs to be replaced or removed from cartridge 24).

More specifically, in this embodiment, the blade 26 includes a plurality of projections 194, 196. Blade separation mechanism 192 includes an actuator 198 and a biasing member 200 that biases actuator 198 in a direction toward front portion 170 of cartridge 24 with biasing member 200. In this embodiment, the actuator 198 comprises a trigger. To attach the blade 26 to the blade holder 24, the front protrusion 194 is first positioned within a hollow space 202 (e.g., a groove or hole) of the blade holder 24. The rear protrusion 196 may then be pushed upward into a hollow space 204 (e.g., a recess or aperture) of the blade holder 24, causing the biasing element 200 to flex and the actuator 198 to move rearward. The rear projection 196 will eventually reach the following position: this position will allow biasing element 200 to urge actuator 198 toward front 170 of cartridge 24, thereby locking blade 26 in place. Blade 26 may then be removed by pushing on finger actuation surface 206 of actuator 198 to release rear protrusion 196 from hollow space 204 of blade holder 24. Thus, in this embodiment, the blade detachment mechanism 192 does not have any threaded fasteners (e.g., screws or bolts) manipulated to detach and remove the blade 26 from the blade holder 24 or attach the blade 26 to the blade holder 24.

In some embodiments, more information about examples of embodiments of the blade separation mechanism 192 may be obtained from U.S. patent 8,454,030; said patent is incorporated herein by reference. In other embodiments, the blade separation mechanism 192 may be configured in any other suitable manner.

In other embodiments, blade 26 may be implemented in any other suitable manner. For example, in some embodiments, as shown in fig. 34 and 35, the blade 26 may include a flow channel 238, the flow channel 238 being made of the ice-contacting material 220, and including an ice-contacting surface 222 and a body 240 connected to the flow channel 238, the body 240 being made of a different material 242 than the ice-contacting material 220. Flow channel 238 and body 240 of blade 26 may be held together in any suitable manner. For example, in some cases, the flow channel 238 may be bonded to the body 240 with an adhesive. As another example, the flow passage 238 and the body 240 may be fastened using one or more fasteners (e.g., rivets, screws, bolts, etc.) in addition to or in lieu of bonding. As yet another example, the runner 238 and the body 240 can be mechanically interlocked (e.g., the body 240 can be overmolded onto the runner 238) by interlocking portions of one of the runner 238 and the body 240 that extend into interlocking spaces (e.g., one or more holes, one or more recesses, and/or one or more other hollow regions) of the other of the runner 238 and the body 240.

In some embodiments, one or more other components of the skate 22 (e.g., tongue 34, footbed 38, etc.) may be integrally molded with the shell 30 in the molding apparatus 150 during the molding process. Thus, the shell 30 and one or more of these other components of the skate 22 can be formed as a unitary, one-piece structure. Thus, a given part of the skate 22 can include a portion 235 that is integrally formed with the shell 30 such that the portion 235 of the given part of the skate 22 is integrally formed with the shell 30 of the skate 22 in the molding apparatus 150 during the molding process.

Thus, the portion 235 of a given component of the skate 22 can include the sub-shell 85 of the shell 30 of the skate 22₁-85_LOf the polymer material M₁-M_NOne or more of (a). For example, the portion 235 of a given component may include inner, intermediate, and outer sub-housings 85₁、85₂、85₃And thus may include a polymer material M associated therewith₁、M₂、M₃One or more of (a). Alternatively, portion 235 of a given component may comprise one or more different materials.

For example, in some embodiments, with additional reference to fig. 36, the toe cap 32, tongue 34, tendon guard 35, footbed 38, and lace member 44₁、44₂May be integrally molded with the shell 30 of the skate boot 22. That is, in the molding process, the toe cap 32, the tongue 34, the tendon guard 35, the footbed 38, and the lace members 44 are molded in the molding apparatus 150₁、44₂At least a portion (i.e., a portion or all) of each of which may be integrally formed with the housing 30.

As shown in FIG. 42, in some embodiments, one or more sub-housings 85 are provided when the footbed 38 is integrally formed with the housing 30 during the molding process₁-85_L A footbed 38 may be formed. Further, in some embodiments, as shown in fig. 43A, when the footbed 38 is integrally formed with the shell 30 during the molding process, a portion of the footbed 38 may protrude outward, for example, to fill a sub-shell 85in the sole portion 69 of the shell 30_iThe gap of (2).

In some embodiments, as shown in FIG. 45, when the footbed 38 is integrally formed with the shell 30 during the molding process, the footbed 38 may be configured to protrude outward, for example, to fill the interior and middle subshells 85in the sole portion 69 of the shell 30₁、85₂The respective gap.

In some embodiments, at least a portion (i.e., part or all) of cartridge 24 may be attached to a sub-housing 85 of housing 30₁-85_LIs given. For example, a portion of cartridge 24 may be attached to sub-housing 85 during formation of housing 30₁-85_LIs given. For example, as shown in fig. 47A, a portion of the cartridge 24 may be affixed to the inner sub-housing 85₁And may form intermediate and outer sub-housings 85 around a portion of cartridge 24₂、85₃。

In other embodiments, as described above, a portion of the cartridge 24 may be formed during molding of the housing 30. For example, as shown in fig. 47B, most or all of the cartridge 24 may be formed from an outer sub-housing 85₃And (4) forming. Further, the footbed 38 may be formed or affixed directly to a portion of the blade cartridge 24 (i.e., at an outer sub-housing 85 that makes up most or all of the blade cartridge 24)₃Above).

In some embodiments, as shown in FIG. 48, the footbed 38 may be integrally formed with the shell 30 so as to project outwardly into an inner sub-shell 85in the sole portion 69 of the shell 30₁In the gap of (a).

In some embodiments, as shown in fig. 52, when the blade holder 24 is integrally formed with the housing 30 during the molding process, portions of the blade holder 24 that are integrally formed with the housing 30 (e.g., a portion or the entirety of the blade holder 24) may be formed by the intermediate sub-housing 85₂Is constituted so that the intermediate sub-housing 85₂Exposed at the cartridge 24. In other embodiments, as shown in fig. 53, the sub-housing 85 when the cartridge 24 is integrally formed with the housing 30 during the molding process₁-85_LMay be formed to surround the cartridge 24. That is, the sub-housing 85₁-85_LA given one of the cartridges 24 may be formed around the cartridge rather than around the housing 30.

In some embodiments, and with additional reference to FIG. 54, the housing 30 and possibly one or more other components of the skate 22 may be manufactured separately from the blade holder 24, and the blade holder 24 may be manufactured separately and attached to the skate 22.

For example, in some embodiments, as shown in FIG. 37, the shell 30 of the skate boot 22 can be separately in the molding apparatus 150Formed, i.e. with the toe cap 32, tongue 34, tendon protector 35, footbed 38, and lace members 44₁、44₂Are formed separately. As shown in fig. 38, the toe cap 32, tongue 34, tendon protector 35, footbed 38, and lace member 44₁、44₂May be attached to the housing 30 after the housing 30 is formed. For example, toe cap 32, tongue 34, tendon guard 35, footbed 38, and lace members 44₁、44₂Any given one of which may be formed on the housing 30 in a separate molding process similar to that described above with respect to the housing 30. For example, toe cap 32, tongue 34, tendon guard 35, footbed 38, and lace members 44₁、44₂May be overmolded on the housing 30. In some cases, in another molding process (e.g., a thermoforming process), the toe cap 32, tongue 34, tendon protection device 35, footbed 38, and lace members 44₁、44₂A given one of which may be formed separately from the housing 30 and attached to the housing 30 by fasteners (e.g., stitching, stapling, etc.) or by gluing (e.g., using an adhesive).

In other embodiments, as shown in fig. 46, footbed 38 may be an insert that is placed within inner sub-shell 85 during formation of shell 30, for example, in a manner similar to that described above with respect to stiffener 115₁And a middle sub-housing 85₂Inter and/or inner sub-housings 85₁And an outer sub-housing 85₃In the meantime. In such an embodiment, the player's foot 11 does not directly contact the footbed 38, but the footbed 38 may still provide comfort to the player's foot 11 through interaction between the sub-housings.

As shown in fig. 49 and 51, in some embodiments, the cartridge 24 may be associated with inner, middle, and outer sub-housings 85 of the housing 30₁、85₂、85₃Are formed separately.

In such embodiments, where the housing 30 and possibly one or more other components of the skate 22 are manufactured separately from the blade holder 24, the skate 22 may include an outsole 42, as shown in FIG. 54. An outsole 42 is affixed to the bottom side of the shell 30 for forming the skate 22. The outsole 42 comprises a rigid material for imparting rigidity to the outsole 42. More specifically, in this embodiment, the rigid material of the outsole 42 comprises a composite material. For example, the composite material may be a fiber-matrix composite material that includes a matrix in which fibers are embedded. The matrix may comprise any suitable polymer resin, such as a thermoset polymer material (e.g., polyester, vinyl ester, vinyl ether, polyurethane, epoxy, cyanate ester, etc.), a thermoplastic polymer material (e.g., polyethylene, polypropylene, acrylic, polyetheretherketone, polyethylene terephthalate, polyvinyl chloride, polymethyl methacrylate, polycarbonate, acrylonitrile-butadiene-styrene copolymer, nylon, polyimide, polysulfone, polyamide-imide, self-reinforced polyphenylene oxide, etc.), or a hybrid thermoset-thermoplastic polymer material. The fibers may be made of any suitable material, for example, carbon fibers, polymer fibers such as aramid fibers, boron fibers, glass fibers, ceramic fibers, and the like. In other embodiments, the rigid material may include any other suitable material (e.g., nylon, polycarbonate material, polyurethane, thermoplastic, thermoset resin, reinforced thermoplastic, reinforced thermoset resin, polyethylene, polypropylene, high density polyethylene).

Further, in such embodiments where the skate 22 and blade holder 24 are manufactured separately, the support 168 of the blade holder 24 and the skate 22 may be affixed to one another in any suitable manner. For example, in some embodiments, as shown in FIG. 55, the front strut 210 and the rear strut 212 are fastened to the skate boot 22 by fasteners (e.g., rivets, screws, bolts). In this example, each of the front and rear struts 210, 212 includes a flange 216, and the flange 216 includes a plurality of apertures 218₁-218_FTo accommodate fasteners that fasten the blade holder 24 to the skate boot 22. In other embodiments, the support 168 may be secured to the skate boot 22 in any other suitable manner (e.g., by an adhesive).

In some embodiments, the skate boot 22 may include a reinforcement member 270 integrally molded with the shell 30 to enhance the torsional strength of the skate boot 22 and/or to protect the player's foot 11 from impact (e.g., from a hockey stick or hockey stick on ice).

For example, the reinforcing member 270 may include an extension 272 that extends in the longitudinal direction of skate 10 beyond the ankle portion 64 of the shell 30 of skate boot 22. In contrast, fig. 56 shows a conventional configuration of housing 30 without reinforcement 270 and therefore without extension 272. As shown, in such conventional configurations, no portion of the housing extends longitudinally of the skate beyond ankle portion 64 of housing 30.

Referring additionally to fig. 57A and 57B, extension 272 may be located forward of ankle portion 64 of housing 30 in the longitudinal direction of skate 10. In this way, the extension 272 may be configured to protect the front of the player's ankle a and the top surface TS of the player's foot 11. Extension 272 may extend in front of ankle portion 64 of shell 30 to varying degrees. For example, as shown in FIG. 57B, the extension 272 may extend from the medial ankle side 74 of the ankle portion 64 of the shell 30 and wrap around the athlete's ankle A such that the extension 272 passes from the medial half 278 of the skate 22 across a centerline 274 that generally bisects the width of the skate 22 and into the lateral half 280 of the skate 22. In some cases, as shown in FIG. 57A, the extension 272 may be shorter and extend forward from the medial ankle side 74 of the ankle portion 64 of the shell 30 and wrap around a portion of the player's foot 11, but not straddle the lateral half 280 of the skate boot 22. Alternatively, in some cases, extension 272 may extend from lateral ankle side 76 of ankle portion 64 of shell 30 rather than medial ankle side 74.

In one example of this variation, as shown in fig. 58, extension 272 may connect medial ankle side 74 of ankle portion 64 of shell 30 to lateral ankle side 76 of ankle portion 64 of shell 30 in a direction forward of ankle portion 64 of shell 30. In other words, the extension 272 may be configured such that the shell 30 wraps around the front and rear of the player's ankle a. In this manner, shell 30 may be continuously present in the area forward of ankle portion 64 of shell 30, and thus may lack an opening in which tongue 34 of skate boot 22 would normally be located. Thus, in such embodiments, the skate 22 may not include the tongue 34 or lacesComponent 44₁、44₂. In addition, the extension 272 may generate a gap 275 (i.e., a space) between the extension 272 and the player's foot 11 in the longitudinal direction of the skate 10 to facilitate movement (e.g., bending) of the ankle a while skating. In other embodiments, as shown in fig. 59, extension 272 may be configured to wrap around the player's foot 11 such that there is substantially no gap between extension 272 and the player's foot 11 in the longitudinal direction of skate 10.

In some embodiments, extension 272 may include a plurality of free ends 276 that are movable relative to one another and converge toward one another₁、276₂. In some embodiments, as shown in FIG. 60, the free end 276 of the extension 272₁、276₂May meet in front of ankle portion 64 of shell 30. For example, the free end 276₁、276₂May converge symmetrically about a centerline 274 of skate 10. In other embodiments, the free end 276₁、276₂May meet in either the medial 278 or lateral 280 halves of the skate boot 22. Although FIG. 60 shows the free end 276₁、276₂At the foot 11 and free end 276 of the player in the longitudinal direction of skate 10₁、276₂Leaving a gap 275 therebetween, but in some embodiments, a free end 276₁、276₂May be relatively close to the player's foot 11 such that the player's foot 11 and the free end 276₁、276₂There is substantially no gap therebetween.

In some embodiments, each free end 276 of extension 272_iCan include in the longitudinal direction of skate 10 and free end 276_iAnd another overlapping portion 282. For example, as shown in FIG. 61, each free end 276_iMay be the free end 276_iWhich faces rearward toward the ankle a of the player.

In one variation, extension 272 may be in rear portion 82 of ankle portion 64 of shell 30. For example, as shown in fig. 62, extension 62 may be configured such that gap 275 is between the rear of the player's ankle a and extension 272. In some cases, increaseThe strength members 270 may include more than one extension. For example, with additional reference to FIGS. 63, 64, and 70, the skate boot 22 can include a first extension 272 that extends forward of the ankle portion 64 of the shell 30 and a second extension 284 that extends rearward of the ankle portion 64 of the shell 30. In some embodiments, as shown in fig. 63, the second extension 284 may include a free end 276₁、276₂So that the free end 276₁、276₂Extending rearward of ankle portion 64 of shell 30.

In some examples of this variation, in which the extensions 272, 284 of the skate boot 22 extend rearward of the ankle portion 64 of the shell 30, the tendon guard 35 may be omitted to provide additional flexibility in skating.

In another variation, the reinforcement member 270 may include the lace member 44 of the skate boot 22₁、44₂. That is, lace members 44₁、44₂May be configured to increase the torsional strength of the skate 22 and/or to protect the athlete's foot 11 from impact. For example, as shown in FIGS. 66-68, lace members 44 extending in a given one of a medial half 278 and a lateral half 280 of the skate 22₁、44₂A given one of which may pass over the other of the medial 278 and lateral 280 halves of the skate boot 22. Lace members 44₁、44₂May be generally parallel to the lace members 44₁、44₂Given one of the defined directions. This may be defined as a "twisted" configuration of the skate boot 22.

As shown in FIG. 69, in some examples of the twisted configuration of the skate boot 22, the reinforcement member 270 can also include an extension 272. For example, extension 272 can extend in the forward direction of the player's ankle a from medial ankle side 74 to lateral ankle side 76 of ankle portion 64 of housing 30 such that a gap 275 exists between extension 272 and the player's foot 11 in the longitudinal direction of skate 10.

The twisted configuration of the skate boot 22 can increase the torsional stiffness and frontal impact protection of the skate boot 22, and thus can allow the shell 30 and/or other components of the skate boot 22 (e.g., the toe cap 32) to be reduced in thickness as compared to conventional skate boots in which the lace members are confined in a single one of the medial or lateral halves of the skate without the twisted configuration. In addition, the twisted configuration of the skate 22 may allow the skate 22 to bend in different directions as compared to conventional skate boots. For example, the twisted configuration of the skate boot 22 can allow the athlete to flex the skate boot 22 in the middle half 278 of the skate boot 22 in the area around the toe box 32. As a result, the twisted configuration of the skate boot 22 may allow for better retention of the athlete's energy used to propel himself/herself on the ice 12.

In another variation, with additional reference to fig. 65, stiffener 270 may include an opening 285 in rear portion 82 of ankle portion 64 of shell 30. The openings 285 may extend vertically for a majority of the height of the skate boot 22. For example, in some cases, the ratio of the height of the opening 285 to the height of the skate boot 22 can be at least 0.3, in some cases at least 0.4, in some cases at least 0.5, in some cases at least 0.6, and in some cases even greater.

In another variation, referring to fig. 74, the cartridge 24 may be configured such that there is no space between the front post 210 and the rear post 212. In such a variation, the support 168 of the cartridge 24 includes a "single" post 213 that is constructed of a material that extends from the front 170 of the cartridge 24 to the rear 172 of the cartridge 24. Specifically, in this example, the blade holder 24 does not have any opening extending from its outer side to its inner side.

In another variation, the housing 30 and/or the blade holder 24 and/or another component of the skate boot 22 integrally formed with the housing 30 may include one or more inserts 315₁-315_NOne or more sub-housings 85₁-85_LMay be molded onto the insert. For example, as shown in fig. 75, in this example, cartridge 24 includes a front insert 315 that forms part of front post 210 and rear post 212, respectively₁And rear insert 315₂. More specifically, in the example of this embodiment, the front insert 315₁And rear insert 315₂ Front posts 210 and 168 of support 168 that make up cartridge 24At least a majority (i.e., a majority or an entirety) of the rear strut 212. In this example, the front insert 315 is molded during the molding of the housing 30₁And rear insert 315₂Is affixed to the housing 30 to integrate the cartridge 24 with the housing 30. For example, once a given number of sub-housings 85 are molded₁-85_LThen front insert 315 is inserted₁And rear insert 315₂Attached to the formed sub-housing 85₁-85_L(e.g., by gluing, taping, or any other suitable means) and one or more other sub-housings 85₁-85_L(in this case the outer sub-housing 85)₃Is molded on front insert 315₁And rear insert 315₂And the sub-housing 85 formed₁-85_LSo as to form a continuous sub-housing 85 extending from the housing 30 to the cartridge 24₃). In other instances, as shown in fig. 76, cartridge 24 may include an insert 315₁、315₂Of (e.g., front insert 315 only)₁Or only the rear insert 315₂)。

In other examples, insert 315₁-315_NMay not be part of cartridge 24 but may instead form part of housing 30. For example, as shown in FIG. 78A, in this example, the housing 30 includes a sub-housing 85 disposed in the housing₁-85_LGiven the insert 315 between the sub-housings_M. For example, insert 315_MCan be arranged in the middle sub-housing 85₂So that the outer sub-housing 85₃May be molded into insert 315_MAnd a middle sub-housing 85₂The above. Insert 315_MMay be provided at any portion of the housing 30. In this example, the insert 315_MAt the middle portion of the shell 30 corresponding to the middle portion 68 of the skate boot 22. Specifically, insert 315_MIs arranged to extend, for example, from an outer portion 66 of the housing 30 to an inner portion 68 of the housing 30 and to surround the housing 30 below a bottom 69 thereof. As shown in FIG. 78B, insert 315_MMay extend to different heights on the inner portion 66 and the outer portion 68 of the housing 30. In some cases, the insertInsert 315_MMay extend substantially the entire height of each of the inboard portion 66 and the outboard portion 68. As shown in FIG. 78C, in some cases, insert 315_MMay not extend to the outer and inner portions 66, 68 of the housing 30, but may be limited to being disposed below the bottom 69 of the housing 30.

In this example, the insert 315₁-315_NIncluding foam materials. Specifically, insert 315₁-315_NHas a density less than that of the outer sub-housing 85₃The density of (c). This may help to reduce the weight of skate 10.

In another variation, as shown in FIG. 79, a given sub-housing 85_x(or more than one sub-housing) may include one or more fill portions 415₁-415_NComposed of a sub-shell 85_xMaterial M of_xDifferent materials M_zAnd (4) preparing. Fill portion 415₁-415_NForm another sub-housing 85_yIs formed to fill the given stator housing 85_xIs a portion of the void in (a). Thus, the filling part 415 can be considered as₁-415_NIs "inserted" into the sub-housing 85_xAnd may therefore be referred to as an "insert". To realize the insert 415₁-415_NFirst, the sub-housing 85 is put in place_xMolded to include voids. This can be achieved in a number of ways. For example, by being mounted in the sub-housing 85_xDuring molding of (2) placing the mold insert in a mold to form the sub-housing 85_xThe voids of (a). Once the sub-housing 85 is installed_xAfter demolding, the mold insert is removed, thereby leaving the sub-housing 85_xLeaving voids in it. Alternatively or additionally, the sub-housing 85 may be removed (e.g., cut away) by_xTo form a gap to form the sub-housing 85_xThe voids of (a). The sub-housing 85, now including voids, will then be_xReinserting into the corresponding mold and injecting the material M_zTo fill the sub-housing 85_xEffectively forming a sub-housing 85 comprising different materials_x. This having desired characteristics for the tool at the selected locationAlternative material replaces the sub-housing 85_xTo change the sub-housing 85_xMay be useful. For example, material M_zMay have a sub-housing 85_xMaterial M of_xIs different (e.g., greater or less) in density. In this example, material M_zComparator housing 85_xMaterial M of_xIs harder. Furthermore, material M_zMay have a sub-housing 85_xMaterial M of_xIs different (e.g., greater than or less than) the density of (a). In this example, material M_zDensity ratio of (2) to the sub-housing 85_xMaterial M of_xThe density of (a) is greater. Specifically, insert 415₁-415_NThe torsional characteristics of the skate boot 22 can be altered so as to interact with the sub-housing 85_xDoes not include inserts 415₁-415_NThe skate boot 22 responds differently to torsional forces than it does.

Insert 415₁-415_NAnd thus may be distributed to achieve the desired performance of the skate boot 22. For example, fig. 80A-80F illustrate an insert 415₁-415_NDifferent possible distributions of. It should be understood that in other embodiments, the insert 415₁-415_NMay be located in different locations.

In some cases, the sub-housing 85 may not be filled_xInstead of filling the void. This may alter the torsional characteristics of the skate 22. For example, as shown in FIG. 89, in the sub-housing 85_xThe remaining void therein may form an opening 550, and the opening 550 may extend to an edge of the shell 30, such as an outside edge 45 or an inside edge 47 of the shell 30. The opening 550 includes opposing edges 551, 552 that converge proximally toward one another and are distally spaced apart from one another. In some cases, the altered torsional behavior of the skate boot 22 by the opening 550 may allow the opposing edges 551, 552 to distally contact each other. The act of contacting one another may restrict the movement of the housing 30 allowed by the opening 550, otherwise, without the opening 550, it may not be possible to restrict the movement of the housing 30.

In another variation, referring to FIGS. 81 and 82, the molding process of the shell 30 (and other components made integral with the shell 30) may include the use of a sheet 615 (e.g., a film) that facilitates the molding process and/or facilitates the addition of aesthetic features (e.g., design) to the skate boot 22. In this embodiment, sheet 615 is a polymer sheet that includes a polymer material such as polycarbonate, polypropylene, polyethylene, or any other suitable polymer material. Further, in this example, the sheet 615 is a transparent sheet (e.g., transparent or translucent) through which a person can view. In other examples, sheet 615 may be opaque, colored (e.g., black, white, or any other color), partially transparent, homogenous, and/or have different arrangements in different areas.

In one example, the sheet 615 covers one or more of the shaped sub-housings 85₁-85_LE.g. to obtain a bottom subshell 85_xE.g., by thermoforming sheet 615). In this example, sheet 615 is in at least a majority of sub-housing 85_xExtend within the range of (a). In some cases, the sheet 615 may be over substantially the entire sub-housing 85_xExtending over the entire range. The sheet 615 may then be sealed (e.g., heat sealed) to form a seam 617. The female mold 154 is then placed_xMounted in a shaped sub-housing 85₁-85_LAnd the subsequent sub-housing 85 is_yMaterial M of_yInjected in the plate 615 and the sub-housing 85 underneath_xIn the meantime. Once the sub-housing 85 is installed_yCuring to a desired amount, the sub-housing 85_yAnd released from the mold 154. Sheet 615 may allow for the sub-housing 85_yFaster than when no sheet is used. Notably, sheet 615 is on material M_yAnd a female mold 154_xMay allow for faster removal of the sub-housing 85 therefrom_yThe reason is the sub-housing 85_yCan be on the material M_yCan be removed from the mold 154 without having to perform its complete polymerization_xAnd (5) removing. Conversely, if no sheet is used in the molding process, the sub-housing 85 is removed from the mold 154x in advance_yThe sub-housing 85 may be damaged_yFor example, it may deform. In addition, the material M is formed_yAnd a female mold 154_xWith sheet 615 in between, the molding process may not need to be at mold 154_xIs added with a release agent, which is usually included to facilitate release. Thus, the presence of the sheet 615 facilitates the sub-housing 85₁-85_LFrom female mold 154 without the use of a mold release agent_xAnd (6) demolding. This may also reduce the sub-housing 85_yBecause the release agent, although useful, is prone to introduce defects in the molded product. Furthermore, if fewer defects are formed, this may improve subsequent sub-housings 85_z(molded in the sub-housing 85)_yUpper) and a sub-housing 85_yBonding between them.

Once the sub-housing 85 is installed_yAs molded, the sheet 615 may be discarded and a new sheet 615 may be used in a similar manner to mold subsequent sub-housings (if any). Because of the relatively low cost of the sheet 615, the use of the sheet 615 in the molding process may inexpensively enhance the sub-housing 85 formed thereby₁-85_LThe quality of (c).

In another example, sheet 615 may not be discarded after molding. Instead, as shown in FIG. 82, the sheet 615 may be affixed to the housing 30, e.g., integrally forming the sub-housing 85₁-85_LGiven the layers between the sub-housings. In this example, sheet 615 is formed on sub-housing 85₁Upper and sub-housing 85₃Molded on sheet 615. Sub-housing 85in which sheet 615 is covered₃In the example of a transparent sub-housing (e.g., transparent or translucent), this may be useful for displaying the sheet 615 in a finished product. Notably, sheet 615 may include one or more design elements 618. Design elements 618 may constitute graphics, colors, patterns, words, letters, symbols, or any other desired visual elements. Design elements 618 may be disposed on sheet 615 in any suitable manner. For example, design elements 618 may be disposed on sheet 615 by screen printing, pad printing, flexographic or offset printing, or any other printing means (e.g., inkjet printing, water decal, sublimation, ink transfer, laser, etc.). The presence of design elements 618 on sheet 615 may allow for concealment or otherwiseFormula covers sub-casing 85₁-85_LIs present in but does not affect the sub-housing 85₁-85_LVisual impairment of mechanical properties. In some cases, sheet 615 with design elements 618 may be implemented as a permanent film. In other cases, the sheet 615 with the design elements 618 may be implemented as a release film with a removable releasable layer and ink that makes up the design elements 618 that remain on the housing 30. Alternatively or additionally, sheet 615 may include reinforcements 115 (e.g., ribs 117)₁-117_ROr reinforcement sheet 119) to which the reinforcement 115 may be affixed in any suitable manner (e.g., gluing, sewing, welding, mechanical interlocking, etc.).

In the example of fig. 81 and 82, the sheet 615 is configured to span across the housing 30 and toe cap 32. In other examples, sheet 615 may be configured to span across housing 30, blade holder 24, toe cap 32, lace member 44₁、44₂Or any other part of the skate 22. Further, the sheet 615 may constitute at least a portion of the outer surface of the skate 22. In other words, sheet 615 may not only be visually exposed, but also be physically exposed (i.e., it may be touched). Further, in some cases, the sheet 615 may constitute a majority of the outer surface of the skate boot 22. For example, the sheet 615 may form substantially the entire outer surface of the skate boot 22.

Although in the example given sheet 615 has been shown as being provided in sub-housing 85₁-85_LIn between, but in other examples, the sheet 615 may be disposed between the liner 36 and the inner sub-shell 85₁In the meantime.

As another example, in some embodiments, polymeric material M is added to₁Inner sub-shell 85 molded over last 152 to form shell 30₁Previously, sheet 615 may be placed on female mold 154₁On the inner surface of the mould 154₁In the cavity 156. This may allow the polymer material M₁To form the inner sub-housing 85₁And then demolded without the use of a mold release agent.

As yet another example, in some embodiments, the polymeric material is moldedM₁To form an inner sub-housing 85 of the housing 30₁Previously, sheet 615 may be placed on last 152.

In some cases, sheet 615 may be applied in a planar fashion to a last 152 or sub-shell 85 that has been molded to obtain₁-85_LThe last 152 or the sub-housing 85in the shape of a given one of₁-85_LIs given. In other cases, the shoe is placed on the last 152 or the sub-housing 85₁-85_LMay be associated with the last 152 or the sub-housing 85 before a given one of them₁-85_LA given one of the non-planar form preformed sheets 615 that are conformal in shape.

Sheet 615 may reduce or eliminate parting lines (i.e., inner and/or outer parting lines) on shell 30. For example, sheet 615 may be configured to avoid at least one parting line on shell 30 that would otherwise result from female mold 154 in the absence of sheet 615₁-154₃The portion 155, 157 of a given one results in the parting line. This allows one or more parting lines to be avoided because sheet 615 covers where one or more parting lines would otherwise be.

In another variation, as shown in FIG. 83, the skate boot 22 can include a cut guard 515, the cut guard 515 being configured to protect the athlete from cuts at a level above the outboard and inboard upper edges 45, 47 of the shell 30. The cutting guard 515 is movable relative to the tendon protection device 35 (or, where a tendon protection device is not included, relative to the rear portion 82 of the ankle portion 64 of the shell 30). This may provide cut-resistant protection to the athlete's ankle and/or shin while allowing them to move.

The cut guard 515 includes a cut resistant material 516 that resists impact cutting. In this example, the cut-resistant material 516 is made of aramid (e.g., aramid)

) Or any other suitable cut resistant material. In this way, the cut guard 515 may be flexible due to its fabric nature. In this embodimentDue to the flexibility of the cut-resistant material, the cut guard 515 may move relative to the tendon protection device 35 (or the rear portion 82 of the ankle portion 64 of the shell 30).

In this embodiment, the cutting guard 515 is integrally formed (i.e., built-in) within the housing 30 and permanently affixed to the housing 30. In other words, in this embodiment, the cut guard 515 is not disconnected from the housing 30 without causing damage to the cut guard 515 and/or the housing 30. Specifically, in this embodiment, the cutting guard 515 is positioned within the sub-housing 85 of the housing 30₁-85_LIn between (i.e., at least one or more sub-housings are overmolded onto the cut guard 515), the cut guard 515 is affixed to the housing 30. More specifically, in this embodiment, the cutting guard 515 is overlaid on the sub-housing 85_xUpper, and subsequent sub-housings 85_yIs molded over the cut guard 515. In this manner, the overlap of the cutting guard 515 with a portion of the housing 30 is sufficient to allow the cutting guard 515 to be permanently affixed to the sub-housing 85_x、85_yWithout the possibility of accidentally removing the cut guard 515. In this example, the cut guard 515 overlaps a majority of the housing 30. In particular, cutting guard 515 extends over a majority of the length of housing 30 (in the longitudinal direction of skate 10). A portion of the cutting guard 515 extending below the outside and inside upper edges 45, 47 of the housing 30 may act as the sub-housing 85_x、85_yWith reinforcing elements (e.g., reinforcing sheet 119) therebetween.

The cut guard 515 extends vertically above the outside and inside upper edges 45, 47 of the housing 30 by a height HP that may be large. For example, the height HP of the cutting guard 515 extending above the outside and inside upper edges 45, 47 of the housing 30 may be significant relative to the height HT of the tendon protection 35 measured from the top of the tendon protection 35 to the outside and inside upper edges 45, 47 of the housing 30. For example, in some cases, the ratio of the height HP of the cutting guard 515 to the height HT of the tendon protection 35 may be at least 0.5, in some cases at least 0.7, in some cases at least 0.9, in some cases at least 1, in some cases at least 1.2, in some cases at least 1.5, in some cases at least 2, in some cases even more.

As shown in FIG. 85, which shows a top view of a portion of the cut guard 515, the cut guard 515 extends vertically above the outside and inside upper edges 45, 47 of the housing 30; in this embodiment, the cutting guard 515 includes an outboard portion 520 for facing the outside of the skate boot 22, an inboard portion 522 for facing the inside of the skate boot 22, and a rear portion 524 for facing the rear side of the skate boot 22. Thus, in this embodiment, the cut guard 515 wraps at least partially around the ankle and/or shin of the player to provide cut protection from the sides and back of the skate 22. In other examples, the cut guard 515 may wrap completely around the ankle and/or tibia of the player such that the cut guard 515 further includes an anterior portion facing the anterior side of the skate 22. In such an example, cutting guard 515 may comprise a type of sleeve through which a player must pass his foot 11 in order to wear skate 10.

In other examples, the cut guard 515 may be configured differently. For example, the cutting guard 515 may not include the rear portion 524 in situations where the tendon protection device 35 is deemed to provide adequate protection for the athlete.

In other embodiments, as shown in FIG. 84, the cutting guard 515 may be removably attached to the skate boot 22. That is, the cutting guard 515 may be selectively attached to or detached from the skate boot 22. In this example, the cutting guard 515 is removably attached to the housing 30 by an interaction between an attachment member 519 of the cutting guard 515 and a portion 517 of the cutting guard 515. Specifically, the attachment member 519 is configured to attach the portion 517 of the cutting guard 515 to the housing 30. In this example, the cut guard 515 does not overlap a substantial portion of the housing 30. The portion 517 of the cutting guard 515 is an extension of the cutting guard 515 that extends vertically below the outside and inside upper edges 45, 47 of the housing 30. In this embodiment, the attachment member 519 is a fastener that secures the cut guard 515 to the housing 30. For example, the attachment member 519 may be a pin, a nut and bolt assembly, a hook and loop fastener, or any other suitable fastener.

In this example of fig. 84, the cut-resistant material 516 of the cut guard 515 may be rigid and/or flexible. For example, the cut-resistant material 516 may include a polymer, such as nylon, polyurethane, and/or any other suitable polymer. In other words, the cut-resistant material 516 is not limited to a flexible fabric. In this example, the cutting guard 515 may be moved relative to the tendon protection device 35 (or the rear portion 82 of the ankle portion 64 of the shell 30) by moving relative to the attachment member 519. In some cases, the cut guard 515 may pivot about the attachment member 519. Thus, where the cut-resistant material 516 is a rigid material, the cutting guard 515 may still be moved relative to the tendon protection device 35 or the rear portion 82 of the ankle portion 64 of the housing 30 by pivoting about the connecting member 519.

In one variation, as shown in fig. 86A-86D, the housing 30 may be molded as multiple pieces 710, 712, and then the pieces 710, 712 may be joined together, rather than integrally molding the housing 30 as a single piece. This may allow, for example, the use of processes other than injection moulding, such as casting or other moulding methods in particular. Further, the sheets 710, 712 may be configured to interlock with one another. Notably, the tabs 710, 712 may include protrusions and corresponding recesses for fitting the protrusions in order to interlock the tabs 710, 712 to one another. An adhesive may be applied between the sheets 710, 712 to allow the sheets 710, 712 to be affixed to one another. As shown in fig. 86A, each tab 710, 712 may form part of the housing 30 and cartridge 24. In some cases, as shown in fig. 86B, each tab 710, 712 may constitute only a portion of the housing 30 or only a portion of the cartridge 24. As shown in fig. 86C and 86D, the sheets may include three or more sheets 710, 712, 714.

In another variation, one or more sub-housings 85 may be injection molded₁-85_LRather than injection molding. This may allow for easier access, for exampleTo form a thinner sub-housing 85₁-85_L(e.g., 0.1 mm).

In another variation, as shown in fig. 87, the cartridge 24 may include an insert 750 configured to receive the blade 26. The insert 750 is affixed to the lower portion 162 of the cartridge 24 in any suitable manner. In this example, the insert 750 includes a protrusion that interlocks into the recess 165 of the cartridge 24. The insert 750 also includes a recess 752 configured to receive the blade 26. The insert 750 may be made integral with the lower portion 162 of the blade holder 24 by inserting it into a corresponding mold during molding of the blade holder 24. Alternatively, the insert 750 may be affixed to the lower portion 162 of the cartridge 24 after the lower portion 162 has been formed. The insert 750 includes a reinforcing material that is stronger and/or stiffer than the material of the lower portion 162 of the cartridge 24. For example, the reinforcement material may be a composite material (e.g., a carbon fiber material).

In another variation, as shown in fig. 88, blade holder 24 may include a void 350 in one of its front and rear posts 210, 212. More specifically, in this example, the voids 350 of the cartridge 24 may be formed by separately molding the cartridge 24 with a mold insert and removing the mold insert after molding the cartridge 24 to obtain a cavity in the cartridge 24. Thus, once the tool holder 24 is assembled with the housing 30, the tool holder 24 includes a void 350 contained between a surface of the tool holder 24 and the bottom 69 of the housing 30. In another example, rather than leaving the cavity of the cartridge 24 as a void, an insert (e.g., insert 315i) may be placed in the cavity and the cartridge 24 secured to the housing 30 such that the insert 315 is contained between the inner surface of the body of the cartridge 24 and the surface of the bottom 69 of the housing 30.

In another variant, the outer sub-housing 85₃May be configured to extend into the recess 190 of the blade retention portion 188 of the blade retention base 164 of the blade holder 24. Thus, when the blade 26 is inserted into the recess 190, the sub-housing 85₃May contact the blade 26. This is at the outer sub-housing 85₃A relatively rigid example may be useful because it may provide compression resistance when the blade 26 is inserted into the groove 190.

In some embodiments, as shown in figures 90 and 91, the subshell 85 of the skate 22_xMaterial M of₁A mixture of polymeric substance 52 and expanding agent 53 may be included. This may help the material M₁Having desirable properties such as being more shock absorbing than a material made entirely of the expansion agent 53 and/or being lighter than a material made entirely of the polymeric substance 52.

Polymeric substance 52 constituting material M_iAnd substantially contribute to the sub-housing 85_xStructural integrity of the structure. For example, in some embodiments, polymeric substance 52 may constitute material M_iAt least 40%, in some cases at least 50%, in some cases at least 60%, in some cases at least 70%, in some cases at least 80%, in some cases at least 90% by weight. In this embodiment, polymeric substance 52 may constitute material M _i50% to 90% by weight.

In this embodiment, the polymeric substance 52 may be an elastomeric substance. For example, the polymeric substance 52 may be a thermoplastic elastomer (TPE) or a thermoset elastomer (TSE).

More specifically, in this embodiment, the polymeric substance 52 includes polyurethane. The polyurethane 52 may be composed of any suitable ingredients, such as isocyanates and polyols and possible additives. For example, in some embodiments, the polyurethane 52 may have a hardness rating of shore 00, shore a, shore C, or shore D, or an equivalent rating. For example, in some embodiments, the hardness of the polyurethane 52 may be shore 5A to 95A or shore 40D to 93D. Any other suitable polyurethane may be used in other embodiments.

In other embodiments, the polymeric substance 52 may include any other suitable polymer. For example, in some embodiments, the polymeric substance 52 may include silicon, rubber, or the like.

The swelling agent 53 is combined with the polyurethane 52. In some cases, doing so may reinforce material M_iThe performance of (c). Alternatively or additionally, in some cases, this may be done so that material M_iIs expanded in the mold 154 to the sub-housing 85_xThe final shape of (a). For example, inIn some embodiments, the expanding agent 54 may constitute the material M_iAt least 10%, in some cases at least 20%, in some cases at least 30%, in some cases at least 40%, in some cases at least 50%, in some cases at least 60%, in some cases even more, by weight. In an example of this embodiment, the swelling agent 54 may constitute 15% to 50% by weight of the material.

In this embodiment, as shown in FIG. 91, the swelling agent 53 includes a quantity of expandable microspheres 63₁-63_M. Each expandable microsphere 63_iIncluding a polymeric shell 67, the polymeric shell 67 being expandable by a fluid encapsulated within the polymeric shell 67. In the example of this embodiment, the polymeric shell 67 of the expandable microspheres 63i is a thermoplastic shell. The fluid encapsulated in the polymer shell 67 is in the sub-shell 85_xIs heated during the manufacturing process to enable the expandable microspheres 63_iAn expanding liquid or gas (in this case a gas). In some embodiments, expandable microspheres 63₁-63_MIt may be an Expancel available from Aksu Nobel^TMAnd (3) microspheres. In other embodiments, expandable microspheres 63₁-63_MMay be Dualite microspheres commercially available from Henkel, Inc.; advancell microspheres commercially available from water accumulation corporation (Sekisui); matsumoto microspheres commercially available from Matsumoto Yushi Seiyaku Co., Ltd; or Kureha commercially available Kureha microspheres. In other embodiments, a variety of other types of expandable microspheres may be used.

In the example of this embodiment, expandable microspheres 63₁-63_MComprising Dry Unexpanded (DU) microspheres which, when combined with polymeric substance 52, form part of material M_iForming material M before being molded_i. For example, the Dry Unexpanded (DU) microspheres may be provided in powder form mixed with one or more liquid components of the polymeric substance 52.

In other embodiments, expandable microspheres 63₁-63_MMay be provided in a variety of other forms. For example, in some embodiments, expandable microspheres 63₁-63_MMay include dry expansionWet expanded and/or partially expanded microspheres. For example, wet unexpanded microspheres may be used to better bond with the polymeric substance 52. Partially expanded microspheres may be used to use less of the polymeric substance 52 or mixed with the polymeric substance 52 in a semi-solid form.

In some embodiments, expandable microspheres 63₁-63_MCan constitute a material M_iAt least 10%, in some cases at least 20%, in some cases at least 30%, in some cases at least 40%, in some cases at least 50%, in some cases at least 60%, in some cases even more, by weight. In this embodiment, expandable microspheres 63₁-63_MConfigurable material M_i15-50% by weight.

Comprising a material M with a polymeric substance 52_iAnd expandable microspheres 63₁-63_MSub-housing 85 of_xMay have various desirable qualities.

For example, in some embodiments, the sub-housing 85 is made entirely of polyurethane 52 as compared to the case where it is made entirely of polyurethane 52_xIs less dense and therefore lighter, but is made up entirely of expandable microspheres 63₁-63_MThe sub-housing 85 is made in comparison with the case_xWith better shock absorption and/or other better mechanical properties.

For example, in some embodiments, material M_iMay be less than the density of the polyurethane 52 (alone). For example, the sub-housing 85_xMaterial M of_iMay be no more than 70%, in some cases no more than 60%, in some cases no more than 50%, in some cases no more than 40%, in some cases no more than 30%, in some cases no more than 20%, in some cases no more than 10%, in some cases no more than 5%, in some cases even lower, than the density of the polyurethane 52. For example, in some embodiments, material M_iMay be 1/75 to 1/2 of the density of polyurethane 52 (i.e., material M)_iMay be about 1% to 50% of the density of the polyurethane 52).

Material M_iThe density of (c) can have any suitable value. For exampleIn some embodiments, material M_iMay not exceed 0.7g/cm³In some cases not exceeding 0.4g/cm³In some cases not exceeding 0.1g/cm³In some cases not exceeding 0.080g/cm³In some cases not exceeding 0.050g/cm³In some cases not exceeding 0.030g/cm³And/or may be at least 0.010g/cm³. In some examples of embodiments, material M_iMay have a density of 0.015g/cm³To 0.080g/cm³And in some cases 0.030g/cm³To 0.070g/cm³And in some cases 0.040g/cm³To 0.060g/cm³。

As another example, in some embodiments, material M_iMay be different from (i.e., greater than or less than) the expandable microspheres 63₁-63_MStiffness (alone). For example, material M_iMay be greater than or less than the elastic modulus (i.e., young's modulus) of the expandable microspheres 63₁-63_MModulus of elasticity (alone). For example based on material M_iElastic modulus of and expandable microspheres 63₁-63_MOf the smaller of the moduli of elasticity, material M_iElastic modulus of and expandable microspheres 63₁-63_MThe difference in elastic modulus of (a) may be at least 20%, in some cases at least 30%, in some cases at least 50%, and in some cases even greater. In some cases, the modulus of elasticity may be evaluated according to ASTM (American society for testing and materials) D-638 or ASTM (American society for testing and materials) D-412.

As another example, in some embodiments, material M_iMay be less elastic than the expandable microspheres 63₁-63_MElasticity (alone). For example, in some embodiments, material M is measured according to ASTM D2632-01 for vertical rebound elasticity_iMay not exceed the elasticity of the expandable microspheres 63₁-63_MIs 70%, in some cases not more than 60%, in some cases not more than 50%, in some cases not more than 40%, in some cases not more than 30% of the elastic modulus of (A)Over 20%, and in some cases, no more than 10%. In some embodiments, material M_iMay be expandable microspheres 63₁-63_M20% to 60% of the elasticity. Alternatively, in other embodiments, material M_iMay be more elastic than the expandable microspheres 63₁-63_MThe elasticity of (2).

Material M_iThe elasticity of (c) can have any suitable value. For example, according to ASTM D2632-01, in some embodiments, Material M_iMay be no more than 40%, in some cases no more than 30%, in some cases no more than 20%, in some cases no more than 10%, and in some cases even less (e.g., 5%), thereby making the sub-housing 85 less elastic than conventional_xAnd has better shock-absorbing property. In other embodiments, material M is according to ASTM D2632-01_iMay be at least 60%, in some cases at least 70%, in some cases at least 80%, in some cases even more, so that the material M is such that_iProviding more bounce.

As another example, in some embodiments, the tensile strength of the material Mi may be greater than the expandable microspheres 63₁-63_MTensile strength (alone). For example, in some embodiments, material M is according to ASTM D-638 or ASTM D-412_iMay be expandable microspheres 63₁-63_MAt least 120%, in some cases at least 150%, in some cases at least 200%, in some cases at least 300%, in some cases at least 400%, in some cases at least 500%, and in some cases even more.

Material M_iThe tensile strength of (a) may have any suitable value. For example, in some embodiments, material M_iThe tensile strength of (a) may be at least 0.9MPa, in some cases at least 1MPa, in some cases at least 1.2MPa, in some cases at least 1.5MPa, in some cases even higher (e.g., 2MPa or higher).

As another example, in some embodiments, material M_iMay be greater than the expandable microspheres 63₁-63_MElongation at break (alone). For example, in some embodiments, the expandable material M is in accordance with ASTM D-638 or ASTM D-412_iMay be expandable microspheres 63₁-63_MAt least 120%, in some cases at least 150%, in some cases at least 200%, in some cases at least 300%, in some cases at least 400%, and in some cases at least 500% elongation at break.

Material M_iThe elongation at break of (a) can have any suitable value. For example, in some embodiments, material M_iThe elongation at break of (a) may be at least 20%, in some cases at least 30%, in some cases at least 50%, in some cases at least 75%, in some cases at least 100%, in some cases even higher (e.g., 150% or higher).

In some embodiments, the material of housing 30 (e.g., material M)₁-M_NA given one of) may be a composite material. For example, the composite material may be a fiber-matrix composite material that includes a matrix in which fibers are embedded. The matrix may comprise any suitable polymeric resin, such as a thermoset polymeric material (e.g., polyester, vinyl ester, vinyl ether, polyurethane, epoxy, cyanate ester, etc.), a thermoplastic polymeric material (e.g., polyethylene, polyurethane, polypropylene, acrylic, polyetheretherketone, polyethylene terephthalate, polyvinyl chloride, polymethyl methacrylate, polycarbonate, acrylonitrile butadiene styrene, nylon, polyimide, polysulfone, polyamideimide, self-reinforced polyphenylene oxide, etc.), or a hybrid thermoset-thermoplastic polymeric material. The fibers may be made of any suitable material, for example, carbon fibers, polymer fibers such as aramid fibers, boron fibers, glass fibers, ceramic fibers, and the like.

Although in the embodiments considered above, skate 10 is designed for use in ice hockey playing on ice skating surface 14, in other embodiments skate 10 may be constructed using the principles described herein for use in playing wheeled hockey or other types of hockey (e.g., field or street hockey) on ice skating surface 14, where ice skating surface 14 is a dry surface (e.g., polymer, concrete, wood or turf playing surface or any other dry surface on which wheeled hockey or field or street hockey is played). Thus, in other embodiments, the skate apparatus 28 could include a set of wheels that roll on the dry skating surface 14 (i.e., the skate 10 could be an inline skate or other roller skate) without the blades 26. Additionally, in other embodiments, skate 10 may be a pattern skate constructed using the pattern skating principles described herein.

Further, although in the embodiments considered above, footwear 10 is a skate for skating on a skating surface 14, in other embodiments, footwear 10 may be any other suitable type of footwear. For example, as shown in fig. 123, footwear 10 may be a ski boot that includes a housing 830, and housing 830 may be configured in the manner described above with respect to a shell of a skate. Specifically, the ski boot 10 is configured to be attachable to and detachable from a ski 802, the ski 802 being configured to travel over the ground 8 (e.g., snow). To this end, the ski boot 10 is configured to interact with the attachment mechanism 800 of the ski 802. In another example, as shown in fig. 124, footwear 10 may be a boot (e.g., a work boot or any other type of boot) that includes a housing 930, and housing 930 may be configured in the manner described above with respect to the skate housing. For example, in various embodiments, boot 10 may be a motorcycle boot (e.g., for motocross or other motorcycles), a work boot for protection, safety, or other purposes (e.g., construction boot, police boot, military boot, etc.), or any other type of boot. In some cases, the shell 930 of the boot 10 may be resilient or semi-rigid, as opposed to rigid as in the embodiments described above.

In some embodiments, any feature of any embodiment described herein may be used in combination with any feature of any other embodiment described herein.

Certain additional elements that may be required for operation of certain embodiments are not described or shown as they are assumed to be within the scope of one of ordinary skill in the art. Moreover, certain embodiments may be absent, may lack and/or may operate without any element specifically disclosed herein.

For ease of description, the numerical designation of any indicated element in one drawing indicates the same element in other drawings. In describing embodiments, specific terminology has been employed for the purpose of description, but the invention is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific terminology includes all equivalents.

If there is any difference, inconsistency, or other discrepancy between the terms used herein and the terms used in any document incorporated by reference, the meaning of the terms used herein will prevail and be used.

While various embodiments have been shown, this is for the purpose of describing the invention and is not to be construed as limiting the invention. Various modifications will become apparent to those skilled in the art and it is within the scope of the invention, which is more particularly defined by the appended claims.

Claims (56)

1. A last for molding a body of a skate boot for a skate, the skate comprising a skate device disposed beneath the skate boot to engage a skating surface, the skate boot configured to receive a user's foot, the last configured to mold the body of the skate boot such that the body of the skate boot includes a medial portion facing an inside of the user's foot, a lateral portion facing an outside of the user's foot, a heel portion receiving the heel of the user's foot, and an ankle portion receiving the ankle of the user, the last being repeatedly configurable to facilitate demolding the body of the skate boot from the last such that the last is changeable between a molded configuration for molding the body of the skate boot on the last and a demolded configuration for demolding the body of the skate boot from the last.

2. The last according to claim 1, wherein the last is contracted in its demolded configuration relative to its molded configuration.

3. The last according to claim 1, wherein the last is configured to mold the body of the skate, such that the body of the skate includes a plurality of undercut.

4. The last according to claim 3, wherein each of the undercut is a medial concavity and a lateral concavity, respectively, of the ankle portion for receiving a medial malleolus and a lateral malleolus of the user.

5. The last according to claim 3, wherein a given one of the undercuts is a recess defined by a curved portion of the heel portion.

6. The last according to claim 3, wherein each said undercut is a recess defined by a curved portion of the medial and lateral portions, respectively.

7. The last according to claim 1, wherein from its molded configuration to its demolded configuration, the volume occupied by the last decreases such that the volume occupied by the last in its demolded configuration is less than the volume occupied by the last in its molded configuration.

8. The last according to claim 7, wherein the last includes a cavity containing a fluid to change a volume occupied by the last by expanding and contracting the last.

9. The last according to claim 1, wherein the last includes a cavity containing particles and configured to contain a fluid such that the particles change a rigidity of the last in response to a flow of the fluid relative to the cavity.

10. The last according to claim 1, wherein the last includes a plurality of last members that are movable relative to one another to change between their molded and their demolded configurations.

11. The last according to claim 10, wherein: each of said last members being movable relative to one another while remaining connected to one another as said last is changed between its molded configuration and its demolded configuration; and the last includes a control system that controls movement of the last members relative to each other.

12. The last according to claim 10, wherein adjacent last members are translatable relative to one last member to change the last between its molded configuration and its demolded configuration.

13. The last according to claim 10, wherein adjacent last members are rotatable with respect to one last member to change the last between its molded configuration and its demolded configuration.

14. The last according to claim 10, wherein adjacent last members are translatable and rotatable relative to one last member to change the last between its molded configuration and its demolded configuration.

15. The last according to claim 10, wherein the last member includes at least three last members.

16. The last according to claim 10, wherein the last members include at least five last members.

17. The last according to claim 10, wherein a first one of the last members is a forward central last member, a second one of the last members is a rear central last member, and a third one of the last members is a medial central last member that is disposed between the forward central last member and the rear central last member; a fourth of the last members is a medial last member; and a fifth of the last members is a lateral last member.

18. The last according to claim 17, wherein the last is configured to mold the body of the skate such that the body of the skate includes a sole portion for facing a bottom surface of a user's foot.

19. The last according to claim 17, wherein the last is configured to mold the body of the skate so that the body of the skate includes a toe portion for enclosing toes of a user's foot.

20. The last according to claim 1, wherein the last is configured to mold the body of the skate such that the body of the skate includes a sole portion for facing a bottom surface of a user's foot.

21. The last according to claim 1, wherein the last is configured to mold the body of the skate, such that the body of the skate includes a toe portion for enclosing toes of a user's foot.

22. The last according to claim 10, wherein: the last includes a base including each of the last members; and a given one of the last members is a removable cover configured to enclose the base and be removable from the base.

23. The last according to claim 22, wherein the thickness of the removable cover varies to define a plurality of undercut of the body of the skate.

24. The last according to claim 22, wherein the removable cover is elastic.

25. The last according to claim 24, wherein the removable cover includes an elastomeric material.

26. The last according to claim 1, wherein the last is configured to injection mold the body of the skate boot.

27. The last according to claim 1, wherein the body of the skate includes a plurality of materials that are different and are molded by flowing around the last.

28. A skate boot comprising a body molded using the last of claim 1.

29. A method of manufacturing a skate boot for a skate, the skate including a skate device disposed beneath the skate boot to engage a skating surface, the skate boot configured to receive a foot of a user, the method comprising:

providing a last that is changeable between a molded configuration and a demolded configuration;

molding a body of the skate on a last in the molded configuration such that the body of the skate includes a medial portion that faces a medial side of the user's foot, a lateral portion that faces a lateral side of the user's foot, a heel portion that receives the heel of the user's foot, and an ankle portion that receives the ankle of the user;

changing the last from a moulded configuration to a demoulded configuration to facilitate removal of the body of the skate from the last; and

demolding the body of the skate boot from the last in the demolded configuration.

30. A last for molding a body of an article of footwear that receives a user's foot, the last being configured to mold the body of the article of footwear such that the body of the footwear includes a medial portion that faces an inner side of the user's foot, a lateral portion that faces an outer side of the user's foot, a heel portion that receives the heel of the user's foot, and an ankle portion that receives the ankle of the user, the last being repeatedly configurable to facilitate demolding of the body of the article of footwear from the last such that the last is changeable between a molded configuration for molding the body of the article of footwear on the last and a demolded configuration for demolding the body of the article of footwear from the last.

31. A method of making an article of footwear for receiving a foot of a user, the method comprising:

providing a last that is changeable between a molded configuration and a demolded configuration;

molding a body of the article of footwear over the last in the molded configuration such that the body of the article of footwear includes a medial side portion facing a medial side of a user's foot, a lateral side portion facing a lateral side of the user's foot, a heel portion to accommodate a heel of the user's foot, and an ankle portion to accommodate an ankle of the user;

changing the last from a molded configuration to a demolded configuration to facilitate removal of the body of the article of footwear from the last; and

demolding the body of the article of footwear from the last in the demolding configuration.

32. A resilient female mold member for molding the body of a skate boot for a skate, the skate comprising a skate device disposed beneath the skate boot to engage a skate surface, the skate boot configured to receive a user's foot, the resilient female mold member configured as part of a female mold and disposed adjacent a last for molding the body of the skate boot, the resilient female mold member comprising an inner surface preformed to define a cavity between the resilient female mold member and the last for receiving a polymeric material for molding at least a portion of the body of the skate boot such that the inner surface of the resilient female mold member forms an outer surface of the portion of the skate boot body.

33. The female elastomeric mold member of claim 32, wherein the female elastomeric mold member is configured to avoid at least one parting line on the skate boot body that would otherwise occur in the absence of the female elastomeric mold member due to the portions of the female mold being movable relative to one another.

34. The female elastic member of claim 32, wherein the female elastic member extends continuously to form at least a majority of an outer surface of the portion of the body of the skate boot.

35. The resilient female die member of claim 32, wherein the resilient female die member is resilient to bend during movement of the female die portions relative to each other when closing and opening the female die and is configured to cover a space in which the female die portions move relative to each other.

36. The female elastic member according to claim 32, comprising medial and lateral portions, an ankle portion, a heel portion and a sole portion, integral with each other and present in succession as a unitary structure.

37. The female elastic mold member of claim 32, wherein the female elastic mold member is elastic and jointless at the rear of the heel portion and the ankle portion, while the medial and lateral portions and the medial and lateral portions of the sole portion are separable and movable relative to each other to allow the female elastic mold member to flex during movement of the female mold portions when closing and opening the female mold.

38. The resilient female mold member of claim 32, comprising an elastomeric material.

39. A method of manufacturing a skate boot for a skate, the skate including a skate device disposed beneath the skate boot to engage a skating surface, the skate boot configured to receive a foot of a user, the method comprising:

providing a female mould and a last for moulding the body of the skate boot, the female mould comprising a resilient female mould member comprising an inner surface pre-formed to define a cavity between the resilient female mould member and the last; and

flowing a polymeric material in the cavity to mould at least a portion of the body of the skate such that the inner surface of the resilient female mould member forms the outer surface of the portion of the body of the skate.

40. A resilient female mold member for molding a body of an article of footwear configured to receive a user's foot, the resilient female mold member configured as part of a female mold and disposed adjacent a last for molding the body of the article of footwear, the resilient female mold member comprising an inner surface preformed to define a cavity between the resilient female mold member and the last to receive a polymeric material molding at least a portion of the body of the article of footwear such that the inner surface of the resilient female mold member forms an outer surface of the portion of the body of the article of footwear.

41. A method of making an article of footwear for receiving a foot of a user, the method comprising:

providing a negative mould for moulding the body of the article of footwear and a last, the negative mould comprising a resilient negative mould member comprising an inner surface pre-formed to define a cavity between the resilient negative mould member and the last; and

flowing a polymeric material in the cavity to mold at least a portion of a body of the article of footwear such that an inner surface of the female elastic member forms an outer surface of the portion of the body of the article of footwear.

42. A method of manufacturing a skate boot for a skate, the skate including a skate device disposed beneath the skate boot to engage a skating surface, the skate boot configured to receive a foot of a user, the method comprising:

placing a sheet in a mould for moulding the body of the skate; and

flowing material in the mould to mould at least a portion of the body of the skate, the sheet conforming to the portion of the body of the skate.

43. The method of claim 42, wherein the sheet is a polymeric sheet.

44. The method of claim 42, wherein the sheet is transparent.

45. The method according to claim 42, wherein the portion of the body of the skate is molded in a mold without the use of a release agent.

46. The method according to claim 42, wherein the sheet remains part of the skate.

47. The method of claim 46, wherein the sheet comprises a design element.

48. The method according to claim 42, wherein the sheet covers at least a majority of the surface of the body of the skate.

49. The method of claim 42, wherein placing a sheet in the mold comprises placing the sheet in a planar form in the mold.

50. The method of claim 42, comprising pre-forming a sheet in a non-planar form prior to placing the sheet in the mold.

51. The method of claim 42 wherein the sheet is configured to avoid at least one parting line on the skate body that would otherwise occur in the absence of the sheet due to the portions of the mold being movable relative to one another.

52. A skate boot for a skate, the skate including a skate device disposed beneath the skate boot to engage a skating surface, the skate boot configured to receive a foot of a user, the skate boot comprising a body including: a layer of material molded by flow; and a sheet provided during molding of the layer of material and conformal with the layer of material.

53. A method of making an article of footwear for receiving a foot of a user, the method comprising:

placing the sheet in a mold for molding a body of an article of footwear; and

flowing a material in the mold to mold at least a portion of a body of the article of footwear, the sheet conforming to the portion of the body of the article of footwear.

54. An article of footwear for receiving a foot of a user, the article of footwear comprising a body, the body comprising: a layer of material molded by flow; and a sheet provided during molding of the layer of material and conformal with the layer of material.

55. A skate boot for a skate, the skate comprising a skate device disposed beneath the skate boot to engage a skating surface, the skate boot configured to receive a user's foot, the skate boot comprising a body including a medial portion that faces an inside of the user's foot, a lateral portion that faces an outside of the user's foot, a heel portion that receives the heel of the user's foot, and an ankle portion that receives the ankle of the user, wherein: the medial, lateral, heel and ankle portions of the body are molded together and integral with one another by the flow of material in a mold; and the bodies have no parting lines opposite each other.

56. An article of footwear for receiving a user's foot, the article of footwear comprising a body including a medial side portion for facing a medial side of the user's foot, a lateral side portion for facing a lateral side of the user's foot, a heel portion for receiving a heel of the user's foot, and an ankle portion for receiving an ankle of the user, wherein: the medial, lateral, heel and ankle portions of the body are molded together and integral with one another by the flow of material in a mold; and the bodies have no parting lines opposite each other.

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