Skate boot

Abstract

A lasted skate boot for enclosing and supporting a human foot, the boot comprising: an outer shell comprising a heel portion for surrounding the heel, an ankle portion for surrounding the ankle, medial and lateral side portions for enclosing the medial and lateral sides of the foot respectively, the outer shell comprising cloth material laminated to a support made of a non-woven fabric, and wherein the outer shell further comprises plastic material fused with the non-woven fabric; an inner lining made of a soft material and mounted in the outer shell; a toe box for enclosing the toes, the toe box being affixed to the medial and lateral side portions; and a tongue for facing the upper frontal portion of the foot, the tongue extending upwardly and rearwardly from the toe box.

1 . A lasted skate boot for enclosing and supporting a human foot when in use, the foot having a heel, an Achilles tendon, an ankle with a medial malleolus and a lateral malleolus, a plantar surface, medial and lateral sides, an upper frontal portion and toes, said boot comprising:
 (a) an outer shell comprising a heel portion for surrounding the heel, an ankle portion for surrounding the ankle, medial and lateral side portions for enclosing the medial and lateral sides of the foot respectively, said outer shell comprising cloth material laminated to a support made of a non-woven fabric, and wherein the outer shell further comprises plastic material fused with the non-woven fabric;   (b) an inner lining made of a soft material and mounted in said outer shell;   (c) a toe box for enclosing the toes, said toe box being affixed to said medial and lateral side portions; and   (d) a tongue for facing the upper frontal portion of the foot, said tongue extending upwardly and rearwardly from said toe box.   
     
     
         2 . A lasted skate boot as defined in  claim 1 , further comprising an insole for facing the plantar surface of the foot. 
     
     
         3 . A lasted skate boot as defined in  claim 2 , wherein each of said medial and lateral side portions comprises a skirt projecting downwardly from its lower edge. 
     
     
         4 . A lasted skate boot as defined in  claim 3 , wherein said skirt overlaps a portion of said insole and is affixed to said insole. 
     
     
         5 . A lasted skate boot as defined in  claim 1 , wherein said heel portion is substantially cup shaped for following the contour of the heel of the foot. 
     
     
         6 . A lasted skate boot as defined in  claim 1 , wherein said inner lining comprises a surface intended for contact with the heel, ankle and lateral and medial sides of the foot. 
     
     
         7 . A skate boot as defined in  claim 1 , further comprising a footbed mounted inside said outer shell, said footbed comprising an upper surface for receiving the plantar surface of the foot and a wall projecting upwardly from said upper surface, said wall partially cupping the heel and extending up to a medial line of the foot. 
     
     
         8 . A skate boot as defined in  claim 1 , wherein said outer shell further comprises a tendon guard for facing at least partially a rear portion of the Achilles tendon. 
     
     
         9 . A skate boot as defined in  claim 4 , further comprising an outsole affixed to a bottom surface of said insole. 
     
     
         10 . An ice skate comprising a skate boot as defined in  claim 9 , said ice skate comprising an ice skate blade holder mounted on said outsole. 
     
     
         11 . An ice skate comprising a skate boot as defined in  claim 9 , said ice skate comprising an ice skate blade holder mounted to a bottom surface of said insole. 
     
     
         12 . A method of making a lasted skate boot for enclosing a human foot when in use, the foot having a heel, an Achilles tendon, an ankle with a medial malleolus and a lateral malleolus, a plantar surface, medial and lateral sides and toes, said method comprising:
 (a) providing a male-female mold having male and female sections for defining a mold cavity therebetween, the male section having sides, a rear portion and a bottom portion for defining a three dimensional shape corresponding to the external three dimensional shape of the foot, the female section defining a recess for receiving the male section, the male section comprising a plurality of inner channels for admitting liquid plastic material in the mold cavity;   (b) providing a pre-cut sheet made of cloth material laminated to a support made of non-woven fabric;   (c) placing the sheet on the male section of the mold such that the non-woven fabric contacts the sides and rear portion of the male section of the mold;   (d) closing the male and female sections of the mold;   (e) injecting liquid plastic material in the inner channels at a temperature of between 160° C. and 200° C. and at a pressure of between 985 psi and 1015 psi such that the liquid plastic material spreads on the sheet, pushes the sheet against the recess of the female section of the mold, fills the mold cavity and fuses with the non-woven fabric to form, after cooling, an outer shell comprising a heel portion for surrounding the heel, an ankle portion for surrounding the ankle, and medial and lateral side portions for enclosing the medial and lateral sides of the foot respectively;   (f) opening the male and female sections of the mold; and   (g) removing the outer shell from the mold.   
     
     
         13 . A method as defined in  claim 12 , wherein the sheet further partially extends over the bottom portion of the male section such that the outer shell further comprises medial and lateral skirts after step (e). 
     
     
         14 . A method as defined in  claim 13 , further comprising positioning an insole, a toe box and the outer shell over a last; and affixing the medial and lateral skirts to the insole. 
     
     
         15 . A method as defined in  claim 14  further comprising affixing a rigid outsole to a bottom portion of said insole. 
     
     
         16 . A method as defined in  claim 15  further comprising affixing an ice blade holder to a bottom surface of said rigid outsole. 
     
     
         17 . A method as defined in  claim 16  further comprising affixing a layer of material to an external surface of the outer shell. 
     
     
         18 . A method as defined in  claim 12  further comprising affixing an inner lining to an inner surface of the outer shell. 
     
     
         19 . A method as defined in  claim 18  further comprising placing a padding element between the inner lining and the inner surface of the outer shell. 
     
     
         20 . A method as defined in  claim 14 , wherein the sheet further comprises an upper portion facing an upper part of the rear portion of the male section of the mold such that the outer shell further comprises a tendon guard for facing the Achilles tendon after step (e). 
     
     
         21 . A method as defined in  claim 12 , wherein the liquid plastic material is selected from the group comprising surlyn, ethylene vinyl acetate, thermoplastic polyurethane, nylon66, hytrel, polypropylene and polyethylene. 
     
     
         22 . A method as defined in  claim 21 , wherein the cloth material is selected from the group of polyester, nylon, carbon fibers, synthetic fibers and fiberglass.