Skate boot

Abstract

A method of making a lasted skate boot comprising providing a pre-cut sheet of thermoformable synthetic material; and thermoforming the sheet of synthetic thermoformable material to form an outer shell comprising a heel counter for receiving the heel of the foot; an ankle portion for receiving the ankle; and medial and lateral quarters for receiving the medial and lateral sides of the foot respectively, the medial and lateral quarters extending forwardly from the heel counter and the ankle portion. The ankle portion is thermoformed such that it comprises an upper part and a lower part that projects outwardly with relation to the upper part, the lower part merging with the heel counter, the upper part following the upper part of the Achilles tendon and the lower part following the lower part of the Achilles tendon.

1 . A method of making a lasted skate boot comprising an upper for enclosing a human foot, the foot having a heel, an Achilles tendon having an upper part and a lower part that projects outwardly with relation to the upper part, the lower part merging with the heel, the foot also comprising 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 pre-cut sheet of thermoformable synthetic material; and    (b) thermoforming said sheet of synthetic thermoformable material to form an outer shell comprising (i) a heel counter for receiving the heel of the foot; (ii) an ankle portion for receiving the ankle; and (iii) medial and lateral quarters for receiving the medial and lateral sides of the foot respectively, said medial and lateral quarters extending forwardly from said heel counter and said ankle portion; wherein said ankle portion is thermoformed such that it comprises an upper part and a lower part that projects outwardly with relation to said upper part, said lower part merging with said heel counter, said upper part following the upper part of the Achilles tendon and said lower part following the lower part of the Achilles tendon.    
     
     
         2 . A method as defined in  claim 1 , wherein said method comprises thermoforming said heel counter such that it is substantially cup-shaped for following the contour of the heel of the foot.  
     
     
         3 . A method as defined in  claim 2 , wherein said method comprises thermoforming said ankle portion such that it comprises a cup-shaped lateral depression for receiving the lateral malleolus and a cup-shaped medial depression for receiving the medial malleolus.  
     
     
         4 . A method as defined in  claim 3 , wherein said ankle portion is thermoformed such that it comprises reinforcing elements having a ridge formed on one of its inner surface or outer surface and a groove registering with said ridge on the other of said inner surface or outer surface.  
     
     
         5 . A method as defined in  claim 4 , wherein said method comprises thermoforming said heel counter such that it comprises reinforcing elements having a ridge formed on one of its inner surface or outer surface and a groove registering with said ridge on the other of the inner surface or outer surface.  
     
     
         6 . A method as defined in  claim 5 , wherein said method comprises thermoforming said medial and lateral quarters such that each of said medial and lateral quarters comprises reinforcing elements having a ridge formed on one of its inner surface or outer surface and a groove registering with said ridge on the other of said inner surface or outer surface.  
     
     
         7 . A method as defined in  claim 3 , wherein said method comprises thermoforming said ankle portion such that said lateral depression is below said medial depression.  
     
     
         8 . A method as defined in  claim 1 , wherein heat and pressure are applied simultaneously during the thermoforming step.  
     
     
         9 . A method as defined in  claim 8 , wherein the applied heat is between 250° F. and 350° F. and the applied pressure is between 75 psi and 150 psi.  
     
     
         10 . A method as defined in  claim 1 , further comprising thermoforming said sheet of thermoformable material such that said outer shell comprises a foldable lower skirt portion.  
     
     
         11 . A method as defined in  claim 10  further comprising folding said lower skirt portion over the bottom surface of an insole and affixing said lower skirt portion to said insole.  
     
     
         12 . A method as defined in  claim 11  further comprising securing an outsole to said insole.  
     
     
         13 . A method as defined in  claim 12  further comprising securing an ice skate blade holder to said outsole.  
     
     
         14 . A method as defined in  claim 12  further comprising securing an inline roller chassis to said outsole.  
     
     
         15 . A method as defined in  claim 1  further comprising securing an inner lining to said outer shell.  
     
     
         16 . A method as defined in  claim 10  further comprising placing said upper over a last and positioning an insole underneath said last and inside said skirt portion.  
     
     
         17 . A method as defined in  claim 16  further comprising folding said lower skirt portion over the bottom surface of said insole and affixing said lower skirt portion to said insole.  
     
     
         18 . A method as defined in  claim 17  further comprising securing an outsole to said insole.  
     
     
         19 . A method as defined in  claim 18  further comprising securing an ice skate blade holder to said outsole.  
     
     
         20 . A method as defined in  claim 18  further comprising securing an inline roller chassis to said outsole.  
     
     
         21 . A lasted skate boot comprising an upper for enclosing a human foot, the foot having a heel, an Achilles tendon having an upper part and a lower part that projects outwardly with relation to the upper part, the lower part merging with the heel, the foot also comprising an ankle with a medial malleolus and a lateral malleolus, a plantar surface, medial and lateral sides and toes; said skate boot comprising an outer shell made of a thermoformable synthetic pre-cut sheet that is thermoformed in a three dimensional shape such that said outer shell comprises: 
 (a) a heel counter for receiving the heel of the foot;    (b) medial and lateral quarters for receiving the medial and lateral sides of the foot respectively, said medial and lateral quarters extending forwardly from said heel counter and said ankle portion; and    (c) an ankle portion for receiving the ankle, said ankle portion comprising an upper part shaped for following the upper part of the Achilles tendon and a lower part shaped for following the lower part of the Achilles tendon, said lower part projecting outwardly with relation to said upper part and merging with said heel counter.    
     
     
         22 . A lasted skate boot as defined in  claim 21 , wherein said ankle portion comprises a cup-shaped lateral depression for receiving the lateral malleolus and a cup-shaped medial depression for receiving the medial malleolus.  
     
     
         23 . A lasted skate boot as defined in  claim 22 , wherein said heel counter is substantially cup shaped for following the contour of the heel of the foot.  
     
     
         24 . A lasted skate boot as defined in  claim 23 , wherein said cup-shaped lateral depression is below said cup-shaped medial depression.  
     
     
         25 . A lasted skate boot as defined in  claim 21  further comprising an insole facing the plantar surface of the foot.  
     
     
         26 . A lasted skate boot as defined in  claim 25 , wherein said outer shell comprises a lower skirt portion foldable to overlap said insole.  
     
     
         27 . A lasted skate boot as defined in  claim 26 , wherein said skirt portion is affixed to said insole.  
     
     
         28 . A lasted skate boot as defined in  claim 27  further comprising a toe box facing the toes of the foot.  
     
     
         29 . A lasted skate boot as defined in  claim 27  further comprising a tongue extending upwardly and rearwardly from said toe box.  
     
     
         30 . A lasted skate boot as defined in  claim 27 , wherein said skate boot further comprising a protective overlay, said overlay recovering a portion of said medial and lateral quarters.  
     
     
         31 . A lasted skate boot as defined in  claim 27 , wherein said outer shell comprises an outer layer and an inner layer, said outer layer being more rigid than said inner layer.  
     
     
         32 . An ice skate comprising the lasted skate boot as defined in  claim 21 .  
     
     
         33 . An in-line roller skate comprising the lasted skate boot as defined in  claim 21.