Sports boot construction

Abstract

A sports boot and a method for constructing the sports boot are disclosed comprising a unitary body and an external upper assembly. In the current embodiment, the unitary body has a sole portion, an upper portion, and an ankle cuff portion, and comprises injection-molded ethylene vinyl acetate. The external upper assembly is of composite construction from relatively rugged materials, and, in a current embodiment, includes side panels, forefoot panels, and one or more instep panels. The external upper assembly is attached to the unitary body to form the boot.

1 . A sports boot comprising:
 a unitary body comprising a sole portion and an upper portion extending upwardly from the sole portion, the upper portion including a toe portion configured to enclose a portion of a user's foot, and a cuff portion configured to wrap about a user's ankle, the upper portion defining an elongate opening extending from the toe portion;   a semi-rigid elongate support attached to the cuff portion of the unitary body;   an external upper assembly attached to the unitary body and covering only a portion of the unitary body; and   a closure means extending across the elongate opening.   
     
     
         2 . The sports boot of  claim 1 , wherein the unitary body comprises injection-molded ethylene vinyl acetate. 
     
     
         3 . The sports boot of  claim 1 , wherein the external upper assembly comprises a side panel, a forefoot panel and an instep panel that are preassembled prior to attachment to the unitary body. 
     
     
         4 . The sports boot of  claim 1 , wherein the cuff portion includes an inner surface defining a recess that is shaped to receive the elongate support such that the elongate support is flush with the inner surface of the cuff portion. 
     
     
         5 . The sports boot of  claim 1 , further comprising a tongue attached to a forefoot end of the elongate opening and extending upwardly along the elongate opening. 
     
     
         6 . The sports boot of  claim 1 , further comprising a gusset attached to an interior surface of the unitary body and extends across the elongate opening. 
     
     
         7 . The sports boot of  claim 1 , further comprising an inner liner sock that covers an interior surface of the unitary body. 
     
     
         8 . The sports boot of  claim 1 , further comprising a reinforcing panel engaging a surface of the unitary body adjacent the elongate opening. 
     
     
         9 . The sports boot of  claim 8 , wherein the reinforcing panel engages an exterior surface of the unitary body. 
     
     
         10 . The sports boot of  claim 8 , wherein the closure means comprises a plurality of lace keepers attached to the reinforcing panel and a lace that slidably engages the lace keepers. 
     
     
         11 . The sports boot of  claim 8 , wherein the unitary body is formed with a recess on the outer surface that is sized and configured to receive the reinforcing panel. 
     
     
         12 . The sports boot of  claim 1 , further comprising a semi-rigid toe cap support that is attached to the toe portion of the unitary body. 
     
     
         13 . The sports boot of  claim 1 , wherein the cuff portion of the unitary body comprises a plurality of thickened sections. 
     
     
         14 . The sports boot of  claim 13 , wherein the thickened sections further comprise transverse channels for increasing the flexibility in a desired flexure direction. 
     
     
         15 . The sports boot of  claim 1 , wherein the semi-rigid elongate support comprises a webbing that is rigid in the tensile direction. 
     
     
         16 . A method of constructing a sports boot comprising:
 injection molding a unitary body comprising a sole portion and an upper portion extending upwardly from the sole portion, the upper portion including a toe portion configured to enclose a portion of a user's foot, and an upwardly extending back portion positioned to extend along a rear portion of a user's leg, the upper portion defining an elongate opening extending from the toe portion to an upper end of the unitary body;   attaching a semi-rigid support to the back portion of the unitary body;   securely affixing a plurality of reinforcing panels to an outer surface of the unitary body;   forming an external upper assembly;   fixedly attaching the external upper assembly to the unitary body by attaching the external upper assembly to the plurality of reinforcing panels.   
     
     
         17 . The method of  claim 16 , further comprising the step of attaching a webbing to the unitary body using at least some of the plurality of reinforcing panels. 
     
     
         18 . The method of  claim 16 , wherein the unitary body comprises an injection-molded ethylene vinyl acetate. 
     
     
         19 . The method of  claim 16 , wherein the external upper assembly comprises a composite construction having side panels that overlie a portion of the unitary body, forefoot panels that attach to the unitary body, and an instep panel that extends over the toe portion of the unitary body. 
     
     
         20 . The method of  claim 16 , wherein the unitary body comprises relatively thick portions that are not covered by the external upper assembly.