Additive Manufactured Ice Skate Boot with Composite Overlay
Solution Overview
Problem
Current sports footwear, particularly hard-shell ice skate boots, lack adequate comfort and durability due to stiff materials, which can lead to discomfort and reduced performance during athletic activities.
Innovation Solution
The integration of a 3-D printed additive manufactured sole and foot form with a composite overlay covering 50-90% of the outer surface, combined with a compressible insulation layer for comfort and enhanced durability, addresses the stiffness issue while maintaining strength and rigidity through a composite carbon fiber or fiberglass shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stiff materials are used in ice skate boots to maintain strength and rigidity, then structural integrity is improved, but comfort deteriorates
Solution Approach 1:
The boot is divided into multiple functional layers: an inner comfort layer (foam or thermoplastic elastomer) that provides cushioning and flexibility, and an outer shell layer that provides structural integrity. This segmentation allows each layer to perform its specialized function without compromising the other.
Solution Approach 2:
The boot combines different materials with complementary properties: soft compliant materials (foam, thermoplastic elastomer) for comfort and rigid materials for the outer shell. This composite construction allows the boot to simultaneously achieve both comfort and structural strength.
2Ease of manufacture
If traditional manufacturing methods are used for ice skate boots, then ease of manufacture is maintained, but durability and performance deteriorate
Solution Approach 1:
The invention changes the manufacturing approach from traditional molding or stitching methods to additive manufacturing (3D printing). This parameter change in the manufacturing process enables complex geometries and integrated structures that improve durability while maintaining or reducing manufacturing complexity.
Solution Approach 2:
The boot integrates multiple components into a unified structure through additive manufacturing, combining the inner comfort layer and outer shell into a single manufactured assembly. This merging eliminates assembly steps and potential failure points from traditional multi-component construction.
3Ease of operation
If thick insulation layers are added to improve comfort, then warmth is improved, but weight increases
Solution Approach 1:
The invention uses foam or thermoplastic elastomer materials with porous or cellular structures that provide insulation and comfort while maintaining low density. These porous materials trap air pockets for thermal insulation without adding significant weight.
Solution Approach 2:
The invention optimizes the thickness and density parameters of the insulation layer to achieve the minimum required for comfort and warmth. By carefully controlling these parameters, the boot provides adequate insulation while minimizing weight addition.
Data Source
AI summary
An additive manufactured hard-shell athletic boot with an integrated sole and foot form that includes a sole form and foot form is contemplated. The athletic boot can comprise a composite overlay, such as a carbon composite, that covers the majority of an outer surface of the sole form and the majority of an outer surface of the foot form. In certain instances, the overlay covers the integrated sole and foot form up to an overlay border that runs along the top of the integrated sole and foot form. One example of a hard-shell athletic boot is a hockey skate boot.