Flow-Molded Skate Boots for Lightweight Fit and Protection
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Solution Overview
Problem
Conventional skates and footwear are often heavy, uncomfortable, lack protection, and have poor fit, while manufacturing is costly and inefficient.
Innovation Solution
The skate or footwear is constructed with materials molded by flowing in molding equipment, such as injection molding, to reduce weight and enhance fit and comfort, with reinforcement for impact resistance and durability, and thermoforming on the user's foot for customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional skates are constructed with multiple assembled components, then structural integrity is maintained, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent merges multiple skate components (shell, toe cap, tendon guard, tongue, heel counter) into a single integrated skate boot constructed by flowing material in a molding process. This consolidation eliminates the need for separate assembly operations, reducing both weight and manufacturing complexity while maintaining structural integrity through the unified molded construction.
Solution Approach 2:
The patent employs composite materials in the integrated skate boot construction, combining different material properties within a single molded structure. This allows the skate to achieve both lightweight construction and structural strength without requiring multiple separate components, thereby reducing weight and manufacturing complexity simultaneously.
2Ease of operation
If conventional skates use multiple assembled components, then structural protection is provided, but comfort and fit deteriorate
Solution Approach 1:
The patent integrates multiple protective components into a single molded skate boot that conforms to the skater's foot anatomy. This unified construction provides customized fit and comfort while maintaining structural protection, eliminating the need for multiple separate components that would compromise both comfort and structural integrity.
Solution Approach 2:
The patent applies local quality by providing enhanced protection and support in specific areas (toe cap, tendon guard, heel counter) through strategically placed reinforced sections within the integrated molded structure. This allows customized protection where needed while maintaining overall comfort and fit, without requiring separate discrete components.
3Ease of manufacture
If conventional skates are manufactured with multiple components, then structural requirements are met, but manufacturing cost increases
Solution Approach 1:
The patent reduces manufacturing cost by merging multiple components into a single integrated skate boot manufactured through a flowing molding process. This eliminates multiple assembly operations and reduces part costs while maintaining structural protection through the unified molded construction that incorporates protective features throughout the entire boot structure.
Solution Approach 2:
The patent uses composite materials in the integrated molded construction to provide structural protection at lower cost than traditional multi-component approaches. The composite material construction allows for cost-effective manufacturing while delivering the necessary structural integrity and protection through the unified molded design.
4Ease of operation
If conventional skates use separate components, then assembly flexibility is maintained, but attachment complexity increases
Solution Approach 1:
The patent eliminates attachment complexity by merging all skate components into a single integrated boot constructed by flowing material in a molding process. This unified construction removes the need for separate attachment operations between components, significantly simplifying assembly while maintaining the functional flexibility needed for skate operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a lightweight, comfortable, and cost-effective skate or footwear with improved fit and protection, facilitating efficient manufacturing and easy installation of components like blades.
Implementation Method 1
molded by flowing in molding equipment during a molding process (e.g., injection molding or casting)
Implementation Method 2
The skate boot or other foot-receiving structure may be customized by being thermoformed on the user's foot more efficiently
Data Source
AI summary
A skate or other footwear, comprising a skate boot or other foot-receiving structure for receiving a user's foot and possibly one or more other components, such as a skating device below the skate boot to engage a skating surface. At least part of the skate 5 boot or other foot-receiving structure and optionally at least part of one or more other components (e.g., the skating device) may be constructed from one or more materials (e.g., foams) molded by flowing during a molding process (e.g., injection molding or casting). This may allow useful performance characteristics (e.g., reduced weight, better comfort, etc.) and cost-effective manufacturing. One or more parts of the skate 0 boot or other foot-receiving structure (e.g., a toe cap, a tendon guard, etc.) may be reinforced to enhance impact resistance, durability, and/or other aspects thereof. The skate boot or other foot-receiving structure may be customized by being thermoformed on the user's foot more efficiently.