Foam Skate Boot Molding for Weight and Fit
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Solution Overview
Problem
Conventional skate boots are often heavy, uncomfortable, lack protection in certain areas, and have poor fit, while being expensive to manufacture, and the attachment of skating devices adds additional manufacturing and installation issues.
Innovation Solution
The use of molding equipment to create skate boots and components from materials like foams, allowing for reduced weight, improved fit, and comfort, while being more cost-effective, using a method that involves injecting different constituents to produce polyurethane materials with specific properties, and integrating the blade holder with the skate boot for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional thermoforming of synthetic material layers is used, then manufacturing process is established, but the skate boot becomes heavy and expensive
Solution Approach 1:
The patent changes the material parameters from conventional synthetic layers to foam materials with specific density and compressibility characteristics. The foam material is injected into a mold in a expanded state and then contracts to form the final shape, achieving both weight reduction and structural integrity through parameter control of the foam properties.
Solution Approach 2:
The patent uses foam materials as composite structures that combine lightweight properties with sufficient strength. The foam material serves as both structural support and cushioning element, eliminating the need for separate heavy synthetic layers while maintaining comfort and protection.
2Strength
If conventional assembly of multiple components is used, then structural integrity is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges multiple separate components (shell, tongue, tendon guard, etc.) into a single integrated foam structure. The foam material is molded to form all these elements simultaneously in one injection process, eliminating assembly operations while maintaining structural integrity through the continuous foam matrix.
Solution Approach 2:
The patent segments the foam material into different density zones within the same molded structure. Different regions of the foam have different densities to provide varying levels of protection and support, allowing complex functionality to be achieved through material segmentation rather than component assembly.
3Object-affected harmful factors
If conventional skate boot design is used, then basic protection is provided, but comfort and fit are insufficient
Solution Approach 1:
The patent applies local quality by varying the foam density and composition in different regions of the skate boot. High-density foam provides protection in areas needing impact resistance, while lower-density foam provides comfort and flexibility in areas requiring movement, achieving both protection and comfort through spatial variation of material properties.
Solution Approach 2:
The patent changes the physical parameters of the foam material including density, compressibility, and elasticity to optimize both protection and comfort. The foam is formulated with specific viscoelastic properties that allow it to cushion impacts while conforming to the skater's foot shape for improved fit and comfort.
4Adaptability or versatility
If multiple separate components are assembled, then functional requirements are met, but installation and manufacturing issues arise
Solution Approach 1:
The patent combines multiple functional components into a single foam structure that is molded in one operation. The blade holder, tongue, tendon guard, and shell are all formed as one integrated piece, eliminating the need for separate manufacturing and assembly operations while maintaining all required functions.
Solution Approach 2:
The patent incorporates the blade holder and other components into the foam structure during the molding process itself, rather than assembling them separately afterward. The foam is molded around and integrating with these components, so they are pre-positioned and secured within the structure before the foam cures, simplifying installation.
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 skate boots that are lighter, more comfortable, provide better protection, and have a proper fit, while being more affordable to produce, with improved manufacturing efficiency and easier installation of skating devices.
Implementation Method 1
at least part of the skate boot or other foot-receiving structure and optionally at least part of one or more other components (e.g., the skating device) of the skate or other footwear may be constructed from one or more materials (e.g., foams) molded by flowing in molding equipment during a molding process
Implementation Method 2
injecting respective ones of the constituents to produce the material of the body of the skate boot; and controlling proportions of the respective ones of the constituents to impart the desired property to the material of the body of the skate boot
Implementation Method 3
injecting the isocyanate, the first polyol, and the second polyol to produce the polyurethane of the body of the skate boot
Data Source
AI summary
A skate (e.g., an ice skate) or other footwear for a user. The skate or other footwear comprises a skate boot or other foot-receiving structure for receiving a foot of the user and possibly one or more other components, such as a skating device (e.g., a blade 5 and a blade holder) disposed beneath the skate boot to engage a skating surface (e.g., ice). In some cases, at least part of the skate 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 in molding equipment during a molding process (e.g., injection molding or 0 casting). This may allow the skate or other footwear to have useful performance characteristics (e.g., reduced weight, proper fit and comfort, etc.) while being more cost-effectively manufactured.