Embedded Cuff Insert Structure for Skate Boot Ankle Support
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Solution Overview
Problem
Existing skate boots lack targeted stiffening in the upper cuff region to optimize ankle support and flexibility during skating, with existing methods providing limited control over material boundaries and adding weight or thickness.
Innovation Solution
A skate boot design featuring a cuff insert made of a harder material embedded within the upper cuff, molded separately and then integrated into the boot body, providing targeted rigidity and flexibility without additional weight or thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a complex multi-material injection molding process is used to create different performance characteristics in different regions, then varying performance characteristics can be achieved, but manufacturing complexity increases and control over material boundaries is limited
Solution Approach 1:
The boot is divided into multiple components with different materials: a boot body made of plastic material and a separate cuff insert made of harder material. This segmentation allows each component to be manufactured independently with optimized properties, then assembled together to achieve varying performance characteristics without requiring complex multi-material injection molding.
Solution Approach 2:
The boot combines different materials (plastic material for the boot body and harder material for the cuff insert) to create a composite structure. This allows each material to contribute its optimal properties - the plastic material provides flexibility and comfort while the harder material provides stiffness and support in the cuff region.
2Adaptability or versatility
If inserts are embedded into the molded boot to provide varying performance characteristics, then performance optimization is achieved, but the inserts add weight and thickness to the boot
Solution Approach 1:
The harder material cuff insert is placed specifically in the upper cuff region where stiffness is needed for ankle support, while the rest of the boot body uses lighter plastic material. This localized application of different materials provides performance optimization only where needed, minimizing the overall weight and thickness increase.
3Strength
If harder material is used in the upper cuff region, then ankle support and shape maintenance are improved, but the boot loses flexibility in that region
Solution Approach 1:
The boot is segmented into a flexible boot body and a stiffer cuff insert, allowing different flexibility characteristics in different regions. The plastic material boot body maintains flexibility for comfort and movement, while the harder material cuff insert provides ankle support and shape maintenance.
Solution Approach 2:
The composite structure combines flexible plastic material with harder material in the cuff region, creating a boot that has both flexibility in the foot area and stiffness in the ankle area, thus maintaining ease of operation while providing strength where needed.
Data Source
AI summary
A skate boot has (i) a unitary, molded boot body formed of plastic material defining a sole, side walls, a rear wall and an upper cuff to surround the foot and lower leg region of a user, and (ii) a cuff insert at least partially embedded within the upper cuff of the boot body by molding the plastic material of the boot body about the cuff insert. The insert includes a rear section and two side sections to align with corresponding portions of the upper cuff of the boot body. The insert is a unitary molded structure that is harder than the boot body material. The insert provides targeted stiffening to the upper cuff region of the boot body so that the upper cuff maintains its shape and securement relative to the lower leg of the user as the user flexes their ankle to optimize performance of the skate boot.