Skate Boot Outer Shell Injection Molding Process
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Solution Overview
Problem
Existing skate boot designs often have multiple components and materials, which complicate manufacturing and do not always provide an aesthetically appealing appearance while ensuring good foot support.
Innovation Solution
A method involving a male-female mold system where a pre-cut cloth sheet laminated with non-woven fabric is used, injected with liquid plastic at specific temperatures and pressures to form a single-piece outer shell that encases the foot, reducing components and enhancing appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components and materials are used in skate boot construction, then performance requirements can be met, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple components (outer shell, lining, and structural elements) into a single integrated boot structure formed by injecting liquid plastic material over a last. This consolidation reduces manufacturing steps and component assembly complexity while maintaining the performance benefits of multi-material construction through the integrated design.
Solution Approach 2:
The invention uses composite materials by combining liquid plastic material with a last (form) to create an integrated boot structure. The liquid plastic material is injected at controlled temperatures (160-200°C) and pressures (985-1015 psi) to bond with the last and form a unified composite structure that eliminates separate component assembly.
2Reliability
If multiple components are used in skate boot construction, then performance can be achieved, but the appearance becomes less appealing
Solution Approach 1:
By merging the outer shell and structural components into a single integrated boot formed through injection molding, the design achieves a smoother, more aesthetically pleasing appearance. The single-piece construction eliminates visible seams and component joints, creating a streamlined look while maintaining foot support through the integrated last structure.
3Ease of manufacture
If a single-piece outer shell is formed, then manufacturing is simplified, but the shell may lack durability
Solution Approach 1:
The invention controls the physical parameters of the liquid plastic material during injection, specifically temperature (160-200°C) and pressure (985-1015 psi), to ensure proper material flow, bonding, and structural integrity. These parameter controls enable the single-piece construction to achieve both manufacturing simplicity and the durability required for skate boot application.
Solution Approach 2:
The single-piece outer shell is formed as a composite structure by injecting liquid plastic material that bonds with the last (form). This composite construction provides both the manufacturing advantages of single-piece formation and the durability of a bonded, multi-layer structure, eliminating the need for separate component assembly while maintaining strength.
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 method simplifies the manufacturing process, reduces the number of components, and creates a skate boot with improved durability and aesthetic appeal by forming a single, integrated outer shell that provides excellent foot support and resistance to wear, abrasion, and moisture.
Implementation Method 1
injecting liquid plastic material in the inner channels at a temperature of between 160° C. and 200° C. and at a pressure of between 985 psi and 1015 psi
Implementation Method 2
injecting liquid plastic material in the inner channels at a temperature of between 160° C. and 200° C.
Implementation Method 3
fills the mold cavity and fuses with the non-woven fabric to form, after cooling, an outer shell
Data Source
AI summary
A method of making a lasted skate boot comprising: (a) providing a male-female mold having male and female sections for defining a mold cavity therebetween, the male section having sides, a rear portion and a bottom portion for defining a three dimensional shape corresponding to the external three dimensional shape of the foot, the female section defining a recess for receiving the male section, the male section comprising a plurality of inner channels for admitting liquid plastic material in the mold cavity; (b) providing a pre-cut sheet made of cloth material laminated to a support made of non-woven fabric; (c) placing the sheet on the male section of the mold such that the non-woven fabric contacts the sides and rear portion of the male section of the mold; (d) closing the male and female sections of the mold; (e) injecting liquid plastic material in the inner channels such that the liquid plastic material spreads on the sheet, pushes the sheet against the recess of the female section of the mold, fills the mold cavity and fuses with the non-woven fabric to form, after cooling, an outer shell comprising a heel portion for surrounding the heel, an ankle portion for surrounding the ankle, and medial and lateral side portions for enclosing the medial and lateral sides of the foot respectively; (f) opening the male and female sections of the mold; and (g) removing the outer shell from the mold.