Skate Toe Cap Extension for Abrasion Protection and Thermoformability

Solution Overview

Problem

Hockey skates have a vulnerable area between the skate boot and toe cap that is prone to abrasion, cuts, and damage due to the rigidity of the toe cap, which can hinder the thermoformability and comfort of the skate boot during use and manufacturing.

Innovation Solution

A toe cap extension made of a more malleable material with a thinner thickness than the toe cap, extending rearwardly to cover the area prone to abrasion, allowing the skate boot to move freely rearward of the forward-most eyelet during formation and use, and integrated with the toe cap without stitching to enhance durability and comfort.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a robust toe cap is used to protect the foot, then protection capability is improved, but flexibility and thermoformability of the skate boot deteriorate

Engineering Contradiction:

Improveprotection capabilityVSAvoidthermoformability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The toe cap is divided into two distinct segments: a rigid toe cap portion for protection and a flexible toe cap extension portion for thermoformability. This segmentation allows each portion to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the toe cap structure are assigned different material properties - the toe cap portion uses rigid material for protection while the toe cap extension uses flexible material for thermoformability. This local differentiation of material quality resolves the contradiction between protection and adaptability.

Inventive Principle:

Principle #3Local quality

2Strength

If a rigid toe cap is used to protect the foot, then protection capability is improved, but comfort of the skate boot deteriorates

Engineering Contradiction:

Improveprotection capabilityVSAvoidcomfort

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The toe cap is divided into two distinct segments: a rigid toe cap portion for protection and a flexible toe cap extension portion for thermoformability. This segmentation allows each portion to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the toe cap structure are assigned different material properties - the toe cap portion uses rigid material for protection while the toe cap extension uses flexible material for thermoformability. This local differentiation of material quality resolves the contradiction between protection and adaptability.

Inventive Principle:

Principle #3Local quality

3Strength

If the toe cap extends backward to cover more area, then protection capability is improved, but the area prone to abrasion between toe cap and boot increases

Engineering Contradiction:

Improveprotection capabilityVSAvoidabrasion susceptibility

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The toe cap extension acts as an intermediary element that bridges the rigid toe cap and the skate boot. It provides a gradual transition zone that reduces stress concentration and minimizes abrasion at the interface between the toe cap and boot.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The toe cap extension is made from a flexible material that can conform to the skate boot and move with it, reducing friction and abrasion. This flexible layer protects the interface area while maintaining the protective function of the rigid toe cap.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS12256804B2Skate with toe cap extension

Publication Date: 2025.03.25 SPORT MASKA

AI summary

A skate includes a skate boot with two opposed boot side portions extending from heel and ankle portions to a forward edge of the boot side portions. A forward-most eyelet is the eyelet closest to the forward edge. A toe cap is connected to the skate boot at a front end, and the toe cap has toe cap side portions extending rearwardly to a rear edge of the toe cap disposed forward of the forward-most eyelet. A toe cap extension extends rearwardly from the rear edge of the toe cap and over a portion of the boot side portions defined rearward of the forward edge and below the forward-most eyelet. The toe cap extension engages the portion of the skate boot and allows movement of at least the skate boot rearward of the forward-most eyelet during formation of the skate boot or use thereof.