A skate having a skate boot with a non-lasted boot shell, the shell having a first non-lasted three-dimensional sub-shell and a second non-lasted three-dimensional sub-shell, the second sub-shell being interior to and adjoining the first sub-shell, the first sub-shell comprising a first material having a first density and the second sub-shell comprising a second material having a second density, the second density being less than the first density, the shell being shaped so as to have a heel portion, an ankle portion, a lateral portion, a medial portion, and a sole portion; and a ground-engaging assembly disposed on an underside of the skate. Additional sub-shells are possible. Methods of manufacturing the skate boot shell, including molding and build-up, are also disclosed.
1. A skate comprising:
a skate boot having a non-lasted shell, the shell having a first non-lasted three-dimensional sub-shell and a second non-lasted three-dimensional sub-shell, the second sub-shell being interior to and adjoining the first sub-shell, one or both of the first sub-shell, the second sub-shell being of variable thickness, the first sub-shell comprising a first material having a first density and the second sub-shell comprising a second material having a second density, the second density being less than the first density, the shell being shaped so as to have a heel portion, an ankle portion, a lateral portion, a medial portion, and a sole portion; and
a ground-engaging assembly disposed on an underside of the skate boot.
2. A skate as recited in claim 1 , wherein the first material has a first stiffness and the second material has a second stiffness, the second stiffness being less than the first stiffness.
3. A skate as recited in claim 2 , wherein the second material is a foam.
4. A skate as a recited in claim 1 , wherein the second material is a foam.
5. A skate as recited in claim 4 , wherein the first sub-shell and the second sub-shell are joined to one another via a chemical fastener, at least one mechanical fastener, or a combination thereof.
6. A skate as recited in claim 4 , wherein the first sub-shell and the second sub-shell are fastenerlessly bonded to one another.
7. A skate as recited in claim 4 , wherein the first sub-shell has a contoured inner surface and the second sub-shell has a contoured outer surface complementary with the inner surface of the first sub-shell.
8. A skate as recited in claim 1 , wherein the first sub-shell is ornamented.
9. A skate as recited in claim 4 , wherein the first sub-shell has an inner surface and the second sub-shell has an outer surface, the inner surface covering an entirety of the outer surface.
10. A skate as recited in claim 1 , wherein at least one of the sub-shells is of a shape in at least one portion of the shell to provide reinforcement in that portion.
11. A skate as recited in claim 1 , further comprising at least one reinforcing element associated with the skate to reinforce at least part of the skate.
12. A skate as recited in claim 1 , wherein at least one of the sub-shells has a left portion and a separately formed right portion, the left portion and the right portion being connected to each other.
13. A skate as recited in claim 1 , wherein the first material is a plastic and the second material is a thermoplastic foam.
14. A skate as recited in claim 1 , further comprising:
a toe cap connected to the shell for protecting toes of a wearer of the skate;
a tongue connected to the toe cap;
a facing connected to the lateral and medial portions of the shell;
a liner disposed within the shell.
15. A skate as recited in claim 14 , wherein the skate boot is an ice skate and the ground-engaging assembly includes a blade adapted for skating on ice.
16. A skate as recited in claim 14 , wherein the facing is more flexible than the skate shell.
17. A method of manufacturing a non-lasted skate boot shell, the shell having a first non-lasted three-dimensional sub-shell and a second non-lasted three-dimensional sub-shell, the shell being shaped so as to have a heel portion, an ankle portion, a lateral portion, a medial portion, and a sole portion, the method comprising:
(i) non-lastedly forming the first three-dimensional sub-shell from first material having a first density, the first sub-shell having an inner surface;
(ii) non-lastedly forming the second three-dimensional sub-shell, separately from the first sub-shell and from a second material having a second density lower than the first density , the second sub-shell having an outer surface registerable with the inner surface of the first sub-shell;
(iii) placing the second sub-shell within an interior of the first sub-shell such that the outer surface of the second sub-shell registers with the inner surface of the first sub-shell; and
(iv) securing the second sub-shell to the first sub-shell to form the shell having the heel portion, the ankle portion, the lateral portion, the medial portion and the sole portion.
18. A method of manufacturing a non-lasted skate boot shell as recited in claim 17 , wherein the second material is a foam.
19. A skate having a skate boot with the non-lasted skate boot shell manufactured according to the method of claim 18 .
20. A method of manufacturing a non-lasted skate boot shell, the shell having a first non-lasted three-dimensional sub-shell and a second non-lasted three-dimensional sub-shell, the shell being shaped so as to have a heel portion, an ankle portion, a lateral portion, a medial portion, and a sole portion, the method comprising:
(i) non-lastedly forming the first three-dimensional sub-shell from a first material having a first density, the first sub-shell having an inner surface; and
(ii) non-lastedly forming the second three-dimensional sub-shell within and secured to the first sub-shell, and from a second material having a second density lower than the first density, the second sub-shell having an outer surface registering with the inner surface of the first sub-shell.
21. A method of manufacturing a non-lasted skate boot shell as recited in claim 20 , wherein the second material is a foam.
22. A skate having a skate boot with the non-lasted skate boot shell manufactured according to the method of claim 21 .
23. A method of manufacturing a non-lasted skate boot shell, the shell having a first non-lasted three-dimensional sub-shell and a second non-lasted three-dimensional sub-shell, the shell being shaped so as to have a heel portion, an ankle portion, a lateral portion, a medial portion, and a sole portion, the method comprising:
(i) non-lastedly forming the second three-dimensional sub-shell from a second material, the second sub-shell having an outer surface; and
(ii) non-lastedly forming the first three-dimensional sub-shell around and secured to the second sub-shell from a first material having a higher density than that of the second material, the first sub-shell having an inner surface registering with the outer surface of the second sub-shell.
24. A method of manufacturing a non-lasted skate boot shell as recited in claim 23 , wherein the second material is a foam.
25. A skate having a skate boot with the non-lasted skate boot shell manufactured according to the method of claim 24 .