U.S. patent application number 11/954091 was filed with the patent office on 2009-06-11 for safety footwear.
This patent application is currently assigned to Baffin Inc.. Invention is credited to Paul Hubner.
Application Number | 20090145006 11/954091 |
Document ID | / |
Family ID | 40720169 |
Filed Date | 2009-06-11 |
United States Patent
Application |
20090145006 |
Kind Code |
A1 |
Hubner; Paul |
June 11, 2009 |
SAFETY FOOTWEAR
Abstract
In accordance with the present invention there is disclosed
safety footwear comprising a unitarily moulded lower member having
a sole portion and a toe cap portion. One or more protective
elements are embedded in the unitarily moulded lower member so as
to prevent breaches thereof.
Inventors: |
Hubner; Paul; (Burlington,
CA) |
Correspondence
Address: |
LANG MICHENER LLP
Brookfield Place, SUITE 2500, 181 BAY STREET
TORONTO
ON
M5J 2T7
CA
|
Assignee: |
Baffin Inc.
Stoney Creek
CA
|
Family ID: |
40720169 |
Appl. No.: |
11/954091 |
Filed: |
December 11, 2007 |
Current U.S.
Class: |
36/77R ; 36/72R;
36/73 |
Current CPC
Class: |
A43B 23/086 20130101;
A43B 13/12 20130101; A43B 13/10 20130101 |
Class at
Publication: |
36/77.R ;
36/72.R; 36/73 |
International
Class: |
A43B 23/08 20060101
A43B023/08; A43B 13/22 20060101 A43B013/22 |
Claims
1. Safety footwear comprising: (a) a unitarily moulded lower member
constructed from polyurethane, wherein said lower member has a sole
portion and a toe cap portion; and, (b) one or more protective
elements embedded in said unitarily moulded lower member.
2. Safety footwear according to claim 1, wherein said protective
elements comprise one or more substantially planar shield members
embedded in said sole portion.
3. Safety footwear according to claim 2, wherein said one or more
shield members comprise a single shield member spanning
substantially the entire length and width of said sole portion.
4. Safety footwear according to claim 3, wherein said shield member
is embedded in said sole portion so as to be fully encased
therewithin.
5. Safety footwear according to claim 4, wherein said shield member
is constructed from one or more composite materials.
6. Safety footwear according to claim 4, wherein said shield member
is constructed from pierce resistant fabric selected from the group
consisting of: woven steel fibers and woven KEVLAR.RTM. fibers.
7. Safety footwear according to claim 1, wherein said protective
elements comprise a toe box embedded in said toe cap portion.
8. Safety footwear according to claim 7, wherein said toe box
comprises a convex shell having an inwardly projecting bottom
flange portion.
9. Safety footwear according to claim 8, wherein said toe box is
embedded in said toe cap portion during moulding so as to be fully
encased therewithin.
10. Safety footwear according to claim 9, wherein said toe box is
constructed from one or more composite materials.
11. Safety footwear according to claim 1, wherein said protective
elements comprise one or more shield members embedded in said sole
portion, and a toe box embedded in said toe cap portion.
12. Safety footwear according to claim 11, wherein said shield
members are embedded in said sole portion so as to each be fully
encased therewithin.
13. Safety footwear according to claim 11, wherein said toe box is
embedded in said toe cap portion so as to be fully encased
therewithin.
14. Safety footwear according to claim 11, wherein said shield
members are embedded in said sole portion so as to be fully encased
therewithin; and, wherein said toe box is embedded in said toe cap
portion so as to be fully encased therewithin.
15. Safety footwear according to claim 12, wherein said one or more
shield members comprise a single shield member spanning
substantially the entire length and width of said sole portion.
16. Safety footwear according to claim 14, wherein said one or more
shield members comprise a single shield member spanning
substantially the entire length and width of said sole portion.
17. Safety footwear according to claim 11, wherein said toe box
comprises a convex shell having an inwardly projecting bottom
flange portion.
18. Safety footwear according to claim 11, wherein said protective
elements are each constructed from one or more composite
materials.
19. Safety footwear according to claim 12, wherein said sole plates
are constructed from pierce resistant fabric selected from the
group consisting of: woven steel fibers and woven KEVLAR.RTM.
fibers.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of
footwear and, more specifically, to improved safety footwear.
BACKGROUND OF THE INVENTION
[0002] In many applications, it is necessary for footwear to
include features aimed at preventing injury to the wearer. Such
footwear is known in the art, and will be referred to herein, as
"safety footwear". Features commonly exhibited by such safety
footwear include toe boxes, sole plates or other protective
elements provided therein at one or more various locations
throughout the footwear (e.g., toe, sole, instep). Such elements
are designed to, for example, minimize penetration of sharp
articles into the safety footwear that may be stepped on by the
wearers thereof. Toe box protection is typically aimed at
preventing crushing of the toes and/or metatarsals of the wearer,
by reinforcing the corresponding region of the safety footwear. One
skilled in the art will recognize that modern safety footwear is
not limited to boots, but also extends to many types of shoes,
clogs, sneakers and other general classes of footwear.
[0003] Metal, and usually rigid metal, is commonly used to
construct many of the aforementioned protective elements; however,
it is, in many instances, not preferable. For example, in some
applications, metals are preferably avoided due to their ability to
conduct electricity and/or heat. Moreover, the relatively high
weight of most metals is another important factor in limiting their
usefulness as a reinforcing material in safety footwear.
[0004] The use of lighter materials (e.g., ceramics, composites,
woven fabrics, and the like) is preferable, as it lessens the
energy that must be expended by a user to move his or her foot. Of
course, this property is advantageous both in applications wherein
the footwear is worn by an adult who desires, for example, to be
able to perform work with less exertion, and to applications where
it is desired that, for example, a child wear safety footwear
without excessive strain.
[0005] One of the most common uses of protective elements in safety
footwear is designed to combat the penetration of nails, screws or
other similarly sharp and rigid objects through the sole of such
footwear when the user of the safety footwear steps on such items.
One skilled in the art will readily appreciate that, since
substantially all of the weight of the wearer may, in such
circumstances, be applied via the nail, screw, or other sharp or
rigid object stepped upon, to protective elements located within
the sole, one problem associated with safety footwear is the actual
displacement of the protective elements within the sole region of
the safety footwear.
[0006] Movement of such a protective element within the safety
footwear may allow the wearer to be injured. Moreover, the
structural integrity of the footwear will be lost, and the footwear
will need to be repaired or, more likely, replaced. Such an
occurrence would be particularly disadvantageous in instances where
the safety footwear is worn in a hazardous environment in which it
will be expected to withstand multiple impacts without being
rendered useless.
[0007] It is also desirable for safety footwear to be waterproof,
and for such a property to be maintained despite minor punctures of
the base of the sole of the boot (e.g., a nail that penetrates the
lower surface of the sole, but is stopped by a protective element
thereabove), or a puncture or cut on the toe. It is thus desirable
for waterproofing of safety footwear to survive punctures or
slicing on the external side of the protective element. Safety
footwear has not been provided that exhibits all of the above
advantageous properties.
[0008] Another problem with prior art safety footwear, in terms of
waterproofing thereof, has been the highly prevalent use of leather
or synthetic leather as the main material for such footwear. While
these materials can be treated so as to be waterproof, such
treatment is time-consuming, and requires re-application,
particularly when safety footwear is used in wet or, for example,
snowy and cold environments.
[0009] Moreover, in prior art safety footwear, protective elements
have not typically been integral to the footwear itself. For
example, sole reinforcement elements have typically been interposed
between the sole of the footwear and, for example, an insole or the
like. In instances where the protective elements may have been at
least partially integral to the safety footwear, the sole and the
remainder of the lower of the boot have typically been separate
components.
[0010] There have, in many instances, been insufficient means of
retaining the position of the sole elements when same is impacted
by a sharp object as aforesaid. Furthermore, maintenance of a
water-proof state upon penetration of the outer sole is problematic
in such a configuration, as a seal is not necessarily effected
about the sole plate.
[0011] Such a seal, i.e., as can be achieved by way of, for
example, providing elements integral to the safety footwear, and
sealed therein, is not necessarily possible in prior art safety
footwear, particularly where such safety footwear is constructed
from leather and the like.
[0012] In this regard, it is noted that such sealed configurations
may be achieved according to the present invention by way of
integrally moulding one or more protective elements within a lower
member, such as a sole portion, of the safety footwear, which lower
member is preferably constructed from polyurethane, due to its
advantageous properties, including low weight, mouldability, and
water-proof nature.
[0013] It is noted that the use of polyurethane to mould a unitary
lower member of safety footwear has not previously been disclosed.
In this regard it is further noted that moulding of safety footwear
necessitates a plurality of design concerns quite apart from those
relevant to the production of non-moulded prior art safety
footwear. For example, the exact position of the protective
elements must be carefully chosen, as such elements may not be
manipulated subsequent to production of the safety footwear.
[0014] Accordingly it is an object of the present invention to
obviate and/or mitigate one or more of the foregoing deficiencies
of the prior art.
SUMMARY OF THE INVENTION
[0015] In accordance with the present invention there is disclosed
safety footwear comprising a unitarily moulded lower member
constructed from polyurethane and having a sole portion and a toe
cap portion. One or more protective elements are embedded in the
unitarily moulded lower member.
[0016] In accordance with another aspect of the present invention,
the protective elements comprise one or more substantially planar
shield members embedded in the sole portion.
[0017] In accordance with another aspect of the present invention,
the one or more shield members comprise a single shield member
spanning substantially the entire length and width of the sole
portion.
[0018] In accordance with another aspect of the present invention,
the shield member is embedded in the sole portion so as to be fully
encased therewithin.
[0019] In accordance with another aspect of the present invention,
the shield member is constructed from one or more composite
materials.
[0020] In accordance with another aspect of the present invention,
the shield member is constructed from pierce resistant fabric
selected from the group consisting of: woven steel fibers and woven
KEVLAR.RTM. fibers.
[0021] In accordance with another aspect of the present invention,
the protective elements comprise a toe box embedded in the toe cap
portion.
[0022] In accordance with another aspect of the present invention,
the toe box comprises a convex shell having an inwardly projecting
bottom flange portion.
[0023] In accordance with another aspect of the present invention,
the toe box is embedded in the toe cap portion during moulding so
as to be fully encased therewithin.
[0024] In accordance with another aspect of the present invention,
the toe box is constructed from one or more composite
materials.
[0025] In accordance with yet another aspect of the present
invention, the protective elements comprise one or more shield
members embedded in the sole portion, and a toe box embedded in the
toe cap portion.
[0026] It is thus an object of this invention to obviate or
mitigate at least one of the above mentioned disadvantages of the
prior art.
[0027] Other advantages, features and characteristics of the
present invention, as well as methods of operation and functions of
the related elements of the structure, and the combination of parts
and economies of manufacture, will become more apparent upon
consideration of the following detailed description and the
appended claims with reference to the accompanying drawings, the
latter of which is briefly described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The novel features which are believed to be characteristic
of the according to the present invention, as to its structure,
organization, use and method of operation, together with further
objectives and advantages thereof, will be better understood from
the following drawings in which, among other things, a presently
preferred embodiment of the invention will now be illustrated by
way of example. It is expressly understood, however, that the
drawings are for the purpose of illustration and description only,
and are not intended as a definition of the limits of the
invention. In the accompanying drawings:
[0029] FIG. 1 is a front perspective view from the top left of a
first embodiment of safety footwear according to the present
invention;
[0030] FIG. 2 is a sectional view of a lower portion of the safety
footwear of FIG. 1 along sight line 2-2 of FIG. 1;
[0031] FIG. 3 is an enlarged view of the encircled area 3 of FIG.
2;
[0032] FIG. 4 is a sectional view of a lower portion of a second
embodiment of safety footwear according to the present invention,
with the protective elements shown fully encased in the lower
member;
[0033] FIG. 5 is an enlarged view of the encircled area 5 of FIG.
4;
[0034] FIG. 6 is a rear perspective view from the top left of a toe
box;
[0035] FIG. 7 is a front perspective view from the top left of the
toe box of FIG. 6; and
[0036] FIG. 8 is a front perspective view from the top left of a
protective element, being a shield member.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0037] Looking to the Figures, there will be seen safety footwear
10 comprising a unitarily moulded lower member 12. The lower member
12, which is formed as a unitary piece by moulding, has a sole
portion 14 and a toe cap portion 16, as can be seen in FIGS. 1 and
2. The lower member 12 is substantially water-proof, and is
constructed from lightweight polyurethane which may be moulded as a
foam, and then allowed to cure and solidify. Moreover, polyurethane
exhibits relatively low weight, exceptional performance as a
mouldable material, and articles formed therefrom are inherently
water-proof, all of which properties are advantageous. Formation of
the lower member 12 by moulding allows for the lower member 12 to
upwardly extend about its periphery without any joints therein
(which are susceptible to leakage) and, thus, allows for production
of safety footwear 10 that is reliably water-proof up to a higher
level from the ground than is typically possible in non-moulded
safety footwear. Further advantages of formation of the lower
member 12 by moulding will be discussed hereinbelow.
[0038] The safety footwear 10 may, but need not necessarily, also
include a flexible upper member 18, that extends upwardly from the
lower member 12, as seen in FIG. 1, and is desirably, in most
instances, also substantially water-proof. The lower member 12 and
the upper member 18 may be stitched together, glued together, or
may be joined in any other conventional manner. The upper member 18
may be composed of one or more flexible materials, such as, for
example, leather, synthetic leather, nylon fabric, combinations of
these materials, and the like. The footwear 10 may also comprise an
inner liner (not shown)--which liner may or may not be
removable--particularly in instances where the footwear 10 is
designed for use in colder environments, which liner serves to have
insulative and cushioning effects with respect to the foot (not
shown) of a user (not shown). As will be appreciated from a
consideration of FIGS. 2 and 4, the lower member 12 may
additionally and advantageously comprise treads 36 integral
thereto. Treads constructed from various different materials may be
bonded to the lower member 12 in some embodiments, if desired.
[0039] One or more protective elements 20 are embedded in the
unitarily moulded lower member 12, as shown in FIGS. 2 through 5.
These protective elements 20 serve to prevent breaches--e.g.,
punctures, slices, etc.--through the lower member 12. The inclusion
of protective elements 20 may be aimed at preventing breaches at
various locations throughout the lower member 12; however, some
locations may be particularly susceptible to such breaches. For
example, the protective elements 20 preferably comprise one or more
substantially planar shield members 22, as seen in FIG. 8, each
embedded in the sole portion 14 of the lower member 12. One skilled
in the art will appreciate that protective elements 20 may also be
provided in, for example, the toe cap portion 16 and in-step area
32 of the safety footwear 10.
[0040] There may most preferably be provided a single shield member
22 that spans substantially the entire length and width of the sole
portion, as will be appreciated from FIG. 2, and from a comparison
of FIGS. 1 and 8. In so spanning the length and width of the sole
portion 14, the single shield member 22 provides a high degree of
protection for substantially the entire lower surface of the foot
of the user. In this regard, it is noted that the shield member 22
is embedded within the sole portion 14 such that the single shield
member 22 is at least laterally fully surrounded thereby, so as to
assist in maintaining the water-proof nature of the safety footwear
10.
[0041] The protective elements 20 may alternatively or
additionally, the latter being highly preferable, comprise a toe
box 24 embedded in the toe cap portion 16 of the lower member 14,
as seen in FIGS. 2 through 5. As best seen in FIGS. 6 and 7, the
toe box 24 preferably comprises a convex shell 26 having an
inwardly projecting bottom flange portion 28. As with the shield
member(s) 22, the toe box 24 is embedded completely within the toe
cap portion 16 during moulding of the lower member 12.
[0042] The toe box 24 is substantially rigid and can withstand high
compressive forces so as to prevent crushing and/or severing of a
user's toes, in addition to preventing punctures and slicing of the
toe cap portion 16. Such compressive forces would typically be
received by way impact of an object on an upper surface of the toe
box 24.
[0043] The nature of embedding of the shield members 22 and the toe
box 24 within the lower member 12 can and will vary between
embodiments of the invention, and may vary between the different
protective elements 20 employed in any particular article of safety
footwear 10. In any event, however, embedding of these protective
elements 20 in the lower member 12 is made possible by formation of
the lower member 12 by way of moulding.
[0044] For example, each protective element 20 may be embedded, as
in the case of the toe box 24 and shield member 22 shown in FIGS. 4
and 5, such that a top surface 22a of the shield member 22, and a
rear surface 25b of the toe box 24 are both exposed. One skilled in
the art will appreciate that, in such an embodiment, each
protective element 20 is sealed into the lower member 12. More
particularly, the lower member 12 is moulded around at least a
portion of each protective element 20. In the case of the toe box
24, the lower member 12 is moulded around the flange portion 28
thereof and also around at least a portion of the convex shell 26
thereof, as seen in FIGS. 4 and 5. In the case of the shield member
22, the lower member 12 is moulded around a toe end 23a and a heel
end 23b thereof. In this manner, punctures or slices of the
portions of the lower member 12 located adjacent a bottom surface
22b of the shield member or located adjacent the front surface 25a
of the toe box 24 do not allow leaks (of air or, for example,
water) into the interior of the safety footwear 10 as each
protective element 20 remains substantially sealed therein after
such punctures or slices of the outer surface of the lower member
12.
[0045] One skilled in the art will readily appreciate that such
sealing of the protective elements 20 within the lower member
12--which is not readily possible in prior art safety footwear
constructed by ways other than by moulding, particularly that
constructed of, for example and without limitation, leather--also
serves to provide resistance to displacement of the protective
elements 20 within the lower member 12, which displacement may
occur, for example when stepping on a sharp, rigid object (such as
a nail).
[0046] The protective element 20 may each preferably be embedded in
the lower member so as to be fully encased therewithin, as shown in
FIGS. 2 and 3. Such embodiments (i.e., as in FIGS. 2 and 3) will
exhibit all of the advantageous properties discussed above with
respect to the embodiment shown in FIGS. 4 and 5, and will do so to
a still further degree, given the increased stability of the
protective elements 20 within the lower member 12, and the more
comprehensive seal accomplished by total encasing of each
protective element 20 within the lower member 12.
[0047] One skilled in the art will appreciate that each protective
element need not be embedded in the same fashion as any others in
the particular article of safety footwear 10. This is, an article
of safety footwear 10 could have a toe box 24 embedded as in FIGS.
2 and 3, and a shield member 22 embedded as in FIGS. 4 and 5.
[0048] Each shield member 22 and the toe box 24 may be constructed
from one or more composite materials. In this specification and the
appended claims, the term "composite materials" is defined as
follows: composite materials are materials composed of two or more
components. One component is typically a fibrous material such as,
for example fibre glass, KEVLAR.RTM., a carbon fibre, or the like,
which may be provided in filamentary or sheet form, and that serves
to provide rigidity and tensile strength. The other component is
typically a resin (e.g., polyester, epoxy, or cyanate ester), which
is typically cured (by way of heat or otherwise), and that serves
to bind together the fibrous material. Such composite materials
exhibit advantageous properties in that they are typically very
light in weight, particularly when considered relative to their
tensile and compressive strength.
[0049] Each shield member 22 may alternatively be constructed from
pierce resistant densely woven fabric selected from the group
consisting of: woven steel fibers and woven KEVLAR.RTM. fibers.
[0050] Other modifications and alterations may be used in the
design and manufacture of other embodiments according to the
present invention without departing from the spirit and scope of
the invention, which is limited only by the accompanying
claims.
* * * * *