U.S. patent application number 14/067144 was filed with the patent office on 2014-08-14 for footwear.
This patent application is currently assigned to Kanyon Outdoor LLP. The applicant listed for this patent is Kanyon Outdoor LLP. Invention is credited to Mark Robert Burman, Lloyd Ian Preston.
Application Number | 20140223773 14/067144 |
Document ID | / |
Family ID | 47998834 |
Filed Date | 2014-08-14 |
United States Patent
Application |
20140223773 |
Kind Code |
A1 |
Burman; Mark Robert ; et
al. |
August 14, 2014 |
Footwear
Abstract
A waterproof safety boot includes a one-piece EVA upper (11) to
which is applied a toe cap (15). A polyurethane toe cap cover (19)
is secured to the upper to encapsulate the toe cap. An outsole (25)
of e.g. synthetic nitrile rubber may be added. The upper may be a
booty.
Inventors: |
Burman; Mark Robert;
(Kettering, Northamptonshire, GB) ; Preston; Lloyd
Ian; (Kettering, Northamptonshire, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kanyon Outdoor LLP |
Kettering |
|
GB |
|
|
Assignee: |
Kanyon Outdoor LLP
Kettering
GB
|
Family ID: |
47998834 |
Appl. No.: |
14/067144 |
Filed: |
October 30, 2013 |
Current U.S.
Class: |
36/87 ; 12/142R;
36/83 |
Current CPC
Class: |
A43B 23/081 20130101;
A43B 23/086 20130101; A43B 23/087 20130101; A43B 1/0027 20130101;
A43B 23/082 20130101 |
Class at
Publication: |
36/87 ; 12/142.R;
36/83 |
International
Class: |
A43B 23/08 20060101
A43B023/08 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 8, 2013 |
GB |
1302264.5 |
Claims
1. Footwear comprising a one-piece moulded EVA upper having a rigid
toe cap applied to the exterior thereof, and a toe cap cover
applied to the exterior of said toe cap, the edge of said cover
being affixed to said upper.
2. Footwear according to claim 1, and further comprising a sole of
synthetic nitrile rubber, said sole being connected to the
upper.
3. Footwear according to claim 1, wherein said toe cap comprises
metal.
4. Footwear according to claim 1, wherein said toe cap comprises a
rigid composite.
5. Footwear according to claim 1, wherein said toe cap cover
comprises polyurethane.
6. Footwear according to claim 5, wherein said toe cap cover
comprises a moulding adhered to said upper by adhesive.
7. Footwear according to claim 5, wherein said toe cap cover is
adhered to said toe cap by adhesive.
8. Footwear according to claim 1, wherein said toe cap is adhered
to said upper by adhesive.
9. Footwear according to claim 1, wherein said upper includes a
moulded depression adapted for flush fitting of said toe cap.
10. Footwear according to claim 1, wherein said toe cap extends
under said upper.
11. Footwear according to claim 10, wherein said toe cap comprises
a continuous inwardly directed flange at the lower edge
thereof.
12. Footwear according to claim 1, wherein said toe cap cover
comprises an external 3D pattern.
13. Footwear according to claim 1, wherein said upper is a
booty.
14. A method of manufacturing a safety footwear comprising moulding
a one-piece upper of EVA, adhering a rigid toe cap to the exterior
of said upper, and adhering a toe cap cover of polyurethane to said
toe cap, said cover being adhered at the periphery thereof to said
upper.
15. The method of claim 14, including the further step of adhering
a sole of synthetic nitrile rubber to the underside of said
upper.
16. Footwear comprising a one-piece moulded upper of one colour,
and a toe cap of a contrasting colour, said toe cap being connected
to the upper.
17. Footwear according to claim 16, wherein said toe cap is adhered
to the upper.
18. Footwear according to claim 17, wherein said toe cap comprises
a reinforcement on the outside of said upper and a toe cap cover on
said reinforcement, said cover being adhered to said upper.
Description
BACKGROUND
[0001] This invention relates to footwear having a strengthened toe
cap, and to a method of manufacture thereof. In a second aspect,
the invention relates to footwear having a toe of contrasting
colour.
[0002] A characteristic of safety footwear is the provision of a
strengthened toe cap. Typically a domed reinforcement of steel is
incorporated at the toe of the footwear, for example a boot, to
provide protection against crushing. Legislation requires that the
reinforcement is incorporated in the footwear in such a manner that
it cannot be removed without damaging the footwear; in practice the
reinforcement is anchored against relative movement within the
footwear, so as to prevent tipping of the reinforcement and
consequent injury to the foot of the wearer. In one example a
conventional work boot comprises an assembly of parts which are
retained in appropriate juxtaposition by sewing and/or
adhesive.
[0003] A strengthened toe cap can be provided in many kinds of
footwear, and the upper (the part of the footwear above the sole)
may range from a front foot covering of a slip-on clog, through a
conventional shoe or ankle boot, to the substantial leg cover of a
wellington boot or wader.
[0004] In cases where absolutely waterproof footwear is required,
it is known to provide the upper as a moulded plastics booty to
encase at least part of the foot. Such a booty may have an integral
tread, or have an outsole applied thereto.
[0005] Several kinds of moulded waterproof boot are known,
consisting of or incorporating a one piece booty. An inexpensive
boot may be moulded in PVC (polyvinylchloride) by single injection
moulding, and have a non-slip rubber outsole fixed thereto by
adhesive. Such a boot may be moulded around a protective toe cap
(typically of steel), which adheres as the plastics material is
cured, and is thus fixed against relative movement within the boot.
A significant disadvantage of PVC footwear is weight, and such
footwear is also somewhat fatiguing to wear because the level of
cushioning underfoot is relatively low. A cushioning in-sole may be
fitted, but this adds both cost and weight. Footwear of PVC is also
undesirable because it does not easily decompose upon disposal, and
has other poor environmental aspects.
[0006] An alternative moulded boot comprises a one-piece
polyurethane (PU) moulding with integral outsole. Such a boot is
expensive compared with a PVC boot, but is lighter and can also
incorporate a protective toe cap which is adhered in the moulding
operation. One disadvantage of a PU sole is that it is not the
optimal material for slip resistance in a wet environment. Another
disadvantage is that the PU grade for the leg portion is generally
different from the foot portion, so as to ensure that the leg
`stands up` in use; this results in additional complication and
difficulty during moulding.
[0007] One characteristic of an in-moulded toe cap is that the
position of the toe cap insert cannot be seen after moulding.
Accordingly the footwear must be cut open for the purpose of
inspection, and confirmation of a correct moulding operation.
Furthermore an in-moulded toe cap substantially stiffens the toe of
the footwear, and may result in difficulty in releasing the
footwear from the mould. A solution to this problem is the adoption
of a mould shape that facilitates removal of the footwear from the
mould, but such a mould may not be ideally suited to the shape of a
foot.
[0008] It has also been proposed to mould footwear of EVA (ethyl
vinyl acetate). Such footwear is light and has very good
dimensional stability, good cushioning characteristics, and an
excellent external finish. However a reinforced toe cap will not
adhere to the plastics material during moulding, and is thus not
fixed relative to the footwear as is consequence of
legislation.
[0009] A characteristic of an EVA moulding is that it expands
substantially upon release from the mould, so that an in-moulded
toe cap is very unlikely to be retained in the correct position, or
the surface of the EVA moulding may become distorted. Consequently
a reinforced toe cap must be inserted into an EVA booty after
moulding, which is somewhat difficult. Furthermore to ensure
stability such a reinforced toe cap is pre-attached to a hard
mid-sole board, which increases the difficulty of insertion post
moulding, and may further require a cushion insole for comfort of
the user.
[0010] It would be desirable to provide a strengthened toe cap to
footwear having a moulded EVA upper which addresses the
difficulties noted above, and in particular to provide an improved
lightweight waterproof boot with a strengthened toe cap, at
relatively low cost.
[0011] A further requirement of safety footwear, particularly those
kinds used in the food industry, is the need for segregation
according to particular factory operations. Thus footwear worn in a
preparation area for raw meat should not also be used in an area
associated with cooked food, Furthermore it may be necessary to
distinguish footwear according to technical features thereof, for
example type of material, type of reinforcement, strength, sole
design etc. Some means of instant identification is typically
required to meet industry standards,
SUMMARY OF PRESENTLY DESIRABLE EMBODIMENTS
[0012] According to one aspect of the invention there is provided
footwear comprising a one-piece moulded EVA upper having a rigid
toe cap applied to the exterior thereof, and a toe cap cover
applied to the exterior of said toe cap, the edge of said cover
being affixed to said upper.
[0013] Such footwear is relatively inexpensive and avoids the
disadvantages of moulding from PVC or PU. The rigid toe cap,
preferably a shell of steel, aluminium or a composite, is applied
from the outside after the EVA upper has cured, and is in use
trapped by the toe cap cover. A suitable adhesive, such as
polyurethane resin or a two part epoxy, is used to attach the toe
cap to the upper and the toe cap cover to the assembly of upper and
toe cap.
[0014] The EVA moulding also provides a comfort lining to the
inside face of the rigid toe cap, thus obviating attachment of an
additional internal component.
[0015] By applying the toe cap from the exterior, correct
positioning is assured, and thus quality control of the footwear is
improved. Destructive testing to determine toe cap position is not
necessary, and a wider range of toe cap material is possible since
the toe cap is not exposed to high mould temperatures. Furthermore
a footwear mould can be better matched to the foot shape since an
allowance for easing the rigid toe cap from the mould is not
required. Insertion of a toe cap into a moulded booty is obviated,
along with the prior art mid-sole board.
[0016] The upper may comprise a one-piece moulded EVA booty, so as
to make the footwear waterproof.
[0017] In one embodiment a synthetic rubber outsole is applied to
the EVA upper, so as to give increased slip resistance and wear
properties according to the surface on which the footwear is
used.
[0018] In one embodiment the EVA upper includes a recessed toe
region adapted to receive and locate the toe cap so as to give a
flush junction. This arrangement further improves location and
retention of the toe cap on the upper. The toe cap may extend on
the underside of the booty in a recess thereof to provide a
substantially flush surface for attachment of a sole.
[0019] In a presently preferred embodiment, the toe cap includes an
interned flange at the lower peripheral edge, said flange being
adapted to fit under the toe of the upper, so as to improve
location and retention of the toe cap. The flange may be
continuous, and in the width range 4-8 mm.
[0020] The toe cap cover is in one embodiment a separately moulded
plastics or synthetic rubber moulding of for example polyurethane.
Such a moulding can be self coloured and provide a suitable means
of distinguishing boots of different kind, for different factory
areas or different uses. The toe cap may be a suitable relatively
hard and durable material, and may be patterned or ribbed.
[0021] In a second aspect the invention provides footwear
comprising a one piece moulded upper of one colour, and having
adhered thereto a moulded toe cap cover of a contrasting colour.
This aspect of the invention permits all kinds of moulded boot to
be distinguished in use, since a wide range of colours and patterns
may be adapted for the toe cap cover.
[0022] According to a third aspect of the invention there is
provided a method of manufacture of a waterproof safety boot
comprising moulding a one-piece upper of EVA, adhering a steel toe
cap to the exterior of said upper, and adhering a toe cap cover of
polyurethane to said toe cap, said cover being adhered at the
periphery thereof to said upper.
[0023] For the avoidance of doubt, by `upper` is meant the upper
visible part of the footwear, which may be attached to a sole to
form an enclosure for a foot, or may be in the form of a booty to
encircle at least the toes and fore part of the foot. In many
cases, a booty will comprise at least an enclosure of the foot,
from toe to ankle, and may further include a leg covering.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Other features of the invention will be apparent from the
following description of a presently preferred embodiment
illustrated by way of example only in the accompanying drawings in
which:
[0025] FIG. 1 is a boot according to the invention, in &de
elevation.
[0026] FIG. 2 is an illustrative transverse cross-section on line
2-2 of FIG. 1.
[0027] FIG. 3 is an illustrative transverse cross-section on line
3-3 of FIG. 1.
[0028] FIG. 4 is an illustrative transverse cross-section on line
4-4 of FIG. 1.
[0029] FIG. 5 is an illustrative transverse cross-section on line
5-5 of FIG. 1.
[0030] FIG. 6 is an illustrative longitudinal cross-section through
the boot of FIG. 1.
[0031] FIG. 7 is an enlarged cross-section of the toe of the boot
of FIG. 1.
[0032] FIG. 8 is an enlarged front elevation of the boot of FIG.
1.
[0033] FIG. 9 illustrates an alternative to the toe of FIG. 7.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0034] The following description of the invention is in relation to
a wellington boot. It will however be understood that the invention
is suitable for many kinds of safety footwear, including clogs,
slip on shoes, laced shoes, ankle boots, wellington boots and
waders.
[0035] With reference to the drawings, a wellington boot 10
comprises a one-piece booty 11 moulded by ethyl vinyl acetate
(EVA). The booty is moulded as a single shot in order to ensure
that no seams, joins or other junctions can impair the ability of
the boot to withstand water ingress when immersed. The wall
thickness of the booty is selected according to the intended duty;
thus the heel portion 12 is thickened for comfort, and the front
upper face 13 is relatively thick as compared to the rear wall 14
to give comparatively good impact resistance. The he& portion
may for example have a thickness in the range 15-25 mm.
[0036] A steel toe cap 15 is adhered to the toe of the booty 11
from the outside, by adhesive. As best illustrated in FIG. 7, the
booty is moulded with a corresponding depression 16 at the front
outer surface, so that the toe cap fits flush around the
substantially semi-circular rear edge thereof. The substantially
semi-circular lower edge of the toe cap comprises an interned
peripheral flange 18, which fits under the booty 11 to give a
degree of form fitting which assists in retaining the toe cap 15 in
position. The flange is continuous and in the width range 4-10 mm.
A recess is provided on the booty for the flange 18, so as to allow
an out-sole to be flush fitted.
[0037] To the outside of the toe cap 15 is adhered a toe cap cover
19, comprising a moulding of thermoplastic polyurethane (TPU). A
TPU moulding is accurate and dimensionally stable, whilst giving
improved impact and abrasion resistance as compared with EVA. An
adhesive such as polyurethane or two-part epoxy is suitable.
[0038] A further advantage of the toe cap cover 19 is that it may
be colour coded to visually identify a boot with a specified use or
factory area, whilst avoiding the necessity of providing means of
identification on the EVA moulding. A self-coloured toe cap cover
gives a permanent marking, unlike the application of an identifier
to the surface of a boot, which may be damaged or rubbed off in
use. For example the booty may be white, and the toe cap of a
primary colour.
[0039] Furthermore the differently coloured toe cap is in a
position where it is always visible in use, notwithstanding that
the boot leg may be covered or shielded by clothing. Additionally,
the applied toe cap provides increased thickness, and may be
moulded of a different material to give enhanced protection against
wear or impact.
[0040] As illustrated in FIG. 7, the cover 19 is tapered at the
rear semi-circular edge 21 so as to be substantially flush and
smooth with the surface of the booty, whilst giving an adhered band
22 (FIG. 1) sufficient to overlap the toe cap 15. The adhered band
may have a width in the range 10-20 mm, and in practice is arranged
in front of the region of the upper which flexes when walking.
[0041] An outsole 25, of for example synthetic nitrile rubber, is
applied to the booty by conventional means, such as adhesive, and
provides a final encapsulation for the toe cap 15. In some
instances the sole may provide an upstanding front bumper 26 (FIG.
8), and in order to save material, the toe cap cover 19 may fit
against, but not overlap this bumper 26 (FIG. 7). In the
alternative, the bumper 26 may be omitted, and the toe cap cover 19
may extend to the outsole (FIG. 9).
[0042] If desired the outsole may be a conventional composite or a
multi-layer construction, for example synthetic nitrile rubber,
polybutadiene rubber (BR9000) and styrene butadiene rubber.
[0043] An insole may be fitted if desired, to improve comfort and
insulation, and the booty may be lined. However EVA has good
properties of thermal insulation and compliance, so that linings
may be obviated.
[0044] A mid-sole, for example a reinforced mid-sole to prevent
piercing may be incorporated on the outsole and beneath the booty
or insole. An integral insole of upstanding moulded projections may
be provided to prevent slipping of the users foot in use.
[0045] The material of the booty comprises typically a suitable
grade of ethyl vinyl acetate with a polyester (PE) plasticiser.
[0046] The toe cap cover is for example a polyurethane consisting
of methylene diphenyl diisocyanate (MDI), toluene diisocyanate
(TDI) and a prepolymer (PPG220).
[0047] A suitable adhesive is polyurethane (PU) resin, methyl ethyl
ketone and ethyl acetate.
[0048] The described embodiment relates to a moulded EVA booty,
which comprises the upper of the footwear with an integral insole.
The upper could however be conventional, in the form of a top
covering, and attached to a sole. The toe cap and toe cap cover of
the invention are applied to the upper in the same manner in both
instances, and where necessary an outsole is added
subsequently.
[0049] In this description, use of boots having differently
coloured toe caps is described in relation to food processing
factories. The use of boots according to the invention is not
limited to such factories.
[0050] The upper part of the upper may be constituted by an
alternative material, such as canvas, nylon or leather, In this way
a composite upper may give a different aesthetic appearance whilst
retaining the practicability and comfort of an EVA moulding with
integrated reinforced toe cap. Such alternative materials may be
attached by conventional methods, such as by in-moulding, adhesive
or by stitching.
EXAMPLE
[0051] The following example describes a wellington boot according
to one embodiment of the invention.
Booty Moulding (EVA)
[0052] Base material: 69.8% Ethyl Acetate+18.6% Poly Ester+11.6%
Engage.TM. ethylene plastomer.
[0053] Moulding temperature 175.degree. C.
[0054] Moulding duration 600-700 seconds.
[0055] Density of moulded material 0.3 g/cm.sup.3.
[0056] Hardness of moulded material SHA 55-60.
[0057] Minimum thickness of material: 3 mm.
[0058] Maximum thickness of material: 15 mm.
Over Cap Moulding (TPU)
[0059] Material: 35.4% MDI (Methylene Diphenyl Diisocyanate)+46.1%
TDI (Toluene diisocyanate)+18,5% PPG220 (polyoxypropylene
propylene-glycol).
[0060] Moulding Temperature 220.degree. C.
[0061] Moulding duration 150 seconds.
[0062] Density of moulded material 1.1 g/cm.sup.3.
[0063] Hardness of moulded material SHA 80-90.
Rubber Outsole:
[0064] Material: 73.2% Nitro Rubber+7.2% BR 9000 (Butadiene
Rubber)+19.6% SBR Rubber (Styrene Butadiene Rubber).
[0065] Moulding temperature 150.degree. C.
[0066] Moulding duration 280 seconds.
[0067] Density of moulded material 1.2 g/cm.sup.3.
[0068] Hardness of moulded material SHA 60-65.
Steel Toecap:
[0069] Material: mild steel with anti-corrosion surface
treatment.
[0070] Size 42
[0071] approximate length 46 m
[0072] approximate width 92 m
[0073] approximate height 51.5 mm
* * * * *