U.S. patent application number 16/013250 was filed with the patent office on 2019-12-26 for footwear with external safety toe cap.
This patent application is currently assigned to Rocky Brands, Inc.. The applicant listed for this patent is Rocky Brands, Inc.. Invention is credited to Mark S. Recchi.
Application Number | 20190387836 16/013250 |
Document ID | / |
Family ID | 68980371 |
Filed Date | 2019-12-26 |
United States Patent
Application |
20190387836 |
Kind Code |
A1 |
Recchi; Mark S. |
December 26, 2019 |
Footwear with External Safety Toe Cap
Abstract
Footwear includes a sole, an upper secured to the sole for
covering a foot of a wearer of the footwear, and an external toe
cap located at a toe portion of the upper and outside of the upper
to form a portion of an exterior surface of the footwear. The toe
cap includes a horizontal bottom flange that extends between the
upper and the sole and is secured to the sole with adhesive. The
toe cap is also secured to the upper with adhesive
Inventors: |
Recchi; Mark S.; (Lancaster,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Rocky Brands, Inc. |
Nelsonville |
OH |
US |
|
|
Assignee: |
Rocky Brands, Inc.
Nelsonville
OH
|
Family ID: |
68980371 |
Appl. No.: |
16/013250 |
Filed: |
June 20, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 7/32 20130101; A43B
23/086 20130101; A43B 23/081 20130101 |
International
Class: |
A43B 7/32 20060101
A43B007/32; A43B 23/08 20060101 A43B023/08 |
Claims
1. Footwear for covering a foot of a wearer, said footwear
comprising, in combination: a sole; an upper secured to the sole
for covering a foot of a wearer of the footwear; a toe cap located
at a toe portion of the upper and outside of the upper to form a
portion of an exterior surface of the footwear; and wherein the toe
cap partially extends between the upper and the sole and is secured
to the sole.
2. The footwear according to claim 1, wherein the toe cap extends
between a front lower edge of the upper and the sole.
3. The footwear according to claim 1, wherein a horizontal bottom
flange of the toe cap extends between the upper and the sole.
4. The footwear according to claim 1, wherein the toe cap is
secured directly to the sole.
5. The footwear according to claim 1, wherein the toe cap is
secured to the sole with adhesive.
6. The footwear according to claim 1, wherein the toe cap is
secured to the upper with adhesive.
7. The footwear according to claim 1, wherein the toe cap comprises
a composite material.
8. The footwear according to claim 1, wherein the upper comprises
leather.
9. The footwear according to claim 1, wherein the toe cap is
located within a recess in the top of the sole.
10. Footwear for covering a foot of a wearer, said footwear
comprising, in combination: a sole; an upper secured to the sole
for covering a foot of a wearer of the footwear; and an external
toe cap located at a toe portion of the upper and outside of the
upper to form a portion of an exterior surface of the footwear;
wherein the toe cap is secured to the upper with adhesive; and
wherein the toe cap is located within a recess in the top of the
sole.
11. The footwear according to claim 10, wherein the toe cap
includes a horizontal bottom flange that extends between the upper
and the sole and is secured to the sole with adhesive.
12. The footwear according to claim 10, wherein the toe cap is
secured directly to the sole.
13. The footwear according to claim 10, wherein the toe cap
comprises a composite material.
14. The footwear according to claim 10, wherein the upper comprises
leather.
15. A method of making footwear for covering a foot of a wearer,
said method comprising the steps of, in combination: securing a toe
cap to a sole; after securing the toe cap to the sole, securing an
upper to the sole for covering a foot of a wearer of the footwear;
and wherein the step of securing the upper to the sole includes
extending a toe portion of the upper into the toe cap so that the
toe cap is located outside of the upper to form a portion of an
exterior surface of the footwear and so that the toe cap partially
extends between the upper and the sole.
16. The method according to claim 15, wherein the toe cap is
secured to the sole with adhesive.
17. The method according to claim 15, further comprising the step
of securing the upper to the toe cap with adhesive.
18. The method according to claim 15, wherein the upper is secured
to the sole with adhesive.
19. The method according to claim 15, wherein a horizontal bottom
flange of the toe cap extends between the upper and the sole.
20. The method according to claim 15, further comprising the step
of locating the toe cap within a recess in the top of the sole.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
PARTIES TO JOINT RESEARCH AGREEMENT
[0003] Not Applicable
REFERENCE TO APPENDIX
[0004] Not Applicable
FIELD OF THE INVENTION
[0005] The field of the present invention generally relates to
footwear and, more particularly, to safety footwear having a rigid
toe cap.
BACKGROUND OF THE INVENTION
[0006] A safety boot or shoe is a durable boot or shoe that has a
protective reinforcement in the toe region which protects the toe
region from falling objects or compression. Safety footwear can
also have other protective reinforcements such as a midsole plate
to protect against punctures from below. The protective
reinforcement in the toe region is typically a toe cap concealed
within the boot or shoe upper. Toe caps are half-dome-like and
formed to the desired toe shape. Although traditionally made of
steel, safety toe caps can also be made of composite materials such
as Kevlar, carbon fiber, and fiberglass, plastics such as
thermoplastic polyurethane (TPU), aluminum, or any other suitable
rigid material. Safety boots and shoes are important in the
construction industry and in many industrial settings. Occupational
safety and health legislation or insurance requirements may require
the use of such boots in some settings, and may mandate
certification of such boots. In the United States, the applicable
standard for protective footwear is ASTM standards F2412-05,
Standard Test Methods for Foot Protection and ASTM F2413-05,
Standard Specification for Performance Requirements for Foot
Protection. OSHA requires compliance of ANSI Z41.1-1991, "American
National Standard for Personal Protection-Protective Footwear".
[0007] While safety footwear can be very effective in protecting
workers feet, they can often be uncomfortable to wear, especially
if you are wearing the wrong size or not breaking them in properly.
Even after proper sizing and breaking them in, they may not be as
comfortable as desired. Accordingly, there is a need for improved
safety footwear that provides increased comfort.
SUMMARY OF THE INVENTION
[0008] Disclosed are safety footwear that overcome at least one of
the disadvantages of the prior art described above. Disclosed is
footwear for covering a foot of a wearer that comprises, in
combination, a sole, an upper secured to the sole for covering a
foot of a wearer of the footwear, and a toe cap located at a toe
portion of the upper and outside of the upper to form a portion of
an exterior surface of the footwear. The toe cap partially extends
between the upper and the sole and is secured to the sole.
[0009] Also disclosed is footwear for covering a foot of a wearer
that comprises, in combination, a sole, an upper secured to the
sole for covering a foot of a wearer of the footwear, and an
external toe cap located at a toe portion of the upper and outside
of the upper to form a portion of an exterior surface of the
footwear. The toe cap includes a horizontal bottom flange that
extends between the upper and the sole and is secured to the sole
with adhesive. The toe cap is also secured to the upper with
adhesive. The toe cap is located within a recess in the top of the
sole.
[0010] Also disclosed is a method of making footwear for covering a
foot of a wearer. The method comprises the steps of, in
combination, securing a toe cap to a sole, and after securing the
toe cap to the sole, securing an upper to the sole for covering a
foot of a wearer of the footwear. The step of securing the upper to
the sole includes extending a toe portion of the upper into the toe
cap so that the toe cap is located outside of the upper to form a
portion of an exterior surface of the footwear and so that the toe
cap partially extends between the upper and the sole.
[0011] From the foregoing disclosure and the following more
detailed description of various preferred embodiments it will be
apparent to those skilled in the art that the present invention
provides a significant advance in the technology and art of
footwear. Particularly significant in this regard is the potential
the invention affords for providing comfortable safety footwear.
Additional features and advantages of various preferred embodiments
will be better understood in view of the detailed description
provided below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] These and further features of the present invention will be
apparent with reference to the following description and drawings,
wherein:
[0013] FIG. 1 is a perspective view of footwear having an external
safety toe cap according to the present invention.
[0014] FIG. 2 a fragmented and enlarged cross-section view
centrally taken through the footwear of FIG. 1 and showing the toe
region.
[0015] FIG. 3 is a bottom elevational view of an outsole with the
safety toe cap secured thereto of the footwear of FIG. 1.
[0016] FIG. 4 is left-side view of the outsole and the safety toe
cap of FIG. 3.
[0017] FIG. 5 is a top elevation view of the outsole and the safety
toe cap of FIG. 3.
[0018] FIG. 6 a cross-section view taken along line 5-5 of FIG.
5.
[0019] FIG. 7 a cross-section view taken along line 6-6 of FIG.
3.
[0020] It should be understood that the appended drawings are not
necessarily to scale, presenting a somewhat simplified
representation of various preferred features illustrative of the
basic principles of the invention. The specific design features of
the footwear as disclosed herein, including, for example, specific
dimensions, orientations, locations, and shapes of the various
components, will be determined in part by the particular intended
application and use environment. Certain features of the
illustrated embodiments have been enlarged or distorted relative to
others to facilitate visualization and clear understanding. In
particular, thin features may be thickened, for example, for
clarity or illustration. All references to direction and position,
unless otherwise indicated, refer to the orientation of the
footwear illustrated in the drawings. In general, up or upward
generally refers to an upward direction within the plane of the
paper in FIG. 1 and down or downward generally refers to a downward
direction within the plane of the paper in FIG. 1. Also in general,
front or forward generally refers to a direction toward the right
within the plane of the paper in FIG. 1 and rear or rearward
generally refers to a direction toward the left within the plain of
the paper in FIG. 1.
DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS
[0021] It will be apparent to those skilled in the art, that is, to
those who have knowledge or experience in this area of technology,
that many uses and design variations are possible for the footwear
disclosed herein. The following detailed discussion of various
alternative and preferred embodiments will illustrate the general
principles of the invention with regard to a laced work boot. Other
embodiments of the present invention suitable for other
applications will be apparent to those skilled in the art given the
benefit of this disclosure. For example, the present invention is
suitable for other types of footwear such as, for example,
western-style boots, outdoor boots, duty or military boots, shoes,
and the like.
[0022] Referring now to the drawings, FIGS. 1 to 7 show a work boot
10 having an external safety toe cap 12 according to the present
invention. The illustrated work boot 10 is adapted for use on a
right foot but it is noted that a similar but mirror image work
boot adapted for the left foot is used in conjunction with the
illustrated "right" work boot 10 for form a pair of the work boots.
The illustrated work boot 10 includes a sole 14 forming a bottom of
the work boot 10 and extending below the boot wearer's foot and an
upper 16 extending upward from the sole 14 to cover the boot
wearer's foot and a small portion of their lower leg.
[0023] The illustrated outsole 14 includes an outsole 18 forming an
exterior bottom surface for the sole 14 and an insole 20 located
above the outsole 18 and forming an upper interior surface of the
sole 14 upon which the boot wearer's foot rests within the upper
16. It is noted that the sole 14 can also include a midsole located
between the outsole 18 and the insole 20 and/or a shank 22 forming
an arch support within the sole 14. The outsole 18 is the outermost
portion of the sole 14 of the boot 10 and forms the bottom surface
of which is exposed to wear. The illustrated bottom surface of the
outsole 18 is provided with tread. The illustrated outsole 18 is
molded of synthetic polymer material but can alternatively comprise
any other suitable material such as, for example, rubber, leather
or the like. The insole 20 can be attached to the outsole 18, the
midsole (if present), and/or the upper 16 or the insole 20 can be
removable and/or replaceable. The insole 20 can form the upper most
surface on the inside of the bottom of the boot 10 or it can be
covered with a sock lining of suitable material. The midsole can be
located between the outsole 18 and the insole 20. The midsole can
be molded of synthetic polymer material but can alternatively
comprise any other suitable material. The midsole is designed to
provide the boot 10 with desired characteristics of cushioning,
support, and flexibility. The illustrated shank 22 is located at
the top of the outsole and below the insole 20 to form an arch
support which supports the arch of the boot wearer's food. The
shank 22 can comprise steel, fiberglass, wood, and/or plastic. It
is noted that the sole 14 can alternatively have any other suitable
construction within the scope of the present invention.
[0024] The illustrated upper 16 includes a vamp 24 which covers the
top and front portion of the boot wearer's foot, a counter or
quarter 26 that encloses the heel or rear portion of the boot
wearer's foot and is secured to the rear of the vamp 24, and a
shaft 28 which fits around the lower leg of the boot wearer's leg
and is secured to the top of the vamp 24 and the quarter 26. The
shaft 28 has an upper edge which forms an upper opening through
which the wearer's foot enters the work boot 10. The illustrated
vamp 24 and the shaft 28 cooperate to form an opening 30 at the
rearward end of the work boot 10 that is selectively closed by a
lace 32 so that the opening 30 can be tightened to secure the work
boot 10 to the wearer's foot and loosened to ease entry and exit of
the wearer's foot into and out of the work boot 10. The illustrated
v shaft 28 is provided with a plurality of eyelets 34 and hooks 36
for the lace 32 as is known in the art. A tongue 38 is also
provided at the laced opening as is also known in the art. The
illustrated upper 16 also is provided with a lining 40 within its
interior. The lining 40 can be secured to the inner surface of the
work boot 10 with an adhesive 39 or the like. The lining 40
typically comprises pigskin, glove leathers, heavy twilled cotton
or linen fabric, and the like. Additionally, the lining 40 can
comprise synthetics such as, for example, Gortex, Sympatex, and the
like to provide waterproof and/or sweat dissipating characteristics
to the work boot 10. It is noted that the upper 16 can
alternatively have any other suitable configuration.
[0025] The illustrated components of the upper 16 comprise leather
such as, for example, cowhide, pigskin, horsehide, kangaroo skin,
and the like but any other suitable material can alternatively be
utilized such as, for example exotic leathers or skins, synthetic
leather or other synthetic materials, cloth, and the like. The
illustrated components of the upper 16 are secured together by
stitching but any other suitable means can alternatively be
utilized.
[0026] The illustrated upper 16 is secured to the sole 14 with a
cemented construction where the upper 16 is glued or adhered to the
sole 14 with adhesive, or the like. It is noted that the upper 16
can alternatively be secured to the sole 14 using any other
suitable construction such as, for example, a welted construction
or the like.
[0027] The illustrated toe cap 12 is an external toe cap. That is,
the toe cap 12 is located outside of the upper 16 and forms a
portion of the exterior surface of the work boot 10. The
illustrated toe cap 12 is located at a front or toe portion of the
upper 16 and is configured to be over the toes of the boot wearer's
foot and adapted to permit the natural flexing of the boot wearer's
foot during walking.
[0028] As best shown in FIGS. 4 to 7, the illustrated toe cap 12
has a body 42 that forms and interior space 44 that is sized and
shaped to receive a user's toes therein through a rear opening 46.
The illustrated body 42 includes an upper roof 48 which slopes
forwardly and laterally in a smooth continuous surface to blend
into a front wall 50 and opposite side walls 52, 54 respectively.
The body 42 is asymmetrical as is well known in the art. The front
wall 50 extends between the opposite side walls 52, 54 on a front
side of the body 42 and the rear opening 46 extends between the
opposite side walls 52, 54 on the rear side of the body 42. The
front wall 50 and the side walls 52, 54 extend generally vertical
but may be curved over their entire extent both vertically and
horizontally as shown. The front wall 50 and the side walls 52, 54
blend together to form a continuous outer surface. The illustrated
body 42 includes an inwardly-turned bottom flange 56 horizontally
extending from lower edges of the front and side walls 50, 52, 54
in a continuous manner along the entire lower edge of the body 42.
The illustrated bottom flange 56 has a flat lower surface 58 for
engagement and attachment to an upper surface 60 of the sole 14 as
described in more detail hereinbelow. It is noted that the toe cap
12 can alternatively have any other suitable configuration.
[0029] The illustrated toe cap 12 is formed of a material rigid
enough to protect toes of the wearer of the work boot 10. The
illustrated toe cap 12 comprises a composite material but can
alternatively comprise steel, plastic, carbon fiber, fiberglass,
aluminum alloy, and the like. The illustrated toe cap 12 is
preferably adapted so that, when installed in the footwear, it is
in compliance with ASTM standard F2412-05 ("Standard Test Methods
for Foot Protection") and ASTM standard F2413-05 ("Standard
Specification for Performance Requirements for Foot Protection")
and/or in compliance with ANSI Z41.1-1991 ("American National
Standard for Personal Protection-Protective Footwear").
[0030] The illustrated toe cap 12 and the illustrated outsole 18
are preferably molded as separate components. The illustrated toe
cap 12 is directly secured to the top front surface of the outsole
18 with a suitable adhesive 19. It is noted, however, that the toe
cap 12 can alternatively be secured to the outsole 18 in any other
suitable manner such as, for example, co-molding and the like. The
illustrated outsole 18 also a recess 62 sized and shaped for
partially and closely receiving the toe cap 12 therein. The
illustrated recess 62 forms an abutment 64 sized and shaped to
engage the inner edge 66 of the bottom flange 56 of the toe cap 12
to limit relative movement between the toe cap 12 and the outsole
18 in horizontal directions (best seen in FIGS. 6 and 7). It is
noted that the abutment 64 can take any other suitable form to
interlock the components in the horizontal direction. With the toe
cap 12 located with the recess 62, the illustrated outsole 18
partially extends upward along and covers the exterior or outer
side surface of the body front wall 50 (best seen in FIG. 6) and
also partially extends upward along and covers the exterior or
outer side surfaces of the body side walls 52, 54 (best seen in
FIG. 7) to further limit relative movement between the toe cap 12
and the outsole 18 in horizontal directions. The toe cap 12 can be
secured to the outsole 18 with a suitable adhesive 19 located at
the exterior surface of the bottom flange 56 and/or at the exterior
or outer side surfaces of the body walls 50, 52, 54.
[0031] As best seen in FIG. 2, the front or toe portion of the
upper 16 extends into the interior cavity 44 of the toe cap 12 and
the toe cap 12 is secured to the upper 16 with adhesive 17. Thus,
the illustrated toe cap 12 is secured to both the outsole 18 and
the upper 16 with adhesive 17, 19. It is noted that the bottom
flange 56 of the toe cap 12 extends below the upper 16 so that the
horizontal bottom flange 56 rearwardly extends between the front
lower edge of the upper 16 and the outsole 18. The illustrated work
boot 10 includes the liner 40 that is located within the work boot
10. The liner 40 is secured to the inner side of the upper 16 and
the inner or upper side of the outsole 18. The illustrated insole
20 is located above the outsole 18 and the toe cap bottom flange 56
with the liner 40 extending therebetween. Alternatively, the liner
40 can be eliminated if desired.
[0032] The illustrated work boot 10 also includes a strip of
anti-scuffing or anti-abrasion material 68 along the edge of the
toe cap 12 at the outer surface of the upper 16. The anti-scuffing
or anti-abrasion material 68 is intended to reduce scuffing or
abrasion of the outer 16 near the toe cap 12, particularly when the
outer 16 comprises leather. The illustrated anti-scuffing or
anti-abrasion material 68 extends partially between the toe cap 12
and the upper 16 and is secured to both the toe cap 12 and the
upper 16 with adhesive 17. The anti-scuffing or anti-abrasion
material 68 can alternatively be secured in any other suitable
manner. The anti-scuffing or anti-abrasion material 68 can also be
eliminated when not desired. The anti-scuffing or anti-abrasion
material 68 can comprise any suitable material such as, for
example, nylon and the like.
[0033] Configured in this manner, the toe cap 12 is located
external of the upper 16 and thus is separated from the wearer's
toes by the upper 16. This configuration enables the work boot 10
to have increased comfort similar to a non-safety work boot. The
toe cap 12 also forms a portion of the outer surface of the work
boot 10 and is substantially exposed. That is, uncovered or free of
any type of covering. The illustrated outer surface of the toe cap
12 can be provided with decorative indicia that will be seen such
as, for example, the shown plurality raised ridges 70. The
decorative indicia can alternatively be eliminated if desired.
[0034] As noted above, the illustrated toe cap 12 and the
illustrated outsole 18 are preferably molded as separate components
and then secured together with adhesive 19. Thus, the footwear 10
can be made by first securing the toe cap 12 into the recess 62 at
the top front of the sole 14 with adhesive 19. Then, after securing
the toe cap 12 to the sole 14, securing the upper 16 to the sole 20
for covering a foot of a wearer of the footwear 10. The step of
securing the upper 16 to the sole includes extending a toe portion
of the upper 16 into the toe cap 12 so that the toe cap 12 is
located outside of the upper 16 to form a portion of an exterior
surface of the footwear 10 and so that the toe cap 12 partially
extends between the upper 16 and the sole 14. The upper 16 is
preferably secured to both the toe cap 12 and the sole 14 with
adhesive.
[0035] Any of the features or attributes of the above the above
described embodiments and variations can be used in combination
with any of the other features and attributes of the above
described embodiments and variations as desired. It is noted that
the footwear 10 can alternatively be made by any other suitable
method.
[0036] It is apparent from the forgoing disclosure and detailed
description that the present invention provides a work boot 10
which has improved comfort over prior work boots having a safety to
cap.
[0037] From the foregoing disclosure and detailed description of
certain preferred embodiments, it is also apparent that various
modifications, additions and other alternative embodiments are
possible without departing from the true scope and spirit of the
present invention. The embodiments discussed were chosen and
described to provide the best illustration of the principles of the
present invention and its practical application to thereby enable
one of ordinary skill in the art to utilize the invention in
various embodiments and with various modifications as are suited to
the particular use contemplated. All such modifications and
variations are within the scope of the present invention as
determined by the appended claims when interpreted in accordance
with the benefit to which they are fairly, legally, and equitably
entitled.
* * * * *