The present invention relates to boots of the type having a separate and distinguishable inner and outer boot with a protective cage there between.

For a number of years it has been common to provide footwear with an inner and an outer boot in order that precise fitting may be achieved by varying the size of the inner

boot whilst maintaining a limited range of outer boot sizes in stock. The outer boot may additionally be tailored to specific uses without varying the design of the inner boot. This method of construction of boots has for some years been quite popular in

relation to ski boots and in-line skates. Protective footwear has also utilised such a

system with a protective cage designed to protect one or more of the wearer's arch, toes or heel interposed between the inner and outer boot. The lastmentioned type of boot can use a very flexible outer boot upper in order to render it waterproof without

adding significantly to the weight of the boot although such boots often have cumbersome arrangements for tightening the upper boot around the wearer's shin.

It is accordingly an object of the present invention to disclose improved systems for

manufacturing footwear of the type described or at least to provide the market with an

alternative.

According to one aspect of the present invention there is disclosed an inner boot having a sole, heel and toe portion formed of resiliently deformable material bonded or otherwise affixed to a sock-like upper; the upper being formed of material capable of stretching in a lateral plane to an extent necessary to permit passing of a foot therethrough whilst being capable of contracting back to a snug position about the wearer's lower calf and shin; the upper being relatively inextensible in a vertical direction to allow it to be pulled vertically without significant stretching during the introduction of the wearer's foot through the upper opening; there being an external

lateral protrusion from the resiliently deformable heel portion of the inner boot adapted to co-operate with an indent in the outer boot in order to prevent relative movement between the inner and outer boot.

According to another aspect of the present invention there is disclosed a sizing and comfort spacer adapted for affixation about the inside of the arch protecting portion of

a protective cage.

According to a further aspect of the present invention there is disclosed an outer boot having an upper portion adapted to fit about the lower shin and calf of a wearer constructed from thin fabric having little form memory; the rear portion of the upper of such outer boot being reinforced by resiliently deformable material in the area of the

Achilles tendon and extending to a position adjacent the upper extremity of the boot

upper; the upper area of such resiliently deformable reinforcement carrying fastening

means adapted to releasably engage complementary fastening means adjacent the top of each side of the material comprising the upper extremity of the boot; the mating of the fastening means being adapted to secure the material comprising the upper extremity of the boot snugly about the wearer's calf and shin whilst the undoing of such fastenings permits opening of the upper extremity of the outer boot so as to facilitate removal or introduction of the wearer's foot.

A number of aspects of the present invention will be described with reference to the accompanying drawings in which:

Figure I is a perspective view of an inner boot constructed in accordance with the present invention;

Figure II is a perspective view of a protective cage in accordance with the

present invention;

Figure III is a section through the arch protector of the protective cage of

figure II;

Figure IV is a perspective view of an outer boot in accordance with the present

invention;

Figure V is a section through an assembled inner and outer boot combination in accordance with the present invention; and

Figure VI is a schematic view of the upper portion of an inner and outer boot in accordance with the present invention.

According to the embodiment of figure I there is disclosed an inner boot having a toe, sole and heel portion 1 formed in a unitary manner from foamed urethane. Foamed polyurethanes and EV A/polypropylene mixes also been tried with success. The material is ideally a foamed cellular product which has impact and cushioning

capabilities.

The unitary toe, sole and heel portion 1 is bonded to a knitted sock-like member 2

which material allows "breathing" of the wearer's foot to the extent that it is capable of passing air at least in one direction. The knitted nature of the sock-like portion 2 further facilitates the manufacture of the product so that it is relatively inextensible in a vertical direction and yet relatively extensible in the horizontal direction. The

horizontal extensibility is necessary in order that a wearer's foot may pass down through opening 3 into the lower portion of the boot whilst expanding the neck portion

4 of the sock-like member. The vertical inextensibility facilitates the wearer pulling on

the inner boot by utilising tabs 5 without unduly distorting the inner boot during such

process.

The toe, sole and heel portion 1 may be attached to the sock-like upper 2 by any appropriate means such as stitching, welding or bonding with appropriate glues. The top of the sock-like upper adjacent opening 3 is reinforced around its peripheral portions in order to better define opening 3 and guard against premature wear.

It will be appreciated that the thickness of toe, sole and heel portion 1 may vary in order that the inner boot may be a tight fit within the outer boot. In this manner a

number of inner boots may be provided in order to accommodate varying foot sizes without varying the size of the outer boot. In order to prevent relative movement

between the inner and outer boot when the boot is in use lateral protrusion 6 is provided extending laterally and rearwardly in an outward direction from the heel

portion of toe, sole and heel unit 1. This lateral protrusion is adapted to "key" into a corresponding indent in the outer boot in a manner best viewed in figure V.

Turning now to figure II a second aspect of the present invention will be described being the sizing and comfort spacer 7 which is adapted to fit onto protective cage 8 and more particularly onto the arch protector 9 of protective cage 8. The protective

cage 8 is intended to be interposed between an inner and outer boot in a manner best

viewed from figure V. The protective cage depicted contains a toe protector portion 10 the arch protector 9 and a heel protector portion 11. The protective cage may be

fabricated from any appropriate material although in this instance it is fabricated from

"Zytel Supertough" TM nylon. Other impact resistant toughened thermoplastic resins may however be just as appropriate.

It has been found that the incorporation of an arch protector in a boot of the type

described is difficult having regard to the fact that the insteps and hence the height of the foot adjacent its mid-length varies greatly from wearer to wearer. It is also the case that the arch protector 9 must be at a height slightly greater than that of the corresponding portion of the wearer's foot in order to facilitate entry and exit of the

foot from the cage. In this regard the height and placement of the arch protector has been found to be one of the most critical dimensions associated with the protective cage and one which is not necessarily related to the length or width of foot being accommodated. In order therefore to ensure the comfort of the wearer as well as a

snug fit of the protective cage about the wearer's foot it has been discovered that a "snap-on" sizing and comfort spacer is desirable. The spacer not only prevents chafing of the wearer's foot by the arch protector but the resiliently deformable padding material from which its internally facing surfaces are constructed ensures a relatively

snug and comfortable fit about the wearer's foot. Various thicknesses of sizing and comfort spacers may therefore be held in stock to ensure a well tailored fit in every

instance.

As will best be viewed from the section comprising figure III one embodiment of the

sizing and comfort spacer may comprise a substantially 'C section frame portion 12

fabricated from a relatively stiff plastic material having flanges 13 adapted to clip around arch protector 9. It is this frame 12 to which the required thickness of padded sizing material 14 may be affixed.

According to a further aspect of the present invention there is disclosed a closing mechanism for footwear in accordance with the present invention having an outer boot

with a flexible upper about the lower shin and calf of the wearer.

According to the embodiment of figure IV there is disclosed an outer boot 15 having an upper constructed of relatively flexible thin waterproof material 16 with little form

memory. This material 16 is reinforced in the area of the Achilles tendon by stiffening member 17 which may itself be formed from resiliently deformable material such as rubber but does possess some memory so as to cause the upper portion of the boot adjacent opening 18 to stand upright.

Stiffening member 17 is adapted to captivate strap 19 provided on either side of stiffening member 17 with a series of slots 20. It will be observed that slots 20 are

adapted to accommodate hook-like members 21 on either side of the material comprising the upper portion of the boot adjacent the upper opening 18. Strap 20 may be fabricated from an elastic type material such as rubber. It will be appreciated that

hook-like members 21 on either side of the boot may be placed into appropriate slots

20 in order to tension the material 16 comprising the upper of the boot about the

wearer's calf and shin into a comfortable sealing relationship therewith. Resiliently deformable padding 22 may additionally be provided around at least the front portion of opening 18 in order that it may bear against the wearer's pants or shin thereby effecting a dust and water seal and promoting comfort.

The closing arrangement depicted in figure IV is further clarified in figure VI in which the boot is shown in the closed position about the pants 23 of a wearer with the inner boot 24 being shown in a schematic manner (not necessarily to scale) within the outer boot and pants.

It will be appreciated that many other embodiments of the present invention may be devised without departing from the scope and intendment thereof and in particular the materials of construction may be varied from those nominated in the embodiments

described above.