CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority of U. S. Provisional Patent Application No. 62/548,820 filed August 22, 2017, which is hereby incorporated by reference in its entirety.

BACKGROUND

1. Field of Invention

[0002] The present invention relates generally to toe caps, and more particularly, to composite toe caps. 2. Description of Related Art

[0003] A toe cap is an item of protective footwear that is worn over a user's toes to protect those toes from injury that might otherwise be caused by falling objects, sharp objects, compression, and/or the like. Such a toe cap typically includes a dome-shaped member that overlies the user's toes when the toe cap is worn by the user, whether the toe cap forms part of or is disposed over the user' s shoe.

[0004] Most existing toe caps are made from metal, such as steel, aluminum, and the like. While such metal toe caps may provide sufficient protection to a user's toes, they tend be relatively heavy and may be uncomfortable to the user (e.g., due to their weight, inflexibility, and/or the like). Furthermore, during impact and/or compression, a metal toe cap may undergo permanent deformation, necessitating replacement of the toe cap or shoe that comprises the toe cap. Metal toe caps may also be electrically conductive, rendering them unsuitable for use in certain situations.

[0005] More recently, toe caps made from plastic have become available. However, to meet safety requirements, such a plastic toe cap often is relatively thick, comprises a bulbous shape, and/or the like. These limitations can render such plastic toe caps uncomfortable for a user, unsuitable for use in space-restricted applications (e.g., within a shoe having a slender profile at its toe portion, and/or the like), and/or the like.

SUMMARY

[0006] Some of the present toe caps include a fiber-reinforced insert that: (1) is positioned in a portion of— but not all of— the toe cap such that the insert is disposed closer to the closed end of the toe cap than to the open end of the toe cap, thereby reducing the cost and/or weight of the toe cap, while providing a sufficient resistance of the toe cap to impact and compression loads to meet safety requirements (e.g., those set forth in EN 12568, EN 12568:2010, ISO 20344:2011, ASTM F2412-11, and/or ASTM F2413-11); and/or (2) is overmolded in the toe cap such that the toe cap has less voids, can be produced more quickly, can possess a more complex shape, and/or the like than a toe cap having a fiber-reinforced portion with a different structure.

[0007] The term "coupled" is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are "coupled" may be unitary with each other. The terms "a" and "an" are defined as one or more unless this disclosure explicitly requires otherwise. The term "substantially" is defined as largely but not necessarily wholly what is specified (and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. In any disclosed embodiment, the terms "substantially" and "approximately" may be substituted with "within [a percentage] of what is specified, where the percentage includes .1, 1, 5, and 10 percent.

[0008] The phrase "and/or" means and or or. To illustrate, A, B, and/or C includes: A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C. In other words, "and/or" operates as an inclusive or.

[0009] Further, a device or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described.

[0010] The terms "comprise" (and any form of comprise, such as "comprises" and "comprising"), "have" (and any form of have, such as "has" and "having"), "include" (and any form of include, such as "includes" and "including"), and "contain" (and any form of contain, such as "contains" and "containing") are open-ended linking verbs. As a result, an apparatus that "comprises," "has," "includes," or "contains" one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, a method that "comprises," "has," "includes," or "contains" one or more steps possesses those one or more steps, but is not limited to possessing only those one or more steps.

[0011] Any embodiment of any of the apparatuses, systems, and methods can consist of or consist essentially of - rather than comprise/have/include/contain - any of the described steps, elements, and/or features. Thus, in any of the claims, the term "consisting of or "consisting essentially of can be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open- ended linking verb. [0012] The feature or features of one embodiment may be applied to other embodiments, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the embodiments.

[0013] Some details associated with the embodiments are described above, and others are described below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. Each of the figures, unless identified as a schematic view, is drawn to scale, meaning the sizes of the elements depicted in the figure are accurate relative to each other for at least the embodiment depicted in the figure.

[0015] FIG. 1A is a front perspective view of a first embodiment of the present toe caps, including a fiber-reinforced insert that forms a portion thereof.

[0016] FIG. IB is a back perspective view of the toe cap of FIG. 1 A.

[0017] FIGs. 1C and ID are front and back views, respectively, of the toe cap of FIG. 1 A.

[0018] FIGs. IE and IF are top and bottom views, respectively, of the toe cap of FIG. 1A.

[0019] FIGs. 1G and 1H are left and right side views, respectively, of the toe cap of FIG.

1A.

[0020] FIG. 2 is a schematic perspective view of a shoe including the toe cap of FIG. 1 A.

[0021] FIG. 3A is a cross-sectional side view of the toe cap of FIG. 1A, taken along line 3A-3A of FIG. IE.

[0022] FIG. 3B is a cross-sectional end view of the toe cap of FIG. 1A, taken along line 3B-3B of FIG. IE. [0023] FIG. 3C is a cross-sectional top view of the toe cap of FIG. 1 A, taken along line 3C- 3C of FIG. 1H.

[0024] FIGs. 4A and 4B are each a cross-sectional side view of a toe cap showing a suitable connection between a fiber-reinforced insert of the toe cap and a first thermoplastic material of the toe cap.

[0025] FIG. 5 is a schematic cross-sectional view of a fiber-reinforced insert that may be suitable for use in some of the present toe caps.

[0026] FIG. 6A is a schematic view that depicts a layup of laminae that may be suitable for use in fiber-reinforced inserts of some of the present toe caps. [0027] FIG. 6B and 6C are schematic views, each depicting a lamina that may be suitable for use in fiber-reinforced inserts of some of the present toe caps.

[0028] FIG. 7A is a front perspective view of a second embodiment of the present toe caps.

[0029] FIG. 7B is a back perspective view of the toe cap of FIG. 7A.

[0030] FIG. 8 is a schematic view that illustrates some of the present methods for producing toe caps.

[0031] FIG. 9 is a schematic perspective view of a fiber-reinforced insert that has been slit to facilitate shaping of the insert and positioning of the insert in a toe cap.

[0032] FIG. 10 is a schematic that illustrates some of the present methods for producing a fiber reinforced insert, the methods including wrapping one or more laminae around a form. [0033] FIGs. 11A and 11B illustrate structural tests for a toe cap.

[0034] FIG. 12 depicts a toe cap subjected to a load.

DETAILED DESCRIPTION

[0035] Referring now to FIGs. 1A-1H, shown is a first embodiment 10a of the present toe caps. Toe cap 10a can receive a user's toes such that a portion of the toe cap overlies and protects the toes from injury that might otherwise be caused by falling objects, sharp objects, compression, and/or the like. For example, toe cap 10a can include a base 14 and a shell 18 that extends from the base and between a first end 22 of the toe cap and a second end 26 of the toe cap to define an interior volume 30 between the base and the shell. A user's toes can be received within interior volume 30 via shell 18 being open at second end 26, and, once so received, a portion of the shell can overlie the toes. To illustrate, at second end 26, shell 18 can define an opening 34 that is in communication with interior volume 30 and through which the user's toes can pass into the interior volume.

[0036] Shell 18 can be closed at first end 22 such that access to interior volume 30 through the first end— other than through base 14, if open— is not permitted. More particularly, all portions of shell 18 other than that at second end 26 can be closed such that access to interior volume 30 is only permitted through the second end or through base 14, if open. In either of these ways, a strength and/or a stiffness of toe cap 10a can be increased, protection provided to the user's toes can be increased, and/or the like. Nevertheless, other embodiments of the present toe caps can each include a shell that is open at a first end (e.g., 22) of the toe cap, at one or more other portions of the toe cap (e.g., at side(s) of the toe cap), and/or the like.

[0037] Base 14 can be open; for example, the base can define an opening 38 in communication with interior volume 30. In this way, materials cost associated with toe cap 10a can be reduced, space provided for the user's toes can be increased, and/or the like. Base 14, and more particularly, a portion of the base that defines opening 38 and underlies interior volume 30, can form a flange 42. Flange 42 can provide support for shell 18, facilitate transfer of loads between the shell and a structure beneath the flange, such as a user's shoe (e.g., 58, FIG. 2), and/or the like.

[0038] Toe cap 10a— as with others of the present toe caps— can be disposed within a shoe. To illustrate, and referring additionally to FIG. 2, shown is an exemplary shoe 58. Shoe 58 can include a sole 62 and an upper 66 that is coupled to the sole such that an interior volume 70 for receiving a user's foot is defined between the sole and the upper. Upper 66 includes a toe box 74, which is a portion of the upper that, when shoe 58 is worn by the user, overlies the user's toes. Toe cap 10a can, for example, be positioned within shoe 58 such that shell 18 underlies at least a portion of, or forms at least a portion of, toe box 74, its second end 26 faces a heel end of the shoe, and its base 14 faces sole 62. The coupling between toe cap 10a and shoe 58 can be fixed; for example, the toe cap can be bonded and/or stitched to a portion of the shoe, such as sole 62 and/or upper 66, integrally formed with a portion of the shoe, disposed within a layer of or between layers of a portion of the shoe, and/or the like. Nevertheless, such coupling can be removable. [0039] In some instances, a toe cap (e.g., 10a) can be worn over a user's shoe (e.g., 58). For example, the toe cap can be positioned on the shoe such that at least a portion of a toe box (e.g., 74) of the shoe is received within an interior volume (e.g., 30) of the toe cap and underlies a shell (e.g., 18) of the toe cap. In such instances, the toe cap can be secured to the shoe in any suitable fashion, such as, for example, via a friction fit between the toe cap and the shoe, one or more straps, which can be coupled to opposing sides of the shell and wrapped around a heel end of the shoe, and/or the like. [0040] Toe cap 10a, or at least a portion of its shell 18, can be defined by a composite body in which a first thermoplastic material 86 and a fiber-reinforced insert 90 having one or more laminae, each including fibers dispersed within a second thermoplastic material (described below), are combined as a unitary structure. As non-limiting examples, the composite body can be formed by overmolding the first thermoplastic material onto the insert, in which the first thermoplastic material is injected into a mold that contains the insert, by compression molding the first thermoplastic material and the insert, in which the first thermoplastic material, in the form of pellets, one or more sheets, and/or the like, and the insert are pressed together in a mold, and/or the like. To illustrate, insert 90 can account for greater than or substantially equal to any one of, or between any two of: 50, 55, 60, 65, 70, 75, 80, 85, or 90% of a weight of toe cap 10a (e.g., approximately 75%), and the remaining percentage can be accounted for by first thermoplastic material 86.

[0041] While insert 90 can contribute strength and stiffness to toe cap 10a, the insert may be more expensive and/or heavier than first thermoplastic material 86. In toe cap 10a— as well as in others of the present toe caps— insert 90 can be sized and positioned in the toe cap such that the toe cap has sufficient resistance to impact and compression loads to meet safety requirements (e.g., those set forth in EN 12568, EN 12568:2010, ISO 20344:2011, ASTM F2412-11, and/or ASTM F2413-11), without undesirably increasing the cost and/or weight of the toe cap. Useful to illustrate the size and position of insert 90 in toe cap 10a, the toe cap can have: (1) a lengthwise axis 102 that extends between first end 22 and second end 26 (FIGs. IF and 1G); (2) a widthwise axis 106 that extends between portions of shell 18 on opposing sides of interior volume 30, the widthwise axis being perpendicular to the lengthwise axis (FIG. 1C and IF); and (3) a heightwise axis 110 that extends between base 14 and a portion of the shell that is across the interior volume from the base, the heightwise axis being perpendicular to each of the lengthwise and widthwise axes (FIGs. 1C and 1G). When toe cap 10a is supported by its base 14 on a horizontal surface, heightwise axis 110 can be perpendicular to the horizontal surface.

[0042] Insert 90 can form at least a portion of shell 18, and, in this way, the insert can overlie interior volume 30. For insert 90 to overlie interior volume 30, the insert need not overlie the entirety of the interior volume nor be disposed vertically above the interior volume; for example, a portion of the insert that is positioned in a side of shell 18 can be said to overlie the interior volume. In toe cap 10a, insert 90 can form at least a portion of base 14.

[0043] As shown, insert 90 can be disposed in toe cap 10a such that, for at least a portion of the toe cap, such as portion(s) of shell 18 and/or portion(s) of base 14, the insert accounts for substantially all of a thickness of that portion, the insert defines an outer surface 114 and an inner surface 118 of toe cap 10a at that portion, and/or the like. Even so, the insert can be described as positioned "in" that portion. For example, for at least a portion of shell 18 at first end 22, a thickness 122 of that portion and a thickness 126 of insert 90 are substantially equal (FIG. 3C), the insert defines outer surface 114 and inner surface 118 of toe cap 10a at that portion, and/or the like. Nevertheless, in some toe caps, an insert can be disposed in the toe cap such that at least a portion of— up to and including all of— the insert is underlied, overlied, and/or embedded within a first thermoplastic material of the toe cap. Provided by way of illustration, an insert of a toe cap can define greater than or substantially equal to any one of, or between any two of: 0, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100% of an inner surface and/or an outer surface of the toe cap (e.g., at a base and/or at a shell of the toe cap), and other portions of the inner surface and/or the outer surface can be defined by a first thermoplastic material of the toe cap.

[0044] Insert 90 can be positioned at first end 22 of toe cap 10a. For example, insert 90 can define outer surface 114 at an apex 130 of shell 18, or, if first thermoplastic material 86 defines that portion of the outer surface, the insert can be disposed between the apex and interior volume 30 (FIGs. IE and 1H). For further example, at first end 22, insert 90 can form at least a portion of base 14, and more particularly, can extend from shell 18 and into the base. Portions of insert 90 at first end 22 can increase toe cap lOa's ability to resist loads applied to the first end as well as facilitate transfer of loads applied to other portions of the toe cap into base 14.

[0045] Insert 90, in base 14 and/or shell 18, can be spaced from at least a portion of toe cap 10a at second end 26. For example, insert 90, in base 14 and/or shell 18, can be positioned closer to first end 22 than to second end 26. For further example, insert 90 in shell 18 can be spaced from at least a portion of the shell at second end 26— such as a portion of shell 18 that partially defines opening 34— in a direction that is parallel to lengthwise axis 102 by a distance 132 (FIG. 1G). To illustrate, distance 132 can be greater than or substantially equal to any one of, or between any two of: 10, 15, 20, 25, 30, 35, 40, 45, or 50% of a length 134 of shell 18 (e.g., at least 10% or at least 40% of the length of the shell, up to 40% of the length of the shell, and/or the like). As used herein, a length is a dimension measured parallel to a lengthwise axis (e.g., 102). For yet further example, shell 18 can be characterized as having a first portion 128 including insert 90 and a second portion 136, none of which includes the insert, where each of the first and second portions extends between opposing sides of base 14, and the second portion is disposed between the first portion and second end 26 (FIG. 1 A). Through such sizing and positioning of insert 90, the cost and/or weight of toe cap 10a can be decreased, without undesirably compromising the toe cap's resistance to impact and compression loads.

[0046] Due, in some instances, to such sizing and positioning of insert 90, the insert may not extend in shell 18 across its entire length 134. For example, insert 90 in shell 18 (meaning the portion of the insert that is in the shell; for example, neglecting the portion of the insert that is in base 14) can have a length 138 that is less than or substantially equal to any one of, or between any two of: 90, 85, 80, 75, 70, 65, 60, 55, or 50% of length 134 of shell 18 (e.g., less than 90% or less than 60% of the length of the shell) (FIG. IE). For further example, and referring additionally to FIG. 3 A, interior volume 30 can have a perimeter 142 taken in a plane that is perpendicular to widthwise axis 106, and insert 90 can define and/or overlie less than or substantially equal to any one of, or between any two of: 90, 85, 80, 75, 70, 65, 60, 55, or 50% (e.g., less than 90%) of all portions of the perimeter that are defined by shell 18 in that plane. Such portions of the perimeter are illustrated using dash-dot lines. The insert can define a portion of the perimeter where the insert defines inner surface 118, and the insert can overlie a portion of the perimeter where the insert is disposed between that portion of the perimeter and outer surface 114 in a direction that is normal to that portion of the perimeter. Nevertheless, in other toe caps, an insert of the toe cap can extend in a shell of the toe cap across any portion of the shell's length, including 90% or more (e.g., up to and including 100%) of the shell's length.

[0047] To enhance a strength and/or a stiffness of toe cap 10a, insert 90 can extend in the shell across at least a majority of a width 146 of the shell and/or across at least a majority of a height 150 of the shell. As used herein, a width is a dimension measured parallel to a widthwise axis (e.g., 106), and a height is a dimension measured parallel to a heightwise axis (e.g., 110). For example, insert 90 in shell 18 can have a width 154 that is greater than or substantially equal to any one of, or between any two of: 70, 75, 80, 85, or 90% of width 146 of the shell (e.g., at least 70% or at least 80% of the width of the shell) (FIG. IE). For further example, insert 90 in shell 18 can have a height 158 that is greater than or substantially equal to any one of, or between any two of: 70, 75, 80, 85, 90, 95, or 100% of height 150 of the shell (e.g., at least 80%, at least 90%, or 100% of the height of the shell) (FIG. 1G). For yet further example, and referring additionally to FIG. 3B, interior volume 30 can have a perimeter 162 taken in a plane that is perpendicular to lengthwise axis 102, and insert 90 can define and/or overlie greater than or substantially equal to any one of, or between any two of: 70, 75, 80, 85, 90, 95, or 100% (e.g., at least 80%, at least 90%, or 100%) of all portions of the perimeter that are defined by shell 18 in that plane.

[0048] Insert 90 can be coupled to first thermoplastic material 86 in any suitable fashion. For example, one or more edges, such as edge 166, of insert 90 can abut first thermoplastic material 86 (FIG. 3 A). A thickness 170 of insert 90 at the edge and a thickness 174 of first thermoplastic material 86 where the first thermoplastic material abuts the edge can be substantially the same such that, for example, little to none of the first thermoplastic material extends past the edge and over and/or under the insert. For further example, and referring additionally to FIGs. 4 A and 4B, at least a portion of a periphery 178 of insert 90 can have a reduced thickness relative to other portions of the insert such that first thermoplastic material 86 extends over and/or under that portion of the periphery, that portion of the periphery is embedded in the first thermoplastic material, and/or the like. Such a periphery (e.g., 178) can be, for example, a stepped periphery (FIG. 4A), a tapered periphery (FIG. 4B), and/or the like. For yet further example, insert 90 can include one or more recesses within which first thermoplastic material 86 can be received and/or one or more protrusions that can be embedded in the first thermoplastic material. In general, the larger the surface area of the interface between insert 90 and first thermoplastic material 86, the stronger the bond between the insert and the first thermoplastic material.

[0049] Insert 90 can have a substantially constant thickness (e.g., 126, FIG. 3C), meaning the thickness of the insert, excluding those— if any— portion(s) of its periphery that have a reduced thickness to facilitate connection between the insert and first thermoplastic material 86, does not vary by more than 10%. Using an insert having a substantially constant thickness can reduce cost and/or complexity associated with production of a toe cap. Provided by way of illustration, a suitable value for a thickness (e.g., 126) of an insert (e.g., 90) can be less than or substantially equal to any one of, or between any two of: 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more millimeters (mm) (e.g., between approximately 4 and approximately 6 mm). [0050] Referring now to FIG. 5, shown is an insert 90a that may be suitable for use in some of the present toe caps. Insert 90a can have a thickness that varies. For example, insert 90a can include a first portion 182 having a first thickness 186 and a second portion 190 having a second thickness 194 that is less than the first thickness. As shown, the difference in thicknesses between the first portion and the second portion can be due to first portion including at least one more lamina than does the second portion. Provided by way of illustration, second thickness 194 can be less than or substantially equal to any one of, or between any two of: 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, or 10% of first thickness 186 (e.g., less than or equal to 75% of the first thickness). When insert 90a is positioned in a toe cap, the first portion can be disposed closer to a first end (e.g., 22) of the toe cap than to a second end (e.g., 26) of the toe cap.

[0051] First thermoplastic material 86 can include any suitable thermoplastic material, such as, for example, polyethylene terephthalate (PET), polycarbonate (PC), polybutylene terephthalate (PBT), poly(l,4-cyclohexylidene cyclohexane-l,4-dicarboxylate) (PCCD), glycol-modified polycyclohexyl terephthalate (PCTG), poly(phenylene oxide) (PPO), polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polymethyl methacrylate (PMMA), polyethyleneimine or polyetherimide (PEI) or a derivative thereof, a thermoplastic elastomer (TPE), a terephthalic acid (TPA) elastomer, poly(cyclohexanedimethylene terephthalate) (PCT), polyethylene naphthalate (PEN), a polyamide (PA), polysulfone sulfonate (PSS), polyether ether ketone (PEEK), polyether ketone ketone (PEKK), acrylonitrile butyldiene styrene (ABS), polyphenylene sulfide (PPS), a copolymer thereof, or a blend thereof (e.g., PP, PC, polyamide 6, or the like). First thermoplastic material 86 can include a filler, such as, for example, talc, calcium carbonate, discontinuous or short fibers (e.g., comprising any of the fiber-types described below), and/or the like, which can account for 10 to 70% of the first thermoplastic material by weight.

[0052] Insert 90 can include one or more laminae that have been consolidated (including partially consolidated) (e.g., heated and pressed together) such that the lamina(e) are bonded to one another. After such consolidation, even though the lamina(e) are bonded to one another, the lamina(e) are still referred to as lamina(e). To illustrate, and referring to FIG. 6A, shown is a layup 200 of laminae, 204a-204e, that can be consolidated to form insert 90. Layup 200 includes five laminae; however, inserts of the present toe caps can be formed from a layup having any suitable number of lamina(e), such as, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, or more lamina(e). [0053] In layup 200, each of laminae 204a-204e includes fibers 208 dispersed within a second thermoplastic material 212. Fibers 208 can include any suitable fibers, such as, for example, carbon fibers, glass fibers, aramid fibers, polyethylene fibers, polyester fibers, polyamide fibers, ceramic fibers, basalt fibers, steel fibers, and/or the like (e.g., glass fibers); fibers of each of the laminae need not be of the same type. Second thermoplastic material 212 can comprise, for example, any of the thermoplastic materials described above, and need not be the same for each of the laminae. Some toe caps (e.g., 10a) can include an insert (e.g., 90) formed from a layup (e.g., 200) in which a second thermoplastic material (e.g., 212) of at least one lamina (e.g., any of laminae 204a-204e) comprises a same thermoplastic material as— or at least a thermoplastic material that is compatible with— a first thermoplastic material (e.g., 86) of the toe cap, which can facilitate a bond between the insert and the first thermoplastic material. A lamina including fibers (e.g., 208) (e.g., any of lamina 204a-204e) can include any suitable pre-consolidation fiber volume fraction, such as, for example, one that is greater than or substantially equal to any one of, or between any two of: 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90% (e.g., between approximately 50% and approximately 70%). Others of the present toe caps can have an insert formed from a layup that includes one or more sheets, films, cores (e.g., a porous, non-porous, honeycomb, and/or the like core), and/or the like, which may or may not comprise fibers (e.g., 208) and can comprise any of the thermoplastic materials described above.

[0054] In layup 200, each of laminae 204a-204e is a unidirectional lamina. More particularly, when layup 200 is placed flatly on a horizontal surface, fibers 208 of lamina 204a, 204c, and 204e can be aligned in a first direction 216, and fibers 208 of lamina 204b and 204d can be aligned in a second direction 220 that is angularly disposed relative to the first direction at an angle of approximately 90 degrees. Thus, when layup 200 is formed into insert 90, fibers 208 of lamina 204a, 204c, and 204e can follow a first path (e.g., 224, FIG. 1C) along insert 90 and fibers 208 of lamina 204b and 204d can follow a second path (e.g., 228, FIG. 1C) along the insert that, where the first and second paths are closest (e.g., at region 230, FIG. 1C), is angularly disposed relative to the first path at an angle of approximately 90 degrees (e.g., the insert can be a 0,90 composite). When insert 90 is positioned in toe cap 10a, at least a majority of the first path can lie in a plane that is substantially perpendicular to (i.e., within 10 degrees of perpendicular to) heightwise axis 110, and at least a majority of the second path can lie in a plane that is substantially perpendicular to widthwise axis 106.

[0055] Referring additionally to FIG. 6B, some of the present toe caps can include an insert that is formed from a layup having a unidirectional lamina 204f comprising fibers 208 that are aligned in any suitable fashion. For example, when its layup is placed flatly on a horizontal surface, fibers 208 of lamina 204f can be angularly disposed relative to fibers 208 of other lamina(e) of the layup at any suitable angle, such as, for example, one that is greater than or approximately equal to any one of, or between any two of: 0, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 degrees. For further example, when its layup is formed into an insert and that insert is positioned in a toe cap, fibers 208 of lamina 204f can follow a path along the insert, at least a majority of which lies in a plane that is angularly disposed at any suitable angle relative to a plane that is perpendicular to a heightwise axis of the toe cap, such as, for example, one that is greater than or substantially equal to any one of, or between any two of: 0, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 degrees (e.g., approximately 45, 15, or 10 degrees, about a lengthwise axis of the toe cap).

[0056] Referring additionally to FIG. 6C, some of the present toe caps can include an insert that is formed from a layup including a woven lamina 204g, such as, for example, one in which fibers 208 are arranged in a plane, twill, satin, basket, leno, mock leno, or the like weave. For example, lamina 204g can include a first set of fibers 232 and a second set of fibers 236 that are woven with the first set of fibers. When its layup is placed flatly on a horizontal surface, fibers 232 of lamina 204g can extend in a first direction 240, and fibers 236 of the lamina can extend in a second direction 244 that is angularly disposed relative to the first direction. A smallest angle 248 between first direction 240 and second direction 244 can be greater than or substantially equal to any one of, or between any two of: 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80 degrees. When its layup is formed into an insert and that insert is positioned in a toe cap, fibers 232 and fibers 236 of lamina 204g can follow any of the paths described above.

[0057] While laminae 204a-204g each include unidirectional or woven fibers 208, some of the present inserts can include non-woven lamina(e). Furthermore, some of the present inserts can include lamina(e) having discontinuous or short fibers. The present inserts can be formed from layups that include any of the laminae described above, which can be stacked in any suitable order, such as, for example, a symmetrical order or an asymmetrical order.

[0058] Exemplary dimensions for toe cap 10a can include a length of approximately 48 mm, a width of approximately 84 mm, and a height of approximately 42 mm. Shell 18 can have a thickness of approximately 6 mm at first end 22 and a thickness of approximately 2 mm at second end 26. Base 14 can have a thickness of approximately 2 mm. [0059] Referring now to FIGs. 7A and 7B, shown is a second embodiment 10b of the present toe caps. Toe cap 10b can be substantially similar to toe cap 10a, with the primary exception being the size and position of insert 90. In toe cap 10b, insert 90 in shell 18 can be positioned at second end 26; for example, the insert can define or surround at least a portion of opening 34. Insert 90 in shell 18 can be spaced from at least a portion of toe cap 10b at first end 22. For example, insert 90 in shell 18 can be positioned closer to second end 26 than to first end 22. For further example, shell 18 can be characterized as including a first portion 256 including insert 90 and a second portion 260, none of which includes the insert, where each of the first and second portions extends between opposing sides of base 14, and the second portion is disposed between the first portion and first end 22.

[0060] Referring now to FIG. 8, some of the present methods for producing a toe cap include disposing an insert (e.g., 90, 90a, or the like) within a mold (e.g., 268) and injecting a thermoplastic material (e.g., 86) into the mold to form a toe cap (e.g., 10a, 10b, or the like) that includes the insert (e.g., an overmolding process). Some methods comprise forming the insert at least by pressing a layup of one or more laminae (e.g., one or more of any lamina described above). Such forming of the insert can be performed prior to disposing the insert within the mold, using, for example, a press, and/or within the mold prior to injecting the thermoplastic material into the mold. In some methods, an insert can be formed within a mold while a thermoplastic material is injected into the mold, using heat and pressure supplied by the thermoplastic material to consolidate lamina(e) of the insert.

[0061] Referring additionally to FIG. 9, in some methods, one or more slits (e.g., 272) can be formed in one or more of the lamina(e) of the insert, which can be performed before and/or after the insert is formed. Such slit(s) can facilitate formation of the insert, positioning of the insert in the toe cap, and/or the like, by, for example, increasing the formability of the lamina(e), mitigating wrinkling of the lamina(e), and/or the like.

[0062] Referring additionally to FIG. 10, in some methods, the lamina(e) can be laid up, as part of forming the insert, by wrapping one or more laminae around a form (e.g., 276). To illustrate, each of one or more laminae (e.g., 280) (e.g., unidirectional fiber tape(s)) can be wrapped around the form such that consecutive wraps of the lamina are positioned beside one another, wherein such consecutive wraps can form at least a portion of a single lamina of the insert, and/or such that consecutive wraps of the lamina overlap one another, wherein such consecutive wraps can form at least a portion of each of two laminae of the insert. Such lamina(e) wrapped around the form and/or consecutive wraps thereof can be bonded to one another via, for example, the form being heated, another heat source (e.g., an infrared heater, an oven, and/or the like), a welder, and/or the like. In some methods, depending on the form, the lamina(e) wrapped around the form can form multiple inserts; for example, as shown in FIG. 10, the lamina(e) can form four inserts, one in each quadrant of the form. The foregoing is provided solely by way of illustration, as in the present methods, lamina(e) can be laid up in any suitable fashion.

[0063] Some of the present methods for producing a toe cap comprise: forming an insert at least by layering two or more laminae, each having fibers dispersed within a thermoplastic matrix material and pressing the layered laminae, and injecting a thermoplastic material into a mold while the insert is disposed within the mold to form a toe cap including the insert, the toe cap having a base, a first end, a second end opposite the first end, and a shell extending from the base and between the first and second ends to define an interior volume between the base and the shell, the shell being open at the second end to permit receipt of a user's toes within the interior volume, wherein the insert forms a portion of the shell such that the insert overlies the interior volume. In some methods, the insert is positioned closer to the first end of the toe cap than to the second end of the toe cap.

[0064] Some of the present methods for producing a toe cap comprise: disposing an insert within a mold, the insert including one or more laminae, each having fibers dispersed within a thermoplastic material, and injecting a thermoplastic material into the mold to form a toe cap including the insert, the toe cap having a base, a first end, a second end opposite the first end, and a shell extending from the base and between the first and second ends to define an interior volume between the base and the shell, the shell being open at the second end to permit receipt of a user's toes within the interior volume, wherein the insert forms a portion of the shell such that the insert overlies the interior volume and is positioned closer to the first end than to the second end.

[0065] In some methods, the toe cap has a lengthwise axis that extends between the first end and the second end, a widthwise axis that extends between portions of the shell on opposing sides of the interior volume, the widthwise axis being perpendicular to the lengthwise axis, and a heightwise axis that extends between the base and a portion of the shell that is across the interior volume from the base, the heightwise axis being perpendicular to each of the lengthwise and widthwise axes.

[0066] In some methods, the insert is positioned at the first end of the toe cap. In some methods, the insert in the shell is spaced from at least a portion of the shell at the second end of the toe cap in a direction that is parallel to the lengthwise axis by a distance that is at least 10%, optionally, at least 40%, of a length of the shell, measured parallel to the lengthwise axis. [0067] In some methods, the shell has a length measured parallel to the lengthwise axis, and the insert in the shell has a length measured parallel to the lengthwise axis that is less than 90%, optionally, less than 60% of the length of the shell. In some methods, the interior volume has a perimeter taken in a plane that is perpendicular to the widthwise axis, and the insert defines and/or overlies less than 90% of all portions of the perimeter that are defined by the shell in that plane. In some methods, the interior volume has a perimeter taken in a plane that is perpendicular to the lengthwise axis, and the insert defines and/or overlies at least 80%, optionally, at least 90% of all portions of the perimeter that are defined by the shell in that plane. [0068] In some methods, the insert includes a first portion having a first thickness, and a second portion having a second thickness that is less than or equal to 75% of the first thickness, wherein the second portion is disposed closer to the second end of the toe cap than is the first portion. In some methods, the thermoplastic material of at least one of the lamian(e) of the insert and the thermoplastic material injected into the mold comprise a same thermoplastic material.

[0069] Some embodiments of the present toe caps comprise: a base, a first end, a second end opposite the first end, and a shell extending from the base and between the first and second ends to define an interior volume between the base and the shell, the shell being open at the second end to permit receipt of a user's toes within the interior volume, wherein the shell includes a first thermoplastic material and insert coupled to the first thermoplastic material, the insert including one or more laminae, each having a second thermoplastic material and fibers dispersed within the second thermoplastic material, wherein the insert overlies the interior volume and is positioned closer to the first end than to the second end.

[0070] In some toe caps, at least one of the lamina(e) is a unidirectional lamina, a woven lamina, or a non-woven lamina, and/or the insert comprises one or more lamina(e), each of which does not include fibers. In some toe caps, the first thermoplastic material and the second thermoplastic material of at least one of the lamina(e) comprise a same thermoplastic material. In some toe caps, the first thermoplastic material is overmolded onto the insert.

[0071] Some toe caps have a lengthwise axis that extends between the first and second ends, a widthwise axis that extends between portions of the shell on opposing sides of the interior volume, the widthwise axis being perpendicular to the lengthwise axis, and a heightwise axis that extends between the base and a portion of the shell that is across the interior volume from the base, the heightwise axis being perpendicular to each of the lengthwise and widthwise axes.

[0072] In some toe caps, the insert is positioned at the first end of the toe cap. In some toe caps, the insert in the shell is spaced from at least a portion of the shell at the second end of the toe cap in a direction that is parallel to the lengthwise axis by a distance that is at least 10%, optionally, at least 40% of a length of the shell, measured parallel to the lengthwise axis.

[0073] In some toe caps, the shell has a length measured parallel to the lengthwise axis, and the insert in the shell has a length measured parallel to the lengthwise axis that is less than 90%, optionally, less than 60% of the length of the shell. In some toe caps, the interior volume has a perimeter taken in a plane that is perpendicular to the widthwise axis, and the insert defines and/or overlies less than 90% of all portions of the perimeter that are defined by the shell in that plane.

EXAMPLES

[0074] The present invention will be described in greater detail by way of specific examples. The following examples are offered for illustrative purposes only and are not intended to limit the invention in any manner. Those of skill in the art will readily recognize a variety of noncritical parameters that can be changed or modified to yield essentially the same results.

[0075] Structural analysis software was used to model toe cap 10a' s (a size 9 version) response to the impact and compression tests set forth in EN 12568. The impact test is illustrated in FIG. 11 A, in which a striker 296 was used to impact the toe cap with an energy of 200 joules, and the compression test is illustrated in FIG. 1 IB, in which a platen 300 was used to apply a 15 kilonewton (kN) compressive load to the toe cap. During each test, a minimum internal clearance 304 between base 14 and shell 18, as shown in FIG. 12, was recorded. The results for each test are shown in TABLE 1. The toe cap met the minimum internal clearance set forth in EN 12568 (21.5 mm).

TABLE 1: Results of Structural Testing of Toe Cap 10a

[0076] Structural analysis software was used to perform the same impact test on toe cap 10b. During the impact test, toe cap 10b had a minimum internal clearance of 22.5 mm. [0077] The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.

[0078] The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) "means for" or "step for," respectively.