Technical field

This invention relates to a protective device .

More specifically, the invention relates to a device to protect metatarsal bones of the foot of a user of an item of footwear .

The protective device according to the invention is designed to be inserted inside safety footwear .

The need is known, in various working sectors , to use protective devices , which are regulated according to parameters required by safety regulations , that are designed to increase the pas sive safety of workers such as , for example , reducing the ri sk of in jury caused by ob j ect s falling on the foot of a user .

Background art

Amongst the prior art protective devices there are those relating to the protection of the metatarsal bones .

These prior art devices are generally used in industrial environment s , such as , for example , in the context of heavy industry or the oil & gas industry and in general in any work and non-work situation, in which there is a risk of in jury to the metatarsal bones of the worker .

Amongst the prior art solutions , there are protection systems inserted directly inside the item of footwear . These prior art systems comprise a main body, usually obtained by in j ection or die-casting moulding .

Prior art protective systems comprise a main body made of a homogeneous rigid or elastic-viscous material , and a semi-rigid bridge positioned and fixed on the main body .

In particular, the semi-rigid bridge is sewn or glued on the main body .

In prior art systems , the presence of the semi-rigid bridge is neces sary to increase the overall resistance of the system against any impact in the portion of the foot which it is neces sary to protect (metatarsal bone ) and to discharge the force imparted, for example by the falling of an ob j ect , on the edges of the item of footwear, that is to say, out side the foot .

However, these prior art systems , whilst protecting the foot from impact s in an acceptable manner, still have drawbacks .

A significant drawback is due to the fact that , as mentioned, the main body, on it s own, does not guarantee an adequate resistance to the impact generated by the falling of an ob j ect on the foot .

For this reason, the prior art systems neces sarily comprise more than one resistant element , increasing the production cost s and the logistical dif ficulties of production and storage .

A further drawback is due to the fact that since they are usually produced by means of a traditional moulding proces s with a viscous elastic material , they have a substantially homogeneous or isotropic composition, resulting in a structural rigidity which negatively characterises the comfort .

A further drawback, again linked to the intrinsic characteristics of the production proces s used, is due to the fact that by using the traditional moulding proces ses it is not pos sible to make the prior art protection systems permeable to air, that is to say, breathable , apart from by making through holes with significant dimensions which worsen the strength .

Aim of the invention

The aim of the invention is therefore to provide a protective device made in a single body and which does not require further reinforcing element s to achieve high levels of protection for the foot of the user and which is not homogeneous inside but characterised by specific three-dimensional structures de signed to give the element greater resistance to the impact of the weight on the metatarsus and at the same time greater comfort for the foot .

A further aim of the invention is to provide a protective device which is at the same time ef fective , comfortable and inexpensive and easy to make .

A further aim of the invention is to provide a protective device which can guarantee customisations , relative to the size , material used and type of item of footwear, in a short time and with limited cost s .

A further aim of the invention is , thanks to the opening of the structures inside the element towards the outside , to provide a breathable protective device , that is to say, which allows a high level of breathability to be maintained inside the item of footwear, without reducing it s impact resistance .

According to the invention, these aims and others are achieved by a protective device comprising the technical features described in the accompanying claims .

Brief description of the drawings The technical features of the invention, according to the above-mentioned aims , are clearly described in the appended claims and it s advantages are apparent from the detailed description which follows , with reference to the accompanying drawings which illustrate non-limiting example embodiment s of it , and in which :

- Figure 1 is a schematic perspective view from above of a protective device according to the invention ; and

- Figure 2 is a schematic perspective view from above of the protective device , in a cross-section according to the plane P of Figure 1 .

Detailed description

With reference to the accompanying drawings , the numeral 1 denotes in its entirety a device to protect the metatarsal bones , made in accordance with the invention . The protecting device 1 to protect metatarsal bones according to the invention, hereinafter also referred to simply as the device 1 , is designed to be inserted inside an item of footwear, in such a way as to protect the foot of a user of the item of footwear from pos sible in jury caused, for example , by the falling of an ob j ect on the foot .

More in detail , the device 1 is designed to be inserted, advantageously, inside the upper of the item of footwear in the zone corresponding to the upper portion of the foot of the user .

In use , therefore , the protective device 1 according to the invention is interposed between at least the outer layer of the item of footwear and the foot of the user . The term outer layer means , for example , the upper of the item of footwear . The device 1 is advantageously fixed to the upper of the item of footwear by stitching or gluing .

With reference to the accompanying drawings , the protective device 1 according to the invention comprises a main body 2 stably connectable to an item of footwear and having a continuous lower wall 4 designed to face the foot of the user and an upper face 5 opposite the lower wall 4 .

Advantageously, the main body 2 is made inside it with three-dimensional structures 11 at least partly empty configured to optimise the discharge of the impact forces out side the metatarsal bones of the foot of the user .

Advantageously, the three-dimensional structures 11 have a geometry and density of material which is variable along the thicknes s of the main body 2 .

Advantageously, moreover, the three-dimensional structures 11 are made in the form of a honeycomb .

In particular, the main body 2 comprises a plurality of layers wherein the layer of contact with the foot of the user has a lower density, and the layer closest to the upper of the item of footwear has a greater density, as shown in the cros s section of Figure 2 .

As mentioned, Figure 2 shows an embodiment in which the density of the three-dimensional structures 11 increases with the approach to the upper face 5 .

This solution maximises the resistance of the main body 2 in the direction of impact s of a weight without causing stif fening and los s of comfort of the device as a whole since the portion in contact with the foot of the user ( lower face 4 ) has a lower density and, therefore , a greater softnes s . As may be noted in the accompanying drawings , advantageously, the upper face 5 has a surface knurling designed to give an optimum grip between the upper face 5 and the item of footwear .

Advantageously, the bottom wall 4 has a surface knurling designed to give greater grip between the lower wall 4 and the foot of the user .

The protective device 1 also comprises a reinforcing and retaining element 3 positioned at least partly superposed on the main body 2 .

The main body 2 and the reinforcing element 3 connected in a non-removable manner on it form a single body .

In particular, the main body 2 and the reinforcing element 3 are made as one during the same production proces s .

The single body therefore has a first portion formed by the main body 2 , and a second reinforced portion formed by main body 2 and the reinforcing element 3 , at least partly superposed .

The first and second portions follow a single longitudinal direction of extension of the device 1 More in detail , the second portion has a greater rigidity than the first portion, due to the superposing of the main body 2 and the reinforcing element 3 .

This superposing generates a connection between the main body 2 and the reinforcing element 3 which is stable and resistant , in particular since they are made using the same production proces s , advantageously by additive manufacturing ( for example of the FDM type ) .

This makes it pos sible to distinguish inside the single body between the first portion, characterised by a high level of comfort for the user, and the second portion, characterised by great compactnes s and a high degree of resistance to impact s .

The first and second portions therefore define a single piece .

The fact of being made as a single piece guarantees an important simplicity of use and production of the device 1 . At the same time , the pos sibility of making a single piece dif ferentiating the features relative to the first and second portions makes it pos sible to combine with the simplicity of use and production also an optimum operating quality, in terms of ef ficiency, safety for the user and convenience of use .

Advantageously, the device 1 according to the invention has an arched shape .

More specifically, this curved shape serves to optimise the level of adhesion of the device 1 both to the foot of the user and to the shape of the upper of the item of footwear .

The curved shape also makes it possible to optimise the discharge of the forces acting on the device 1 in a zone out side the foot of the user, thereby safeguarding it . As shown in the drawings , the reinforcing and retaining element 3 has at least two flaps 6 emerging from the main body 2 and designed to be connected to the item of footwear to retain the main body 2 in a predetermined position relative to said item of footwear .

The term "predetermined position" means that the main body 2 is positioned to protect the metatarsal bones of the foot of the user . The two flaps 6 , perform the function of discharging on the edges of the item of footwear, that is to say, out side the foot , the force imparted, for example by the falling of an ob j ect on the item of footwear .

Advantageously, the two flaps 6 are positioned specularly relative to the main body 2 , that is to say, they extend on opposite sides of the main body 2 .

According to other embodiment s , not illustrated in the drawings , the above-mentioned flaps 6 are greater than two .

These further embodiment s make it pos sible to optimise the fixing of the main body 2 to the item of footwear .

The reinforcing and retaining element 3 also has a central portion 7 , interposed between the two flaps 6 , and stably constrained to the upper face 5 of the main body 2 .

The central portion 7 is therefore interposed between the upper of the item of footwear (to which it is stably fixed by stitching or gluing) and the main body 2 ( to which it is stably fixed since it is made as a single piece ) .

Moreover, advantageously, the reinforcing and retaining element 3 compri ses a tab 9 prot ruding behind the main body 2 .

In particular, the tab 9 advantageously has a thin and elastic structural shape in such a way as to further facilitate , in terms of grip and comfort , the adhesion of the protective device 1 to the foot of the user .

As shown in the accompanying drawings , the upper face 5 of the main body 2 has notches 8 designed to favour the deformability of the main body 2 along at least one longitudinal and/or transversal direction of extens ion . More specifically, the deformability of the main body 2 along at least one direction of longitudinal and/or transversal extension imparted by the above-mentioned notches 8 , contributes to damping the force applied on the item of footwear by the falling of an ob j ect on it as well as increasing the adaptability of the main body 2 to the shape of the item of footwear and the foot of the user .

Advantageously, the notches 8 have a hexagonal shape . This hexagonal shape makes it pos sible to optimi se the absorption of the stres s forces to which the item of footwear can be sub j ected during use , thus protecting the user .

Moreover, according to an embodiment not illustrated in the drawings , the main body 2 has a plurality of breathable holes , which pas s from the lower wall 4 to the upper face 5 .

Advantageously, the presence of breathable holes is designed to make the protective device 1 , according to the invention, permeable to air, that is to say, breathable .

In particular, the presence of breathable holes makes it possible to expel moisture out side the protective device 1 , making the item of footwear much more comfortable for the user .

The protective device 1 also comprises a TAG, not illustrated in the drawings , designed to transmit identification signals of the device 1 . In particular, the above-mentioned TAG is designed to transmit identification signals of the device 1 such as , for example : identification code , production date , date of marketing, EC declaration of conformity .

The above-mentioned identification signals and others represent very important information for the knowledge of the state of the product .

According to a pos sible embodiment , the TAG is positioned on the main body 2 .

According to a further pos sible embodiment , the TAG is positioned on at least one of the two flaps 6 .

Advantageously, the TAG comprises an RFID .

Advantageously, the main body 2 and the reinforcing and retaining element 3 are made by additive manufacturing FDM .

In particular, the manufacturing technique by means of additive manufacturing FDM makes it pos sible to use a wide range of materials , which dif fer from each other for example in terms of mechanical characteristics .

The term "mechanical characteristics" means everything relating to the ability of the materials to withstand the action of external forces or stres ses , such as , for example , mechanical strength, wear resistance , impact resistance and hardnes s .

Additive manufacturing also allows a large freedom of design as well as not having to prepare individual moulds for the respective shapes neces sary for the various sizes of the footwear .

In effect , by way of example , the protective device 1 according to the invention may be made of antibacterial material . In particular, the chemical structure of an antibacterial material constitutes a natural barrier against the proliferation of fungi , viruses , germs and bacteria .

Moreover, the protective device 1 according to the invention may be made of transparent material .

Moreover, the protective device 1 according to the invention may also be made of antistatic material .

In particular, the production using antistatic material offers many advantages compared with the production using other materials , including resistance to wear and the discharging of any current to earth or to the other element s of the shoe .

Alternatively, the main body 2 and the reinforcing and retaining element 3 are made by additive manufacturing in SLA ( stereolithography) and SLS ( selective laser sintering) .

Amongst the various materials which can be used to make the device 1 according to the invention there are thermoplastic polyurethane TPU, polyactic acid PLA or acrylonit rile-butadiene-styrene ABS .

The protective device 1 according to the invention achieves the preset aims and brings further important advantages .

A first advantage of the protective device 1 according to the invention is represented by the fact that the device 1 is made as a single body, that is to say, without the need to apply further reinforcing element s to guarantee an adequate protection of the metatarsal bones of the user of the item of footwear . This advantage result s in the pos sibility of providing a device which is simple to produce and with limited cost s with respect to the prior art .

Another advantage of the protective device 1 according to the invention is due to the presence of the plurality of breathable openings between the inner structures 11 and the out side .

This means that the device 1 is permeable to air and therefore able to expel the moisture generated by the foot of the user, guaranteeing excellent ease of use . Another advantage of the protective device 1 according to the invention is the pos sibility of using or combining with each other a wide range of dif ferent materials .

This makes it pos sible to use dif ferent mechanical characteristics in such a way as to personalise the device on the basis , for example , of various further functions such as , for example , antibacterial , transparency and/or anti-static features .