Protective footwear

Abstract

A safety boot including an upper having a foot enclosing portion and a shaft, a toe cap located within a toe portion of the upper, and a molded outsole having a bottom and a toe cover at a proximal end of the outsole. The toe cover defines a toe cavity adapted for receiving the toe portion of the upper, wherein the upper is secured to the outsole such that the toe portion of the upper is positioned within the toe cavity, with the outsole side stitched to the upper around the periphery of the outsole and across the toe cover, distal to the toe cap. Side stitched protective footwear having a toe cap and side stitching that extends around the upper periphery of an outsole including across a toe cover distal to a toe cap is also provided, as well as methods for assembling safety boots and protective footwear.

Description

BACKGROUND

[0001] Protective footwear in the form of shoes or boots, also known as safety footwear, is a durable shoe or boot that has a protective covering positioned in the toe area of the boot (or other footwear such as a shoe) for protecting the wearer's toes and forefoot from impacts and 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 usually in the form of a toe cap concealed within the upper of the boot or shoe. Toe caps typically comprise a hard concave shell (e.g., half-dome shaped) formed to fit within the toe portion of the upper. While traditionally made of steel or other metal, safety toe caps can also be made of hard composite materials such as Kevlar, carbon fiber, fiberglass, plastics such as thermoplastic polyurethane (TPU), or other rigid material suitable for protecting the wearer's toes and forefoot.

[0002] Safety boots are particularly important for firefighters, and these boots are subjected to extreme conditions and excessive wear. Not only must firefighter boots have the protection provided by internal toe caps, they should also be fire and heat resistant and include additional protections for firefighters such as padding (e.g., in the shin region) and slip-resistant bottom surfaces. Firefighter boots intended for use in colder climates should also have added insulation and bottom surfaces having ice slip resistance.

[0003] Safety boots, particularly firefighter boots, are often subject to extreme wear, particularly in the toe region. Frequent firefighter training exercises require movements such as repeated crouching and dragging of the toes, causing firefighter boots to fail prematurely. With the traditional cemented construction wherein the upper is simply cemented to the outsole, boots will often delaminate at the toe, whereby the upper separates from the outsole. This is a tripping hazard for the firefighter and also reduces the protection provided by the boot. Toe portions of the boots can also wear through quickly. In either instance, the firefighter boots must be replaced. While side stitch construction is often more durable than cemented construction of boots and shoes, true side stitching in the toe portion has not been possible due to the presence of the hard toe cap.

[0004] While a variety of devices and techniques may exist for providing protective footwear, particularly certified safety boots and certified firefighter boots, it is believed that no one prior to the inventors have made or used an invention as described herein.BRIEF DESCRIPTION OF DRAWINGS

[0005] While the specification concludes with claims particularly pointing out and distinctly claiming the invention, it is believed that the invention will be better understood from the detailed description of certain embodiments thereof when read in conjunction with the accompanying drawings. Unless the context indicates otherwise, like numerals are used in the drawings to identify similar elements in the drawings (e.g., outsole (50, 150)). In addition, some of the figures may have been simplified by the omission of certain elements in order to more clearly show other elements. Such omissions are not necessarily indicative of the presence or absence of particular elements in any of the exemplary embodiments, except as may be explicitly stated in the corresponding detailed description.

[0006] FIG. 1 depicts a perspective view of one embodiment of a protective boot according to the present disclosure.

[0007] FIG. 2 depicts a right side view of the protective boot of FIG. 1.

[0008] FIG. 3 depicts a partially exploded view of the protective boot of FIG. 1.

[0009] FIG. 4 depicts a perspective view of the toe cap used in the protective boot of FIGS. 1 and 14.

[0010] FIG. 5 depicts a side view of the toe cap of FIG. 4.

[0011] FIG. 6 depicts a bottom view of the toe cap of FIG. 4.

[0012] FIG. 7 depicts a top view of the toe cap of FIG. 4.

[0013] FIG. 8 depicts a side view of the outsole of the protective boot of FIG. 1.

[0014] FIG. 9 depicts a bottom view of the outsole of FIG. 8.

[0015] FIG. 10 depicts a top view of the outsole of FIG. 8, with the location of the toe cap shown in hidden line.

[0016] FIG. 11 depicts a cross-sectional view of the boot of FIG. 14, taken along the centerline thereof.

[0017] FIG. 12 depicts an enlarged cross-sectional view of the toe portion of the protective boot of FIG. 11.

[0018] FIG. 13 depicts a cross-sectional view of the outsole of FIG. 10, taken along the line 13-13 thereof.

[0019] FIG. 14 depicts a right side view of an alternative embodiment of a protective boot.

[0020] FIG. 14A depicts an enlarged view of the forefoot portion of the boot of FIG. 14.

[0021] The drawings are intended to illustrate rather than limit the scope of the present invention. Embodiments of the present invention may be carried out in ways not necessarily depicted in the drawings. Thus, the drawings are intended to merely aid in the explanation of the invention. Thus, the present invention is not limited to the precise arrangements shown in the drawings.DETAILED DESCRIPTION

[0022] The following detailed description describes examples of embodiments of the invention solely for the purpose of enabling one of ordinary skill in the relevant art to make and use the invention. As such, the detailed description and illustration of these embodiments are purely illustrative in nature and are in no way intended to limit the scope of the invention, or its protection, in any manner. It should also be understood that the drawings are not to scale and in certain instances details have been omitted, which are not necessary for an understanding of the present invention.

[0023] Embodiments of the present disclosure provide side stitched protective footwear, particularly side stitched certified safety boots, certified firefighter boots, and certified EMS boots. The footwear (e.g., a boot, a shoe, or other article of footwear) generally comprises an upper and an outsole, wherein the outsole is side stitched to the upper. In some embodiments of the present disclosure, the upper is also secured to the outsole by an adhesive, such as a cement suitable for use in footwear construction. The upper includes a toe cap located within a toe portion of the upper, wherein the toe portion refers to the proximal end portion of the forefoot (e.g., the proximal half of the forefoot). The outsole generally comprises a bottom having upper and lower surfaces, opposing sidewalls and a heel wall extending upwardly from the bottom, and an integral toe cover located at the proximal end of the outsole and providing a toe cavity. In some embodiments, the outsole, including the toe cover, is molded as a unitary structure (e.g., injection molded as a single piece). The sidewalls and heel wall extend upwardly away from the bottom of the outsole so as to form a first cavity that is distal to the toe cavity. The upper is positioned within the first cavity of the outsole with the toe portion of the upper located within the toe cavity of the outsole. The outsole is side stitched to the upper around the periphery of the outsole, with the side stitching extending around substantially the entire (or the entire) upper periphery of the outsole. The side stitching extends not only along the sides and the heel of the boot, but also across the top of the toe portion of the boot, distal to the location of the toe cap. In some embodiments, the side stitching is located within a stitching groove that extends substantially continuously (or continuously) around substantially the entire (or the entire) periphery of the outsole (including the toe portion). As used herein, “substantially continuously” includes continuously (i.e., without interruption), and “substantially entirely” includes entirely (i.e., without any break). In embodiments of the present disclosure, the side stitching does not extend around the proximal end (i.e., proximal to the wearer's toes) of the footwear. Instead, the side stitching extends around the heel, along opposing sides, and over and across the toe portion distal to the toe cap.

[0024] As used herein, the term “upper” generally refers to the boot components other than the outsole (50), wherein the outsole can include an optional heel plug (78), outsole plate (90), and shank (88) (as described further herein). It will be understood, however, that the outsole (50) can include other components and features known to those skilled in the art. It should also be noted that a removable footbed insert can be provided with the footwear but is not shown in the drawings. In addition, although the present disclosure is shown and described in connection with boots, protective shoes having the same construction can also be provided (but without a boot shaft (14, 114)).

[0025] As used herein, the term “certified safety boot” means a protective boot that satisfies ASTM standard F2413 (“Standard Specification for Performance Requirements for Protective (Safety) Toe Cap Footwear”) in effect on the filing date hereof, and available from ASTM International. As used herein, the term “certified firefighter boot” means a protective boot that satisfies the NFPA 1971 standard (Standard on Protective Ensembles for Structural Fire Fighting and Proximity Fire Fighting) and / or the NFPA 1970 standard in effect on the filing date hereof. As used herein, the term “certified EMS boot” means a protective boot that satisfies the NFPA 1999 standard (Standard on Protective Clothing and Ensembles for Emergency Medical Operations) in effect on the filing date hereof. It will be understood that some boots according to the present disclosure meet more than one of the applicable standards. For example, a certified firefighter boot is also a certified safety boot (but not all certified safety boots are certified firefighter boots.)

[0026] FIGS. 1-3 depict one embodiment of a protective boot (10) according to the present disclosure. The boot (10) generally includes an upper (12) secured to an outsole (50). The upper (12) is adapted to receive the foot and at least the lower portion of the lower leg and calf of a wearer. The upper generally comprises a shaft (14) extending upwardly away from the foot enclosing portion of the upper, and the foot enclosing portion comprises an instep (17), an outer leather vamp layer (18), a heel counter (16), and a reflective strip (20). The bottom of the upper (12) is not shown in FIGS. 1-3. The instep (17) is contiguous with the toe portion (22) of the upper and the vamp (18) extends over the toe portion. In the embodiment shown, these portions of upper (12) generally comprise various layers of materials, including leather outer layers forming the shaft (14), instep (17) and vamp (18), an inner lining (25), and a waterproof thermal barrier between the leather and inner lining. The inner lining (25) generally extends over the entire interior of the upper (12), including the interior bottom of the upper. The heel counter can comprise a molded or thermoformed polymer material (e.g., a thermoplastic material).

[0027] The outer vamp (18) covers the top and front portion of the boot wearer's foot, and the heel counter (16) encloses the heel or rear portion of the boot wearer's foot. The shaft (14) has an upper edge which forms an upper opening through which the wearer's foot enters the boot (10). A pair of handles (15) in the form of cutouts are provided on opposite sides of the upper end of the shaft, and are used by the wearer for pulling the boots on. Padding is also provided in the shin area (23) of the shaft for added protection for the wearer, with the padding located between an outer leather layer and the lining (25). The illustrated boot has a slip-on configuration, however, it will be understood that the boot can be configured to have a conventional lace-up configuration. The upper (12) also is provided with a lining (25) within its interior. The lining (25) can be secured to the other layers of the upper with an adhesive and / or by stitching. The lining (25) typically comprises pigskin, glove leather, heavy twilled cotton, linen fabric, or other suitable material. Additionally, the lining (25) can comprise synthetic fabric materials such as, for example, Gortex®, Sympatex®, or other materials having waterproof and / or sweat dissipating characteristics. Although not shown in FIGS. 1-3, a puncture resistant bottom layer is also provided, covering substantially the entire bottom surface of the upper.

[0028] In the alternative embodiment of FIGS. 11-12, 14 and 14A, the upper (112) of the boot (110) has a shaft (114) comprising a plurality of leather panels (127) stitched to one another in the arrangement shown. A lining (125) is provided throughout the interior of the upper (112), and a waterproof thermal barrier (126) is provided adjacent the outer surface of the lining (e.g., between the leather panels (127) and the lining (125)), as best seen in FIG. 12. Padding (123) is also provided beneath a portion of the leather panels (127), with the padding positioned between the interior surface of the leather panels and the lining / barrier (125, 126). It should be noted that the padding is not shown in the cross-sectional view of FIG. 11. The upper (112) of boot (110) also includes a first outer leather vamp layer (118A) that extends around the toe portion of the upper (112) and along a portion of the bottom of the upper at the proximal end of the toe portion, and a second outer leather vamp layer (118B) overlapping with and extending upward from the first vamp layer (118A).

[0029] The upper (112) of boot (110) further includes a thermoformed or molded heel counter (116) that extends into the outsole (as described below), as well as a puncture resistant bottom layer (144) covering substantially the entire bottom surface of the upper. The bottom layer (144) is secured to the lining (125), with the thermal barrier (126) therebetween, such as by using an adhesive. Suitable materials for puncture resistant bottom layer (144) include puncture resistant fabrics, particularly composite fabrics such as L-Protection® fabric available from Meramac Group, Sullivan, Missouri.

[0030] The illustrated components of the upper (12, 112) are secured together by stitching and adhesive but any other suitable means can alternatively be utilized. The components of the upper (12, 112) described herein are merely exemplary as any of a variety of configurations can be employed.

[0031] As seen in FIGS. 3, 11 and 12, the boot (10, 110) also includes a safety toe cap (30) positioned within the toe portion of the upper (12, 112). In the embodiment of FIGS. 1-3, the toe cap (30) is located between the lining (25) and the vamp layer (18). In the embodiment of FIGS. 11-12, 14, and 14A, the toe cap (30) is located between the interior surface of the leather first vamp layer (118A) and the lining / barrier (125 / 126). When the upper (12, 112) is attached to the outsole to assemble the boot (10, 110), the toe portion of the upper containing the toe cap (30) is located within the toe cavity (64) of the outsole (50), as further described below. The toe cap is located, sized, and configured to extend over the toes of wearer's foot while still permitting the natural flexing of the wearer's foot during walking.

[0032] As best seen in FIGS. 4 to 7, the toe cap (30) has a curved front wall (32), an arched upper surface (34), a flat bottom surface (35), a semicircular cutout (36) in the bottom surface, and a concavely curved reward edge (37) that extends between the arched upper surface (34) and the bottom surface (35). Because of the cutout (36) in the bottom surface, bottom surface (35) is in the form of semi-circular flange. The toe cap (30) forms an interior space (38) that is sized and shaped to fit within the toe portion (22, 122) of the upper (12, 112), thus providing the toe box of the boot. When secured within the toe portion (22, 122) of the upper (12, 112) and within the toe cavity (64) of the outsole (50), the wearer's toes, within the toe portion of the upper, are received within the interior space (38) of the toe cap (30). The arched upper surface (34) of the toe cap slopes forwardly and laterally in a smooth continuous surface to blend into the front wall (32). The toe cap is also generally asymmetrical to correspond to the typical shape of a wearer's forefoot and the toe portion (22, 122) of the upper, as is known in the art. Thus, the front wall (32) and arched upper surface blend together to form a continuous outer surface. The outer surfaces of the toe cap (30) are adapted for attachment to and between the leather vamp layer (18, 118A) and the lining / barrier (25, 125 / 126) of the upper (12, 112) (e.g., using an adhesive). It is noted that the toe cap (30) can alternatively have any other suitable configuration.

[0033] The toe cap (30) is formed of a rigid material that protects the toes of the wearer of the boot (10). In the embodiment shown, the toe cap comprises a composite of two or more materials such as a fibrous material (e.g., fiberglass, carbon fiber, or a blend of thereof) in a resin (e.g., polyester or epoxy). Alternatively, the toe cap (30) can comprise metal (e.g., steel or aluminum alloy), plastic, or other material that resists compression, cracking, and puncture (and thereby protects the wearer's toes) (e.g., plastics such as thermoplastic polyurethane (TPU), or other rigid material suitable for protecting the wearer's toes and forefoot). In the boot embodiment shown, the toe cap is adapted so that the assembled boot will comply with ASTM standard F2413. The toe cap (30) is secured within the upper using a suitable adhesive.

[0034] In the particular embodiment shown, the toe cap (30) also includes a rubber transition edge (39) that extends over the rearward edge (37) of the toe cap. The rubber transition edge (39) has a tapered thickness and provides a smoother transition between the toe cap (30) and the portion of the upper (12) immediately adjacent the toe cap. This construction provides additional comfort as the edge of the toe cap is less noticeable. The semicircular cutout (36) in the bottom surface of the toe cap (30) also provides additional comfort as the bottom surface of the toe cap will be positioned outside of the periphery of the wearer's foot,

[0035] The outsole (50) of the boot (10) is best seen in FIGS. 3-4, and 8-13. In the embodiment shown, outsole (50) is molded from a rubber compound, particularly a flame and hear resistant rubber compound suitable for high heat and extreme cold such as the Vibram® Fire & Ice® compound. The outsole can be molded from a variety of other polymer materials suitable for the intended environment where the boot will be used, particularly thermoplastic materials. In the embodiment shown, the outsole is molded as a unitary structure, such as by injection molding.

[0036] The outsole (50) is configured to receive the lower-most portion of the upper (12) as well as the entirety of toe portion (22) of the upper, including the toe cap (30). When the upper (12) is secured within the outsole (50) (as described below), the sidewalls (54A, 54B), rear heel wall (58), and toe cover (56) of the outsole extend sufficiently above the interior surface (53) of the upper such that the outsole (50) can be functionally secured to the upper (12) by stitching (also referred to as side stitching). “Functionally securing” refers to stitching that retains the securement of the upper to the outsole, rather than decorative stitching that is often used to mimic side stitching. The toe cover (56) of the outsole also extends over the entirety of the toe cap (30), extending rearward of (distal to) the location of the reward edge (37) (and optional transition edge (39)) of the toe cap (30). This allows the outsole (50) to be stitched to the upper (12) behind (i.e., rearward or distal to) the location of the toe cap (12), thereby reinforcing and strengthening the bond between the upper and the outsole as compared to conventional cementing of the upper to the outsole. This also eliminates the problem of delamination in the toe portion of the boot.

[0037] The bottom portion of outsole (50) includes an exterior (or lower) surface (52), an upper interior surface (53), opposing sidewalls (54A, 54B) extending upwardly away from the upper surface (53) along opposite sides thereof, a rear heel wall (58) extending upwardly from the interior surface (53) at a rear (or distal) end thereof, and an integral toe cover (56) located at the forward (proximal) end of the outsole. Sidewalls (54A, 54B) curve upwardly at the distal end of the toe cover (56), forming a curved transition between the sidewalls and the toe cover. The distal sides (60A, 60B) of the toe cover extend upwardly from sidewalls (54A, 54B) at an angle greater than vertical, and the upper surface (62) of the toe cover is domed such that a toe cavity (64) is provided therebeneath. The toe cavity is defined by the upper interior surface (53) of the outsole and the inner surface of the toe cover (56). The sidewalls (54A, 54B) and rear heel wall (58) extend upward of the upper interior surface (53) of the outsole, thereby defining a first cavity (59) between the sidewalls (54A, 54B), rear heel wall ((58) and upper interior surface (53). This cavity (59) communicates with (i.e., is contiguous with) the toe cavity (64) and together are configured to receive the lower portion of the upper (12) therein. The heel, midfoot, and part of the forefoot of the upper are received within the cavity (59) and the proximal end of the forefoot, including the entirety of the toe cap (30), are received within the toe cavity (64).

[0038] In the embodiment shown, the sidewalls (54A, 54B) and the toe cover (56) have a thickness of between about 2 and about 6 mm. However, in this particular embodiment the lower portion (55) of the sidewalls and lower portion (57) of the toe cover are thicker, thereby providing a raised portion that transitions from the sidewalls and toe cover to the bottom (52) of the outer. This raised portion provides additional strength, rigidity, and durability to the outsole and toe cover (56) in regions typically subjected to greater wear. The thickness of the lower portions (55, 57) may also increase towards the bottom surface (52) in order to provide a smooth transition between the sidewalls (54A, 54B) and toe cover (56) and the bottom surface (52). The exemplary outsole (50) further includes an integral toe bumper (65) on the proximal end of the toe cover (56), located forward (proximal) of the lower portion (57) of the toe cover. Toe bumper (65) comprises a thicker region of the toe cover, and also includes ribs (66) extending across the width of the toe bumper.

[0039] The bottom surface (52) of the outsole includes a tread for providing additional traction on wet, icy, or otherwise slippery surfaces. The tread arrangement shown is merely exemplary, and forms no part of the claimed invention. In this example, the tread comprises a plurality of raised lugs (70, 72, 74). Any of a variety of lug shapes and arrangements can be provided, and that shown is merely one example. As best seen in FIG. 9, outsole (50) includes outer lugs (70) arranged on opposite sides of the bottom surface (52). Outer lugs (70) also extend upward from the bottom surface (52) onto the lower portion (55) of the sidewalls (54A, 54B) and lower portion (57) of the toe cover (56) so as to provide traction along the edges of the boot. Outer lugs (70) are also provided along opposite sides of the bottom surface (52) on the heel portion (50A), a proximal portion of the midfoot portion (50B), and the forefoot portion (50C) of the outsole (50). A row of inner lugs (72) are provided between the rows of outer lugs (70) on the midfoot portion (50B) and the forefoot portion (50C) of the outsole (50). One or more inner lugs (72) are also provided between the rows of outer lugs (70) on the heel portion (50A) of the outsole.

[0040] Two rows of traction lugs (74) are provided on opposite sides of the inner lugs (72), between the inner lugs (72) and the outer lugs (70) along the heel portion (50A), midfoot portion (50B), and forefoot portion (50C) of the outsole (50). Traction lugs (74) are arranged and constructed to provide enhanced grip (traction), particularly on icy and / or wet surfaces, providing increased traction as compared to one or more of the other lugs (70, 72) of the outsole. In some embodiments, this feature is provided by proving a traction coating or outer layer on traction lugs (74) that enhances traction on icy and / or wet surfaces as compared to the other lugs (70, 72). In other embodiments, traction lugs (74) comprise a modified composition (as compared to that of the other lugs (70, 72) that enhances traction on icy and / or wet surfaces as compared to the other lugs (70, 72). In some embodiments, the outsole (50) having traction lugs (74) is still molded as a unitary structure, but with the material in at least an outer portion of the traction lugs (74) having a modified formulation as compared to the remainder of the outsole (50).

[0041] By way of example, traction lugs (74) may have outer surfaces (the surface that contacts the ground during use) having a higher coefficient of friction with respect to an icy surface (wet ice and / or dry ice) and / or a wet surface as compared to the outer surfaces of one or more of the other lugs (70, 72), such as described in U.S. Pat. Pub. No. 2020 / 0315293, “Footwear Outsole With Resistance Elements,” which is incorporated by reference herein. Alternatively, the traction lugs (74) may comprise a molded material having glass fibers within a plastic material, as described in U.S. Pat. No. 10,952,499, “Ice Slip Resistance Formula and Process,” which is incorporated by reference herein. As yet another alternative, the traction lugs (74) may include an outer layer (as seen FIG. 13) comprising a polymer blend formulated to have improved traction on icy surfaces such as Arctic Grip® polymer formulation available from Vibram S.p.A.

[0042] It will be understood that traction lugs (74) may be provided in any of a variety of locations on the bottom surface (52) of the outsole. In general, however, not all of the lugs on the bottom of the outsole will comprise traction lugs. Instead, only a portion of the lugs will comprise traction lugs that provide increased traction on icy and / or wet surfaces.

[0043] As best seen in FIGS. 10 and 11, the outsole (50) is molded such that a heel plug cavity (76) is provided in the interior of the heel portion (50A) of the outsole. Heel plug cavity (76) is configured to receive heel plug (78) therein. Heel plug (78) is molded from a polymeric material that is lighter and more resilient as compared to the material of the unitary outsole (50). This allows for the heel portion of the boot to be thicker and provide greater cushioning without significantly increasing the weight of the boot. As best seen in FIG. 11, a plurality of holes (79) extend from the upper surface (80) of the heel plug through at least a portion of the thickness of the heel plug in order to further reduce the weight of the heel plug (78). Since the heel plug is located in the interior of the boot (10), the heel plug can be manufactured of a material (e.g., polyurethane) that would not be suitable for the outsole (50) in a firefighter certified boot.

[0044] Similarly, a plurality of channels (80) and holes (81) may be provided in the bottom of the outsole, extending from the upper interior surface (53) in the midfoot and forefoot portions (50B, 50C) of the outsole through a portion of the thickness of the outsole, as seen in FIGS. 10 and 11. The channels extend across the central region of the of the outsole in a corrugated pattern, and the holes (81) extend along the length of the midfoot and forefoot portions along either side of the channels (80). The channels (80) and holes (81) extend through more than half of the thickness of the outsole, and serve to reduce the weight of the outsole. The channels (80) and holes (81) also facilitate cementing of the upper to the outsole.

[0045] As best seen in FIG. 11, the outsole (50) optionally includes an outsole plate (90), and a shank (88) (both of which are omitted in FIG. 3). The outsole plate (90) covers the heel plug and extends over the heel portion (50A) and midfoot portion (50B) of the outsole.

[0046] In order to provide support for the boot and facilitate affixing the upper to the outsole by side stitching, sidewalls (54A, 54B) and rear heel wall (58) extend above the interior surface (53) by at least about 2.5 mm (distance D in FIG. 13), at least about 5 mm, between about 5 and about 30 mm, or between about 10 and about 20 mm. This helps to provide sufficient outsole material to provide a functional (rather than merely decorative) side stitch, and prevent separation (delamination) of the upper (12) and the outsole (50). It should be noted that the distance the sidewalls (54A, 54B) and rear heel wall (58) extend above the interior surface (53) of the outsole (i.e., the depth of the cavity (59)) is not necessarily constant throughout the outsole.

[0047] To further facilitate functional side stitching of the outsole to the upper, a stitching groove (84) is provided around the upper periphery of the outsole. In the embodiment shown, stitching groove (84) extends around substantially the entire upper periphery of the outsole (50) just below the upper edge of the sidewalls (54A, 54B), and rear heel wall (58), and just below (proximal to) the distal outer edge (67) of the toe cover (56). Thus, the stitching groove (84) extends substantially continuously around at least substantially the entire open upper periphery of the cavity (59) and toe cavity (64). In some embodiments, the stitching groove (84) is located between about 1.5 and about 6 mm of the upper edge of the sidewalls (54A, 54B) and rear heel wall (58), and the distal outer edge (67) of the toe cover (56). In the exemplary embodiment shown, the stitching groove (84) has a depth of between about 1 and about 1.5 mm, and is arcuate in cross-section (see FIG. 13). The stitching line (86) for functionally affixing the outsole (50) to the upper (12) is located within the stitching groove (84). The stitching groove aids in proper location of the stitching, and also allows the stitching (86) to be recessed below the surface of the outsole (50).

[0048] In the embodiment shown in FIGS. 14 and 14A, the stitching groove (84) is interrupted at the molding seam (87) of the outsole (50). The molding seam (85) results from the molding process for the outsole (50) (the seam is located where the two mold halves meet). The molding seam (85) extends from the distal outer edge (67) of the toe cover (56), interrupting the stitching groove at groove gap (85), across the side of the toe cover (56), across and around the toe bumper (65), and across the opposite side of the toe cover. The seam (87) along the left side of the boot (10) is identical to the right side of the boot shown in FIG. 14A. Thus, the stitching groove (84) is interrupted on both sides of the boot (110) at gaps (85). By way of example, groove gaps are about 0.5 to about 10 mm in width, or between about 1 and about 5 mm in width. In some embodiments, the stitching itself is still continuous, extending along the interior side of the vamp (118A) (jumping over the molding seam (85)). In other embodiments, the stitching is interrupted at the molding seam (85) on one or both sides of the outers. In the embodiment shown, the stitching groove (84) and side stitching (86) extend continuously over and across the toe cover (56) of the outsole (50), distal to the toe cap, with the stitching groove gap (85) located adjacent where the sidewalls of the outsole (50) curve upwardly at the distal end of the toe cover (56). (The molding seam and groove gap are not shown in the other figures.) Thus, in the depicted embodiments, the side stitching does not extend around the proximal end (i.e. proximal to the wearer's toes) of the boot, such as around the toe bumper (65). Instead, the side stitching extends around the heel wall (58), along opposite sidewalls (54A, 54B), and over and across the toe cover (56) of the outer.

[0049] During assembly, in one embodiment the lower portion of the upper (12, 112), including the toe portion, is adhesively secured within the first cavity (59) and toe cavity (64) of the outsole, such as by using conventional cement. Thereafter, the outsole is side stitched to the upper, with the stitching extending around substantially the entire periphery of the outsole within the stitching groove. Since the toe cover (56) extends behind (i.e., rearward or distal to) the location of the rearward edge (37) of toe cap (12), the stitching does not penetrate or otherwise damage or compromise the toe cap (12). In this fashion, a side stitched certified safety boot and certified firefighter boot is provided. In some embodiments, the side stitching extends through the outer layers of the upper (e.g., one or more of the outer leather layers (18, 118A) and heel counter (16, 116)) as well as the lining (25, 125) and thermal barrier (126). In other embodiments, after the lower portion of the upper (12, 112) is adhesively secured within the first cavity (59) and toe cavity (64) of the outsole, the lining (25, 125) (and thermal barrier (126)) is flipped out of the upper (pulled way and turned inside out), the outsole side stitched to the outer leather layers (e.g., 18, 118A) and the heel counter (16, 116), and the lining / barrier sprayed with cement and flipped back into the boot so as to cement the lining / barrier in place. (In some instances, the lining (25, 125) and thermal barrier (126) portion is referred to as the “bootie.”)

[0050] While various embodiments of safety boots and firefighter boots have been described in detail above, it will be understood that the components, features and configurations, as well as the methods of manufacturing the devices and methods described herein are not limited to the specific embodiments described herein.

Claims

1. A safety boot comprising:(a) an upper adapted to receive the foot of a wearer, the upper having a foot enclosing portion and a shaft extending upwardly away from the foot enclosing portions, the foot enclosing portion further comprising a toe portion;(b) a toe cap located within the toe portion of the upper; and(c) a molded outsole having a bottom and a toe cover at a proximal end of the outsole, the toe cover defining a toe cavity adapted for receiving the toe portion of the upper,wherein the upper is secured to the outsole such that the toe portion of the upper is positioned within the toe cavity of the outsole, with the outsole side stitched to the upper around the periphery of the outsole and across the toe cover, distal to the toe cap, with the stitching not penetrating the toe cap.

2. The safety boot of claim 1, wherein substantially the entire upper periphery of the outsole is stitched to the upper.

3. The safety boot of claim 2, wherein the stitching extends around a heel portion of the outsole, along opposing sides of the outsole, and over and across the toe portion of the outsole distal to the toe cap.

4. The safety boot of claim 3, wherein said stitching functionally secures the upper to the outsole, and further wherein said stitching does not extend over or proximal to the toe cap.

5. The safety boot of claim 1, wherein the outsole further comprises opposing sidewalls and a heel wall at the distal end of the outsole, the sidewalls and heel wall extending upwardly away from the bottom of the outsole so as to form a first cavity that is distal to and in communication with the toe cavity, wherein a lower portion of the upper is received within the first cavity of the outsole.

6. The safety boot of claim 4, wherein the outsole further comprises opposing sidewalls and a heel wall at the distal end of the outsole, the sidewalls and heel wall extending upwardly away from the bottom of the outsole so as to form a first cavity that is distal to and in communication with the toe cavity, wherein a lower portion of the upper is received within the first cavity of the outsole.

7. The safety boot of claim 5, wherein the outsole further includes a stitching groove extending around the upper periphery of the outsole, wherein the outsole is side stitched to the upper such that the stitching is located within the stitching groove.

8. The safety boot of claim 7, wherein the stitching groove extends around substantially the entire upper periphery of the outsole adjacent an upper edge of the sidewalls, an upper edge of the heel wall, and a distal outer edge of the toe cover.

9. The boot of claim 8, wherein the stitching grove is interrupted such that there is at least one gap in the stitching groove.

10. The boot of claim 6, wherein the stitching grove is interrupted at two locations on the upper such that there are two gaps in the stitching groove located on opposite sides of the upper, wherein a molding seam for the upper extends through said gaps.

11. The boot of claim 1, wherein said upper comprises a plurality of leather panels stitched to one another, and a heel counter, wherein the upper is side stitched to at least one of said leather panels and to said heel counter.

12. The boot of claim 1, wherein said boot is a certified safety boot.

13. The boot of claim 1, wherein said boot is a certified firefighter boot.

14. Protective footwear comprising:(a) an upper adapted to receive the foot of a wearer, the upper having a foot enclosing portion and a shaft extending upwardly away from the foot enclosing portions, the foot enclosing portion further comprising a toe portion;(b) a toe cap located within the toe portion of the upper; and(c) a one-piece, unitary, molded outsole havinga bottom having upper and lower surfaces,a heel wall extending upwardly from the bottom at a distal end of the outsole,opposing sidewalls extending upwardly from the bottom along opposing sides of the outsole, andan integral toe cover located at a proximal end of the outsole,the toe cover defining a toe cavity between an inner surface of the toe cover and the upper surface of the bottom, the outsole further defining a first cavity between the heel wall, the sidewalls and the upper surface of the bottom, the first cavity located distal to the toe cavity;wherein a lower portion of the upper is secured within the outsole, with the toe portion of the upper, including the entirety of the toe cap, positioned within the toe cavity of the outsole and the remainder of the lower portion of the upper secured within the first cavity; andfurther wherein the outsole is secured to the upper by side stitching that extends around the upper periphery of the outsole including across the toe cover distal to the toe cap.

15. The protective footwear of claim 14, wherein the upper periphery outsole has an upper edge defined by upper edges of the opposing sidewalls, an upper edge of the heel wall, and a distal outer edge of the toe cover, wherein said side stitching is located about 1.5 mm to about 6 mm from the upper edge of the outsole.

16. The protective footwear of claim 15, wherein said side stitching extends around substantially the entire upper periphery of the outsole.

17. The protective footwear of claim 15, wherein the outsole further includes a stitching groove extending around the upper periphery of the outsole, wherein the side stitching is located within the stitching groove.

18. The protective footwear of claim 17, wherein said upper comprises a plurality of leather panels stitched to one another, and a heel counter, wherein the upper is side stitched to at least one of said leather panels and to said heel counter.

19. The protective footwear of claim 18, wherein said footwear is a certified firefighter boot.

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