GB2544606A

GB2544606A - Toe box and footwear comprising the same

Info

Publication number: GB2544606A
Application number: GB1616204.2A
Authority: GB
Inventors: Hitchcock Melissa
Original assignee: Individual
Current assignee: Individual
Priority date: 2015-09-23
Filing date: 2016-09-23
Publication date: 2017-05-24
Also published as: GB201516883D0; GB201616204D0

Abstract

Disclosed is a toe box including a toe puff 107, wherein the toe puff comprises an elastomeric or viscoelastic foam. The foam may selected from a group consisting of ethylene-vinyl acetate (EVA) foams, memory foams, or polyurethane (PU) foams. The foam may be low density EVA foam or high density PU foam. Preferably the foam is perforated and preferably the toe puff consists essentially of the foam. The toe puff foam may have a thickness in the range of 1 to 10mm. Also disclosed is an item of footwear 100, such as a heeled shoe, comprising the disclosed toe box. The item of footwear may further comprise a heel counter 105 and/or an insole sock, both of which are at least partially formed from, or consist essentially of, an elastomeric or viscoelastic foam. The foam of the heel counter and/or insole sock may be low density EVA foam or high density PU foam. The heel counter may have a thickness of 1 to 10mm, and the insole sock may have a thickness of 6mm or less. Also disclosed is an insole 111 having a patch 113 of elastomeric or viscoelastic foam proximal to the inner ball of the foot.

Description

TOE BOX AND FOOTWEAR COMPRISING THE SAME Field of the Invention

The present invention relates to footwear, in particular to a toe box for an item of footwear. More particularly, the present invention relates to a toe box comprising a toe puff which is optimised for the comfort of the wearer.

Background of the Invention

It is well known that the wearing of footwear, in particular dress or work shoes or boots exerts pressure on the wearer’s foot, leading to discomfort and pain. In particular, the wearer may experience rubbing at the heel of the foot and at the toes which can lead to blisters, causing pain to the wearer. This problem is exacerbated in new footwear due to their stiffness, and can further cause compression of the foot, particularly if the footwear is ill-fitting. Further, the ball of the foot may also be put under considerable amounts of pressure, particularly in heeled shoes and boots.

In the past efforts to ease discomfort and pain experienced by the wearer have been focused on the provision of gel, foam or silicone insoles. In particular, there is a huge market built around the provision of insole socks made from such materials which are usually bought separately to the item of footwear and fitted when discomfort or pain is first experienced. However, the provision of such insoles socks may not necessarily alleviate the problem but create different problems in this regard.

The retrospective fitting of an insole sock to an item of footwear can exaggerate the problem of compression of the foot, causing discomfort to the upper part of the foot, and increase the pressure exerted to the toes, as the toes are squashed up against rigid plastics used to form the toe box of an item of footwear. In particular, if the original item of footwear is not designed to accommodate the retrofitted insole sock, the interior area of the footwear may be greatly reduced by the fitting of such an insole sock, thus reducing the area for the foot of the wearer.

Accordingly, the present invention seeks to provide footwear which reduces or preferably eliminates the problems associated with the discomfort or pain of the wearer. Further, the present invention seeks to reduce the problems associated with the insoles and insole socks known in the art.

Summary of the Invention

In a first aspect of the present invention, there is provided a toe box for an item of footwear comprising a toe puff, wherein said toe puff comprises an elastomeric or viscoelastic foam.

As is appreciated in the art, a toe box is the part of an item of footwear which at least partially covers and, in certain embodiments, protects the toes of the wearer and is fixed to the sole, i.e. bottom, of the item of footwear. Prior to the present invention toe puff typically comprised a rigid thermoplastic material inserted between the lining and upper of the toe box or item of footwear, in order to maintain the shape of the toe box. However, the rigid nature of such materials exacerbates the discomfort of the wearer, particularly when the footwear is new and the materials are at their highest degree of rigidity.

The provision of a toe puff comprising an elastomeric or viscoelastic foam enhances the comfort of the wearer. This is because the toe box is no longer a rigid in nature but is, at least in part, flexible and/or resilient which alleviates the compression of the foot experienced by the wearer and prevents rubbing at the toes. In particular, the elastomeric or viscoelastic foam provides softness and flexibility to the toe puff, and therefore the toe box, to better accommodate the toes of the wearer.

In a convenient embodiment the foam is a perforated foam.

Preferably the foam is a polymer selected from the group consisting of ethylene-vinyl acetate (EVA) foams or memory foams. Alternatively preferably, the foam is a polyurethane (PU) foam. Such foams provide the necessary softness and flexibility to the toe box to enhance the comfort of the wearer. Ethylene-vinyl acetate (EVA) is a co-polymer of ethylene and vinyl acetate is an elastomeric polymer foam which is soft and flexible/resilient but is capable of being processed like a thermoplastic. An example of a viscoelastic foam is memory foam, which is polyurethane treated with additional chemicals to increase its viscosity and density and are typically low-resilience polyurethane foams. The resilience of such foams imparts the necessary features to the toe box. High density memory foam may be employed as it softens in reaction to body heat, allowing it to mould to the shape of the foot of the wearer, further enhancing comfort.

Alternatively, the foam is a low density EVA foam. An EVA foam is preferred as it is a breathable and antibacterial, therefore, preventing or at least reducing any foot odour problems arising from the use of a foam in the toe puff. Further, a low density foam is preferred as it is less susceptible to abrasion resistance in use. “Low density” EVA foam typically has a density in the region of 0.1 to 250kg/m3, preferably 1 to 100kg/m3 and more preferably 5 to 50kg/m3.

Alternatively the foam is a high density PU foam. “High density” PU foam for example has a density greater than 50kg/m3. A high density PU foam has high resilience to maintain comfort and retauin its shape well without looking bulky.

Where embodiments are discussed herein by way of example making use of a low density EVA foam for the toe puff or other elements it will be understood that high density PU foam may be used in the alternative or in combination.

The toe puff may further comprise a stiffener, such as a rigid thermoplastic material, to maintain the shape of the toe box. However, it has been surprisingly found that the foam can maintain the shape of the toe box when it is applied under tension, while also providing the aforementioned flexibility and softness, therefore dispensing with the need to provide a stiffener within the toe puff. Accordingly, it is preferable that the toe puff consisting essentially of the foam.

The thickness of the foam may be varied to optimise for the footwear and intended application. In a preferred embodiment, the foam has a thickness in the range of 1 to 10 mm, more preferably a thickness of 2 to 6mm and most preferably a thickness of 3 mm. A thickness of 3 mm has been found to be optimum as it provides the necessary comfort, whilst providing aesthetically pleasing footwear, which is typically a design requirement for fashion shoes.

In a second aspect of the present invention, there is provided a item of footwear comprising the toe box of the first aspect.

As will be appreciated, an item of footwear includes any article worn to cover the foot and includes shoes, boots and sandals. For example, the footwear of the present invention may be heeled shoes including wedge heeled shoes, lace-up shoes, slip-on shoes, sandals, court shoes, flat shoes, ballet flats, flip flops etc. In one embodiment, the item of footwear may be a dress shoe or work shoe. A dress shoe is a smart, casual or formal shoe. Such shoes require the presence of stiffeners in the toe box to maintain the shape thereof, in contrast to athletic shoes and slippers. Accordingly, as will be appreciated, the item of footwear of the present invention may not be an athletic shoe or slipper. More preferably, the item of footwear is a heeled shoe.

The item of footwear may further comprise a counter which is at least partially formed of an elastomeric or viscoelastic foam. The preferred elastomeric or viscoelastic foams of the toe box of the present invention apply vis a vis the counter.

The counter extends around the portion of the item of footwear in contact with the heel of the wearer and typically continues to the toe box. As with the toe box, known counters contain a stiffener, such as a rigid thermoplastic material, to maintain the shape of the item of footwear. However, the presence of such a stiffener can be instrumental in providing discomfort to the heel of the wearer, in particular causing rubbing which can lead to blisters.

The counter may comprise a combination of the known stiffener and an elastomeric or viscoelastic foam. For example, the portion of the counter proximal to the heel of the wearer in use may consist of the elastomeric or viscoelastic foam, while the remaining portion of the counter may comprise a known stiffener. However, as the foam has been found to maintain the shape of the counter when applied under tension, the counter may be formed solely of the foam to further increase comfort to the wearer. Therefore, in a preferred embodiment, the counter consists essentially of the foam.

The counter preferably comprises an elastomeric or viscoelastic foam. The counter may comprise the same foam as the toe box. In a convenient embodiment the foam is a perforated foam.

In one embodiment, the counter comprises a low density EVA foam having a thickness of 3 mm. In another embodiment the counter comprises a high density PU foam.

As will be appreciated, an item of footwear comprising the above described counter may be provided in absence of the toe box of the first aspect of the present invention. However, it is preferred that the item of footwear comprises both the counter and the toe box to provide optimum comfort to the wearer.

The item of footwear may further comprise a removable insole sock which is at least partially formed of elastomeric or viscoelastic foam. The insole sock may comprise the same foam as the toe box which may be a perforated foam. The removable insole sock may be formed of a combination of known insole sock materials, such as gels, foams or silicone, together with the elastomeric or viscoelastic foam. Preferably, the removable insole sock consists essentially of the foam.

It is preferable that the foam of the removable insole sock is a low density EVA foam or high density PU foam having a thickness of 1 to 10 mm, preferably no greater than 6 mm. A thickness of no greater than 6 mm is preferred so as not to greatly reduce the interior area of the item of footwear and space for the foot of the wearer.

The insole sock may comprise a patch of elastomeric or viscoelastic foam positioned to be proximal to the inner ball of the foot in use. As will be appreciated the inner ball of the foot is the region of the foot at the base of the big toe. The provision of a patch of foam in this region lifts the toes slightly to alleviate the pressure experienced in the ball of the foot. This is particularly problematic in heeled shoes in which the highest concentration of pressure is experienced at the base of the big toe of the ball of the foot. Accordingly, the additional patch of foam further improves the comfort of the wearer.

In one embodiment, the patch of foam comprises a low density EVA foam having a thickness of 3 mm. A layer of sponge or elastomeric or viscoelastic foam shaped to fit the ball of a foot may be disposed between the insole sock and the patch of foam to further enhance the comfort of the wearer. The layer may have a thickness in the range of 1 to 100mm, preferably 5 to 50 mm, more preferable 10 to 20 mm. In one embodiment the layer may have a thickness of 15 mm. The preferred features of the elastomeric or viscoelastic foam of the toe box apply mutatis mutandis to the layer shaped to fit the ball of a foot.

The preferred features of the elastomeric or viscoelastic foam of the toe box apply vis a vis the removable insole sock and patch of foam.

As will be appreciated, a removable insole sock comprising a patch of elastomeric or viscoelastic foam positioned to be proximal to the inner ball of the foot in use may be provided in absence of the item of footwear and/or the toe box of the present invention.

The item of footwear may further comprise an insole having a patch of elastomeric or viscoelastic foam positioned to be proximal to the inner ball of the foot in use. In this embodiment, the insole is an integral part of the item of footwear and so the patch of foam is incorporated into the item of footwear during manufacture.

The preferred features of the elastomeric or viscoelastic foam of the toe box apply vis a vis the patch of foam. Preferably the patch of foam is preferably a low density EVA foam having a thickness of 3 mm.

In one embodiment, the insole further comprises a layer of elastomeric or viscoelastic foam shaped to fit the ball of a foot on which the patch of foam is disposed. In this embodiment, the patch of foam may be formed integrally with the layer or may be adhered to the layer and the layer adhered to the insole after formation. The foam of the layer may have a thickness in the range of 1 to 100mm, preferably 5 to 50 mm, more preferable 10 to 20 mm. In one embodiment the layer may be a low density EVA foam having a thickness of 15 mm. The preferred features of the elastomeric or viscoelastic foam of the toe box apply mutatis mutandis to the layer shaped to fit the ball of a foot.

Alternatively, the insole may comprise a layer of sponge shaped to fit the ball of a foot having a thickness of in the range of 1 to 100mm, preferably 5 to 50 mm, more preferable 10 to 20 mm, most preferably 15 mm. The sponge is preferably well known in the art, such as those used to increase comfort and/or provide odour control and/or provide shock absorption. As in the previous embodiment, the patch of foam may be disposed on the layer of sponge and so in this embodiment, the patch of foam may be formed separately and adhered to the sponge layer, which is subsequently adhered to the insole using a suitable adhesive.

It will be appreciated that the insole comprising the patch of elastomeric or viscoelastic foam positioned to be proximal to the inner ball of the foot in use may be provided in absence of the toe box of the first aspect. However, it is preferable that these features are provided in combination in the item of footwear of the present invention to provide optimum comfort.

Detailed Description

Various embodiments of the present invention will now be described more particularly by way of examples, with reference to the accompanying figures in which:

Figure 1 is a exploded view of a schematic of an item of footwear in accordance with one embodiment of the present invention.

As illustrated in Figure 1, the item of footwear is a heeled court shoe 100 comprising an upper 101 and an upper lining 103. These are typically formed from leather or an equivalent thereof and a flat seam is used to attach the upper 101 and upper lining 103 to avoid the stitching rubbing on the foot of the wearer.

The shoe further comprises a counter 105 and a toe puff 107 disposed between the upper 101 and the upper lining 103. The counter 105 and toe puff 107 are formed of 3 mm low density EVA foam, available under the trade name Algefoam - White -

Shore A-20 from Algeos and consist solely of the EVA foam. In this embodiment, the toe box consists of the toe puff 107 and the corresponding regions of the upper 101 and upper lining 103 but is integral with the counter 105 and corresponding regions of the upper 101 and upper lining 103.

The insole 111 of the shoe 100 comprises a sponge layer 114 cut in the shape of the ball of the foot and glued to the insole 111, which is 15 mm and formed of materials well known in the art. The insole 101 further comprises a patch 113 of 3 mm low density EVA foam (Algefoam - White - Shore A-20, Algeos) adhered to the sponge layer 114 at a position which is proximal to the inner ball of the foot, directly below the big toe, using a suitable adhesive. The insole 111 is covered by insole lining 109, such that the sponge layer 114 and patch 113 are disposed between the insole 111 and the insole lining 109. The insole lining 109 is formed of leather or the like, as is standard in the art.

The shoe further comprises a metal shank 115, sole 117, leaf 119, heel 121 and top piece 123 which are made of material standard in the art.

The shoe 100 also comprises an insole sock (not shown) formed from 6 mm low density EVA foam (Algefoam - White - Shore A-20, Algeos). The insole sock comprises comprises a cow hide leather or the like lining disposed on top of the low density EVA foam, on to which a design and/or logo may be stamped.

In the embodiment EVA foam is described by way of example. Other suitable elastomeric or viscoelastic foams may be used. For example high density PU foam may be used in the alternative or in combination.

The suitable elastomeric or viscoelastic foam is used at least for the toe puff and may be used additionally for the upper and/ or the insole sock. The foam may be a perforated foam. A fabrication method is discussed by way of example to illustrate how the shoe 100 is formed, in particular, how the toe puff 107 and counter 105 in accordance with one embodiment of the present invention are incorporated into the shoe 100.

In such a possible fabrication method the upper lining 103 which defines the interior of the shoe 100, is held around the heel region and over the toe region (i.e. the toe box) and is adhered to the insole 111 of the shoe 100. The 3 mm low density EVA foam of the counter 105 and toe puff 107 are adhered to the upper 101 and to part of the upper lining 103. The EVA foam is then stretched over the upper lining 103 under tension and adhered to the insole 111 to provide a toe box and counter which maintains the shape of the shoe 100 whilst providing a soft and flexible interior to enhance the comfort of the wearer. The finished shoe has the appearance of a standard shoe (which desirable for aesthetics) but offers superior comfort compared to other shoes known in the art.

Claims

1. A toe box for an item of footwear comprising a toe puff, wherein said toe puff comprises an elastomeric or viscoelastic foam.

2. A toe box according to claim 1 wherein the foam is a polymer selected from the group consisting of ethylene-vinyl acetate (EVA) foams or memory foams or polyurethane (PU) foams.

3. A toe box according to claim 1 or claim 2 wherein the foam is a low density EVA foam.

4. A toe box according to claim 1 or claim 2 wherein the foam is a high density PU foam.

5. A toe box according to any preceding claim wherein the foam is perforated.

6. A toe box according to any preceding claim wherein the toe puff consisting essentially of the foam.

7. A toe box according to any preceding claim wherein the foam has a thickness in the range of 1 to 10 mm.

8. A toe box according to any preceding claim wherein the foam has a thickness of 3 mm.

9. An item of footwear comprising the toe box of any of claims 1 to 8.

10. An item of footwear according to claim 9 wherein said item of footwear is a shoe.

11. An item of footwear according to claim 10 wherein said shoe is a heeled shoe.

12. An item of footwear according to any of claims 9 to 11 further comprising a counter which is at least partially formed of an elastomeric or viscoelastic foam.

13. An item of footwear according to claim 12 wherein the counter consists essentially of the foam.

14. An item of footwear according to claim 12 or claim 13 wherein the foam is a low density EVA foam or high density PU foam having a thickness of 1 to 10 mm.

15. An item of footwear according to any of claims 9 to 14 further comprising a removable insole sock which is at least partially formed of elastomeric or viscoelastic foam.

16. An item of footwear according to claim 15 wherein the removable insole sock consists essentially of the foam.

17. An item of footwear according to claim 13 or claim 14 wherein the foam is a low density EVA foam or high density PU foam having a thickness of no greater than 6 mm.

18. An item of footwear according to any of claims 15 to 17 wherein the insole sock comprises a patch of elastomeric or viscoelastic foam positioned to be proximal to the inner ball of the foot in use.

19. An item of footwear according to claim 18 wherein the patch of foam is a low density EVA foam or high density PU foam having a thickness of 1 to 10 mm.

20. An item of footwear according to any of claims 9 to 19 further comprising an insole having a patch of elastomeric or viscoelastic foam positioned to be proximal to the inner ball of the foot in use.

21. An item of footwear according to claim 20 wherein the patch of foam is a low density EVA foam or high density PU foam having a thickness of 1 to 10 mm.

22. An item of footwear according to claim 20 or claim 21 wherein the insole further comprises a layer of elastomeric or viscoelastic foam or sponge shaped to fit the ball of a foot disposed between the insole and the patch of foam.

23. An item of footwear according to claim 22 wherein the layer has a thickness of 1 to 100 mm.