WO2001051263A1

WO2001051263A1 - Safety shoes and other protective articles comprising a fabric-plastic composite and their methods of manufacture

Info

Publication number: WO2001051263A1
Application number: PCT/US2000/001097
Authority: WO
Inventors: Thomas L. Hursman
Original assignee: Spectrum Medsystems, Inc.
Priority date: 2000-01-14
Filing date: 2000-01-14
Publication date: 2001-07-19

Abstract

A fabric/plastic composite material is disclosed which may be used to form various articles including toe caps (10), sole plates (12), and shanks (14) which can be incorporated into safety shoes. The composite can also be used in helmets, sports pads, bullet proof vests, etc. The composite can be formed by an injection molding process wherein a first layer of fabric is precut and positioned within the cavity of a mold. Thereafter, a molten or flowable plastic is injected into the mold so as to become bonded to the first layer of fabric. The composite may also be formed by an alternative hand lay-up method.

Description

-I-

SAFETY SHOES AND OTHER PROTECTIVE ARTICLES

COMPRISING A FABRIC-PLASTIC COMPOSITE AND THEIR METHODS OF MANUFACTURE

Field of the Invention The present invention relates to composite materials, - personal protective articles formed of such composite materials, and their methods of manufacture. More specifically, the invention pertains to certain fabric- plastic composites and methods of manufacturing and forming such materials into formed articles, such as protective components for safety shoes (e.g., toe guards, sole guards, etc..) and other personal protective articles.

Background of the Invention Various personal protection articles (e.g., helmets, bullet proof vests, heart shock covers for bullet-proof vests, safety footwear, sports equipment, etc..) have heretofore been utilized to protect anatomical portions of the human body from injury due to impact or penetration by foreign objects.

In particular, safety shoes and boots of the type typically worn by construction workers, firemen, mechanics, outdoorsman, etc, have typically included toe guards and/or sole guards formed of rigid material, such as metal, to protect the wearers feet from being injured by impact or penetration by objects which fall upon or roll over the toe area of the shoe and/or which are stepped upon by the wearer of the shoe. One drawback associated with the prior art safety shoes which incorporate toe guards and/or sole guards formed of metal is that the presence of the metal toe guard and/or metal sole guard results in substantial added weight to the shoe, increased thermal conductivity, electrical conductivity and corrosivity.

In view of the problems associated with the use of metal toe guards in safety foot wear, efforts have been made to develop non-metallic toe guards for incorporation into safety shoes. For example, United States Patent No. 4,862,606 (Siskind et al ) entitled TOE GUARD FOR FOOTWEAR, PROCESS FOR ITS MANUFACTURE, AND FOOTWEAR SO MADE describes a non-metal toe guard for safety footwear formed of composite material which includes a polymer matrix and a filler of high tensile strength fibers embedded in the polymer matrix. Although the non-metal toe guards described in U.S. Patent No. 4,862,606 (Siskind et al ) may avoid the corrosivity, electrical conductivity, excessive weight and thermal conductivity problems associated with the metal toe guards of the prior art, the composite material described by Siskind et al., provides less than optimal resistance to multiple impacts (e.g., initial impact may cause cracking such that subsequent impact will result in fracture of the toe-guard) and/or penetration resistance.

Accordingly, there remains a need in the art for the development of an improved composite material and associated methods for manufacturing for personal protective articles, such as toe guards and sole guards for safety foot wear, capable of exhibiting improved impact resistance properties and/or improved penetration resistance properties, than has been attainable in the prior art.

Summary of the Invention

The present invention is directed, in part, to a composite material, which is usable to form various articles, including but not limited to personal protective articles. The composite material of the present invention generally comprises a layer of plastic affixed in abutting juxtaposition to a layer of armoring fabric material. The layer of plastic may comprise reinforced plastic wherein the plastic resin is reinforced with a suitable solid reinforcement material including various particulate or fiberous reinforcement materials such as graphite, boron, silica, silicon, calcium carbonate, etc. The armoring fabric layer of the composite material may be formed of any suitable woven or unwoven fibers. In this regard, individual fibers of the textile, graphite, glass or aramid (Kevlar®, E.I., du Pont de Nemours & Co. , Inc., Wilmington, Delaware 19898) may be interwoven to form the desired fabric, or may be arranged in one or more non-woven layers so as to form the desired armoring layer of the composite material. In a presently preferred embodiment, the plastic layer of the composite material is formed of glass fiber reinforced polycarbonate having a glass fiber content between 5% and 20%, while the armoring fabric layer of the composite material is formed of woven Kevlar® fibers. One or more bonding agents, such as neoalkoxy titanate coupling agents, may be incorporated into the plastic layer to facilitate coupling or bonding of the reinforcement fibers to the plastic. One example of a neoalkoxy titanate coupling agent which may be incorporated into the preferred glass fiber reinforced polycarbonate to facilitate coupling of the glass fibers to the polycarbonate is neopentyl(diallyl)oxy, trim(m-amino)phenyl titanate, which is commercially available as LICA 97 from Kenrich Petrochemicals, Inc., 140 East 22nd Street, Bayonne, New Jersey 07002-0032.

Further in accordance with the invention, the layer of fabric is preferably located on the exterior of the plastic layer, and is not fully encapsulated or surrounded by the plastic layer. However, the material of the plastic layer may penetrate, permeate or otherwise protrude into the fabric layer to facilitate firm fusion or bonding therebetween. Such penetration permeation or protrusion of the plastic layer into the fabric layer may be accomplished by injection molding of a molten plastic (e.g., polycarbonate) directly against one side of the fabric layer, such that the molten plastic flows into the woven structure of the fabric layer prior to solidification of the plastic Also, one or more adhesives, chemical bonding agents, solvent welding, thermal bonding and/or mechanical bonding may be used to cause or enhance the attachment or fusion of the plastic layer to the fabric layer.

Still further in accordance with the invention, there are provided certain personal protective articles formed by the composite material of the foregoing character. In particular, the personal protective articles of the present invention include helmets, bullet proof vests, heart shock cover plates for bullet proof vests, sports protective equipment such as football & hockey pads and protective members for safety footwear, such as toe guards, sole guards and shoe arch support members known as "shanks".

Still further in accordance with the invention, there are provided methods for manufacturing articles formed of the composite materials of the foregoing character. One method for forming the composite material comprises the steps of (a) inserting a layer of fabric into a mold, and (b) shooting a quantity of flowable plastic material into the mold such that the plastic material will form a layer in abutting juxtaposition to, and affixed to, the layer of fabric In this method, the layer of fabric (e.g., Kevlar® fabric) may be precut to a desired size and configuration, prior to insertion into the mold. After the precut layer of fabric has been inserted and positioned within the cavity of the mold, the mold is closed and a flowable plastic (e.g., molten polycarbonate) is introduced into the mold (e.g., by standard injection molding techniques) to form the plastic layer in abutting juxtaposition to the fabric layer. The pressure of the molten plastic within the mold, and the weave-density of the fabric layer, are preferably such that the molten plastic will permeate, penetrate or otherwise protrude into the fabric layer thereby establishing a firm interconnection between the plastic layer and the fabric layer. In an alternative method, the fabric layer (e.g., Kevlar® fabric) may be precut to its desired size and, thereafter, may be bonded or fused to one surface of a previously formed plastic layer. Such bonding of the fabric layer to the plastic layer may be accomplished by soaking the fabric layer in a solvent or solvent-plastic solution prior to placing of the fabric layer on the desired surface of the plastic layer. For example, a solution of 60% methylene chloride and 40% dichloroethylene may be prepared, and an excess quantity of polycarbonate resin beads may be placed in such methylene chloride/dichloroethylene solution to result in saturated dissolution of the polycarbonate within the methylene chloride/dichloroethylene solution. Thereafter, a pre-cut layer of fabric (e.g., Kevlar® fabric) is emersed within the polycarbonate/methylene chloride/dichloroethylene solution so as be fully wetted thereby. Thereafter, the fully wetted fabric layer is placed upon the desired surface of a pre-molded plastic layer (e.g., polycarbonate or glass-reinforced polycarbonate) and the solvent content is thereafter allowed to evaporate. This results in fusion of the fabric layer to the plastic layer, thereby proving a composite material of the foregoing character.

Further objects and advantages will become apparent to those skilled in the art upon reading and understanding of the following detailed description and upon viewing of the accompanying drawings . Brief Description of the Drawings

Figure 1 is a perspective view of a safety shoe having a toe guard, sole guard and arch support member of the present invention positioned therewithin. Figure 2 is a cross sectional view through line 2-2 of Figure 1.

Figure 3 is an exploded view of the toe guard, sole guard and arch support member of the shoe shown in Figure 1. Figure 4 is a rear perspective view of the toe guard of the shoe shown in Figure 1.

Figure 5 is a partial top perspective view of the sole guard of the shoe shown in Figure 1.

Figure 6 is a partial bottom perspective view of the sole guard of the shoe shown in Figure 1.

Detailed Description of the Preferred Embodiments

The following detailed description and the accompanying drawings are provided for purposes of demonstrating and illustrating certain preferred embodiments of the invention only, and are not intended to specifically describe all embodiments in which the invention may be utilized. It will be appreciated by those skilled in the art that various other embodiments may also be arrived at, without departing from the intended spirit and scope of the present invention.

In particular, the invention is described herebelow with respect to toe guards, sole guards and shank members utilized in safety footwear. It will be appreciated, however, that the composite materials of the present invention may be utilized to form a wide variety of personal protective articles other than safety footwear, including but not limited to: helmets, bullet proof vests, heart shock cover plates for bullet proof vests; sports equipment (e.g., football & hockey pads), and other protective articles of the types typically worn by sportsman, construction workers, fire fighters, electrical workers, and others who's bodies are exposed to potential impact and/or penetration type injuries. With reference to the drawing, Figures 1-6 are directed to an improved safety shoe which incorporates the toe guard 10, sole guard 12 and shank member 14 of the present invention.

One example of a preferred composite material used to form the toe guard 10, sole guard 12 and shank member 14 generally comprises a fabric reinforced plastic laminate (hereinafter referred to as the "WF/RP" composite) . This WF/RP composite comprises a first layer 18 of woven fibers fused in abutting juxtaposition to a second layer 20 of fiber or particle reinforced plastic.

The type of fabric used to form the first layer 18 of the WF/RP composite material of this example are spun aramid fibers (e.g., Kevlar® 49, E.I. du Pont de Nemours & Co., Inc., Textile Fibers Department, Wilmington, Delaware 19898). Such aramid fibers are woven to form a fabric which has the following specifications: SPECIFICATION NO.

Weights (oz./yd. ) 5.0

Thickness (Mils.) 10.0 Count (WxF) 17x17

Yarn WxF (deiner) 1140x1140

Weave Plain

Tensile WxF (lbs. /in.).. 620x655

One example of a commercially available woven aramid 49 fabric material which has the above-listed specifications is: Style 352, Clark Schwebel, Inc., 14063 Borate St., Santa Fe Springs, CA 90670.

The second layer 20 of reinforced plastic may be formed of glass fiber-reinforced polycarbonate resin or any other suitable plastic resin reinforced with particulate or fiber reinforcement matter such as, graphite, boron, silica, silicon, calcium carbonate, glass, etc

In embodiments wherein the second layer 20 is formed of glass-fiber-reinforced polycarbonate, the glass fiber content of such polycarbonate resin may be varied to optimize the physical properties of the composite material for its intended end use application.

For example, one glass-fiber reinforced polycarbonate which may be used to form the second layer 20 of the toe guard 10 of the present invention preferably comprises a polycarbonate resin having a nominal 10% glass fiber content and a density of approximately 1.27 g/cm³, while that used for the sole guard 12 and shank member 14 applications preferably has a nominal 15% glass fiber content.

One example of a commercially available polycarbonate resin which contains the nominal 10% glass fiber reinforcement desirable for the toe guard 10 application is Makrolon 9415, Bayer U.S.A., Inc., Mobay Corporation, Plastics and Rubber Division, Pittsburgh, Pennsylvania 15205-9741.

One example of a commercially available glass fiber reinforced polycarbonate resin which contains the nominal 15% glass fiber reinforcement preferable for the sole guard 12 and shank member 14 applications is Makrolon DPI—1095 1510 Black, 9415,Bayer U.S.A., Inc., Mobay Corporation, Plastics and Rubber Division, Mobay Road, Pittsburgh, Pennsylvania 15205-9741. In many applications, it will be preferable for the glass fiber content of the polycarbonate resin used to form the second layer 20 to be in the range of 5%-20% by weight. It is to be appreciated, however, that the exact glass fiber content of the polycarbonate resin may be varied, depending on the physical properties and performance characteristics desired of the WF-RP composite.

In some applications, it will be desirable to incorporate one or more chemical coupling agents to facilitate chemical bonding or coupling of the reinforcement matter (e.g., particular or fibers — such as glass fibers) to the surrounding plastic matrix. Such chemical coupling agent ( s ) may be combined with the plastic and/or reinforcement matter at the time the plastic resin is formulated. Alternatively, such chemical coupling agent (s) may be added to the molten flow of the reinforced plastic material as it passes into the mold. In embodiments wherein the second layer 20 is formed of glass fiber reinforced polycarbonate, as in the preferred embodiment described hereabove, a neoalkoxy titanate coupling agent may be utilized to facilitate bonding of the glass reinforcement fibers to the surrounding polycarbonate matrix. One particular neoalkoxy titanate coupling agent which is usable for this purpose is neopentyl (diallyl) oxy, trim(m-amino)phenyl titanate, which is distributed commercially under the trademark LICA 97 by Kenrich Petrochemicals, Inc., 140 East 22nd Street, Bayonne, New Jersey 07002-0032.

In the particular embodiment shown in the drawings, it is preferable that the first layer 18 of fabric (e.g., aramid fabric) be fused or affixed to one side of the second layer 20 of plastic (e.g., glass fiber reinforced polycarbonate) , and that the first layer 18 not be fully encapsulated, surrounded by, or sandwiches between the second layer 20. The in situ directional orientation of the WF-RP composite material is dependant upon the physical properties required or desired of the end use application. For example, in the toe guard 10 application, it is desirable that the first layer 18 of woven aramid fibers be located on the outer surface of the toe guard 10, as shown in Figure 1. Such positioning of the first layer 18 of woven aramid fibers on the outer surface of the toe guard 10 provides optimal resistance to breakage or indentation of the toe guard 10. On the other hand, in the sole guard 12 application, it is desirable that the first layer 18 of woven aramid fibers be located on the upper surfaces of the sole guards 12 as shown in Figure 1, to provide optimal resistance to upward penetration through the sole guard 12 by nails or other sharp objects. The specific design and configuration of the safety shoe protective members (i.e., and the toe guard 10, sole guard 12, and shank member 14) may further optimize their resistance to breakage and/or penetration. For example, as can be seen in Figures 3-4, the toe guard 10 of the present invention is of a generally arcuate configuration having an inwardly turned lip 32 formed about the bottom edge thereof. Applicant has determined that the toe guard 10 exhibit superior resistance to fracture when impacted vertically if the first layer 18 of woven aramid fibers is terminated at a lower first layer boundary line 30 which is located at or slightly above the inwardly turned lip 32 of the underlying second layer 20 of glass reinforced polycarbonate. If the first layer 18 of woven aramid fibers were to extend fully over the entire surface of the toe guard 10, so as to extend onto the underside of the inwardly turned lip 32 , there would result in a diminution of the vertical strength properties of the toe guard 10. Accordingly, the first layer 18 of woven aramid fibers is preferably terminated at the lower first layer boundary line 30, to provide optimal vertical strength properties of the toe guard 10, with less likelihood of breakage or fracture thereof.

Methods of Forming Articles of the Preferred WF-RP Composite Material The personal protective articles, such as the toe guard 10, sole guard 12, and shank member 14, may be formed by any suitable manufacturing methodology. i. Method by Injection Molding Plastic Layer Directly Onto Fabric Layer One particular method which may be utilized to form articles of the present invention is an injection molding method whereby the first layer 18 of fabric material is by a) initially precutting the fabric material to its desired shape and b) inserting the precut woven fiber material into the cavity of an injection mold. Thereafter, molten or flowable plastic is injected into the mold. The location of the sprue/gate or passageway through which the plastic enters the mold is located such that the plastic will flow against one side of the woven fiber material, thereby causing the second layer 20 of plastic material to become formed in abutting juxtaposition to one side of the first layer 18 of fabric.

It is desirable that the mold be designed such that the flow of molten polycarbonate resin through the sprue/gate or entry passageway of the mold, and the subsequent flow pattern of the plastic within the mold cavity, does not cause wrinkling, puckering or displacement of the pre-inserted first layer 18 of fabric In this regard, the molten or flowable injected plastic may be caused to penetrate, between, permeate or otherwise flow into the fabric material such that, when the plastic sets or solidifies, a firm interconnection will be formed between the first layer 18 of fabric material and the second layer 20 of plastic material. Also, any suitable adhesive or bonding agent may be applied to the first layer of fabric 18 prior to shooting of the molten or flowable plastic into the mold to facilitate firm bonding of the second layer 20 of plastic to the first layer 18 of fabric. ii. Alternative Method of Affixing Fabric Layer to Previously Molded Plastic Layer Another method which may be utilized to form articles of the present invention is a lay-up fabrication method whereby the second layer 20 of plastic material is initially formed by molding (e.g., injection molding) of the desired plastic material into the desired shape of the second layer 20. Thereafter, the first layer 18 of fabric material, which has been pre-cut to the shape it is desired to have when disposed on the surface of the first layer 20, is wetted with a solvent, adhesive, or other suitable bonding agent and the precut first layer 18 is then laid onto the desired surface of the previously-molded second layer 20. The solvent, adhesive or other bonding agent is then allowed to dry, cure, set, or otherwise activate sufficiently to form the desired connection between the first layer 18 of fabric and the second layer 20 of plastic material. For example, a solvent/plastic solution may be utilized to facilitate firm bonding of the first layer 18 of fabric to the second layer of plastic material. Such solvent/plastic solution may be prepared by dissolving a quantity of plastic in an appropriate solvent, to form a plastic/solvent solution. Thereafter, the first layer 18 of fabric is dipped into the plastic/solvent solution. In many instances, it will be desirable for the plastic used in the plastic/solvent solution to be the same as the plastic of which the second layer 20 is formed. For example, in embodiments wherein the second layer 20 is formed of the above-described glass reinforced polycarbonate material, and acceptable plastic/solvent wetting solution may be prepared by blending an initial mixture of 60% methylene chloride with 40% dichloroethylene. Thereafter, a quantity of polycarbonate resin pellets are added to the 60% / 40% methylene chloride/dichloroethylene mixture, and dissolved therein at room temperature. It is preferable that the polycarbonate resin beads be dissolved in the methylene chloride/dichloroethylene solution to a point of saturation, such that some solid polycarbonate beads remain in the bottom of the container. Thereafter, the precut first layer 18 of fabric may be dipped into such solution, such that the first layer 18 becomes fully wetted by the polycarbonate/methylenechloride/dichloroethylene solution. Thereafter, the fully-wetted first layer 18 will be laid onto the desired surface of a pre-molded second layer 20 formed of glass reinforced polycarbonate material as described hereabove. The methylene chloride/dichloroethylene solvent system is then permitted to evaporate, and the polycarbonate material which resides within or upon the precut first layer 18 of fabric will become firmly bonded to the adjacent surface of the second layer 20 of glass reinforced polycarbonate material. This alternative method results in firm bonding of the first layer 18 to the second layer 20.

The term "shoe" as used in the following claims shall be taken in a generic sense and shall mean any footwear, including low cut shoes and high cut boots.

It is to be appreciated that the invention has been described hereabove with reference to certain presently preferred embodiments only. Other embodiments of the invention may also be arrived at without departing from the intended spirit and scope of the invention. Accordingly, the above-set-forth description of preferred embodiments is intended to be taken in an illustrative sense, and not in a limiting sense.

Claims

WHAT IS CLAIMED IS:

1. A composite material comprising: a first layer of fabric; and, a second layer of plastic fused to said first layer of fabric, in abutting juxtaposition thereto.

2. The composite material of Claim 1 wherein said first layer of fabric comprises woven/aramid fibers.

3. The composite material of Claim 2 wherein said first layer of woven aramid fibers has approximately the following specifications:

Weights (oz./yd.²) 5.0

Thickness (Mils.) 10.0

Count (WxF) 17x17

Yarn WxF (deiner) 1140x1140 Weave Plain

Tensile WxF (lbs. /in.).. 620x655

4. The composite material of Claim 1 wherein said second layer of plastic comprises a reinforced plastic

5. The composite material of Claim 4 wherein said reinforced plastic is a glass fiber reinforced plastic.

6. The composite material of Claim 5 wherein said glass fiber reinforced plastic comprises polycarbonate having glass reinforcement fibers therein.

7. The composite material of Claim 4 wherein said reinforced plastic comprises solid reinforcement matter disposed within a plastic matrix and at least one chemical bonding agent for chemically bonding said reinforcement matter to said plastic matrix.

8. The composite material of Claim 7 wherein said chemical bonding agent comprises a neoalkoxy titanate coupling agent.

9. The composite material of Claim 8 wherein said neoalkoxy titanate coupling agent comprises neopentyl(diallyl)oxy, tri(m-amino)phenyl titanate.

10. The composite material of Claim 1 wherein said second layer of plastic comprises a thermoplastic.

11. The composite material of Claim 10 wherein said thermoplastic is polycarbonate.

12. The composite material of Claim 11 wherein said polycarbonate contains solid reinforcement matter.

13. The composite material of Claim 12 wherein said reinforcement matter comprises glass fibers.

14. The composite material of Claim 13 wherein said polycarbonate contains 5%-20% glass fibers.

15. The composite material of Claim 14 wherein said polycarbonate containing 5%-20% glass fibers has a density of approximately 1.2g/cm³.

16. A personal protective article comprising the composite material of Claim 1 formed into a configuration which is positionable on a portion of a mammalian body to protect said portion of the mammalian body.

17. The personal protective article of Claim 16 wherein said article is a toe guard for safety footwear, said toe guard having an outer surface, an inner surface, a bottom edge and a generally concave configuration sized to fit over the toes of a human foot.

18. The personal protective article of Claim 17 wherein the first layer of said composite material forms the outer surface of said toe guard and the second layer of said composite material forms the inner surface of said toe guard.

19. The personal protective article of Claim 18 wherein the second layer of said composite material forms an inwardly turned lip about the bottom edge of said toe guard, and wherein said first layer terminates above said inwardly turned lip.

20. The personal protective article of Claim 16 wherein said article is a sole guard for safety footwear, said sole guard having an upper surface, a lower surface, and being configuration to fit beneath and protect the planter surface of the foot of a human being wearing said safety foot wear.

21. The personal protective article of Claim 20 wherein said first layer of said composite material forms the upper surface of said sole guard and the second layer of said composite material forms the lower surface of said sole guard.

22. The personal protective article of Claim 21 wherein said sole guard, has a transverse bend formed therein at a first location, such that a front portion of said sole guard exists on one side of said transverse bend and a rear portion of said sole guard exists on the outer side of said transverse bend, the upper surface of the rear portion of said sole guard being disposed at an acute upward angle relative to the upper surface of the front portion thereof.

23. The personal protective article of Claim 16 wherein said article is a shank member, said shank member for safety footwear, said shank member comprising an elongate member which is positionable within the under-foot portion of said safety footwear to impart strength thereto.

24. The personal protective article of Claim 16 wherein said composite material is not electrically conductive.

25. A foot protective member positionable within safety footwear to protect at least a portion of the foot of a human being who is wearing said safety footwear, said protective member comprising: a first layer of armoring fabric; and, a second layer of plastic fused to said first layer of armoring fabric, in abutting juxtaposition thereto.

26. The foot protective member of Claim 25 wherein said protective member is a toe guard for safety footwear, said toe guard having an outer surface, an inner surface, a bottom edge and a generally concave configuration sized to fit over the toes of a human foot.

27. The foot protective member of Claim 26 wherein the first layer of armoring fabric of said composite material forms the outer surface of said toe guard and wherein the second layer of plastic of said composite material forms the inner surface of said toe guard.

28. The foot protective member of Claim 25 wherein the second layer of said composite material is configured such that it forms an inwardly turned lip about the bottom edge of said toe guard, and wherein said first layer terminates above said inwardly turned lip.

29. The foot protective member of Claim 25 wherein said protective member is a sole guard, said sole guard having an upper surface, a lower surface and being configured to fit beneath and protect the plantar surface of the foot of a human being wearing said safety footwear.

30. The foot protective member of Claim 29 wherein the first layer of said composite material forms the upper surface of said sole guard and the second layer of said composite material forms the lower surface of said sole guard.

31. The foot protective member of Claim 25 wherein said protective member is an shank member having a generally elongate configuration, said shank member being positionable within said safety footwear to provide structural support for the arch of the foot of a human being wearing said safety footwear.

32. The foot protective member of Claim 25 wherein said first layer of said composite material comprises woven aramid f bric .

33. The foot protective member of Claim 32 wherein said woven aramid fabric has the following specifications :

Weights (oz./yd. ) 5.0 Thickness (Mils.) 10.0 Count (WxF) 17x17

Yarn WxF (deiner) 1140x1140

Weave Plain

Tensile WxF (lbs. /in.).. 620x655

34. The foot protective member of Claim 25 wherein said second layer of said composite material comprises a reinforced plastic

35. The foot protective member of Claim 34 wherein said reinforced plastic is a glass fiber reinforced plastic.

36. The composite material of Claim 34 wherein said reinforced plastic comprises solid reinforcement matter disposed within a plastic matrix and at least one chemical bonding agent for chemically bonding said solid reinforcement matter to said plastic matrix.

37. The composite material of Claim 36 wherein said chemical bonding agent comprises a neoalkoxy titanate coupling agent.

38. The composite material of Claim 37 wherein said neoalkoxy titanate coupling agent comprises neopentyl(diallyl)oxy, tri(m-amino)phenyl titanate.

39. The foot protective member of Claim 35 wherein said reinforced plastic comprises polycarbonate having glass reinforcement fibers therein.

40. The foot protective member of Claim 25 wherein said second layer comprises a thermoplastic.

41. The foot protective member of Claim 40 wherein said thermoplastic is polycarbonate.

42. The foot protective member of Claim 41 wherein said polycarbonate contains solid reinforcement matter.

43. The foot protective member of Claim 42 wherein said reinforcement matter comprises glass fibers.

44. The foot protective member of Claim 43 wherein said polycarbonate contains 5%-20% glass fibers.

45. The foot protective member of Claim 44 wherein said polycarbonate containing 5%-20% glass fibers has a density of approximately 1.2gm/cm³.

46. A safety shoe comprising: a shoe configured to be worn on the foot of a human being, said shoe having an upper portion and a sole portion; at least one protective member positionable within said shoe to protect at least a portion of the foot of a human being who is wearing said shoe, said at least one protective member is formed of a composite comprising: i) a first layer of fabric; and, ii) a second layer of plastic fused to said first layer of fabric, in abutting juxtaposition thereto.

47. The safety shoe of Claim 46 wherein said protective member is a toe guard disposed within said shoe, and wherein said toe guard has an outer surface, an inner surface, and a bottom edge, said toe guard being of a generally concave configuration sized to fit over the toes of said human foot.

48. The safety shoe of Claim 47 wherein the first layer of said composite material is disposed on the outer surface of said toe guard.

49. The safety shoe of Claim 48 wherein said toe guard has an inwardly turned lip formed about the bottom edge thereof, and wherein said first layer of said composite material is terminated above said inwardly turned lip.

50. The safety shoe of Claim 46 wherein said protective member is a sole guard, and wherein said sole guard has an upper surface, and a lower surface, said sole guard being configured to fit within said shoe, beneath the plantar surface of the foot of a human being upon which said shoe is being worn.

51. The safety shoe of Claim 50 wherein the first layer of fabric of said composite material of which said sole guard is formed is located on the upper surface of said sole guard.

52. The safety shoe of Claim 46 wherein said protective member is a shank member having a generally elongate configuration, said shank member being positionable within said shoe to provide structural integrity to said shoe.

53. The safety shoe of Claim 46 wherein said first layer of fabric of said composite comprises aramid fibers .

54. The safety shoe of Claim 53 wherein the first layer of aramid fibers are woven into a fabric having the following specifications: Weights (oz./yd.²) 5.0

Thickness (Mils.) 10.0

Count (WxF) 17x17

Yarn WxF (deiner) 1140x1140

Weave Plain Tensile WxF (lbs. /in.).. 620x655

55. The safety shoe of Claim 46 wherein the second layer of said composite comprises a reinforced plastic

56. The safety shoe of Claim 55 wherein said reinforced plastic is a glass fiber reinforced plastic.

57. The composite material of Claim 55 wherein said reinforced plastic comprises solid reinforcement matter disposed within a plastic matrix and at least one chemical bonding agent for chemically bonding said reinforcement matter to said plastic matrix.

58. The composite material of Claim 57 wherein said chemical bonding agent comprises a neoalkoxy titanate coupling agent.

59. The composite material of Claim 58 wherein said neoalkoxy titanate coupling agent comprises neopentyl(diallyl)oxy, tri(m-amino)phenyl titanate.

60. The safety shoe of Claim 56 wherein said glass fiber reinforced plastic comprises polycarbonate having glass reinforcement fibers therein.

61. The protective member of Claim 46 wherein said second layer of said composite material comprises a thermoplastic .

62. The protective member of Claim 61 wherein said thermoplastic is polycarbonate.

63. The protective member of Claim 62 wherein said polycarbonate contains reinforcement matter.

64. The protective member of Claim 63 wherein said reinforcement matter comprises glass fibers.

65. The protective member of Claim 62 wherein said polycarbonate contains 5%-20% glass fibers.

66. The protective member of Claim 65 wherein said polycarbonate containing 5%-20% glass fibers has a density of approximately 1.2gm/cm .

67. A method of manufacturing an article formed of a composite material which comprises a first layer of fabric and a second layer of plastic fused in abutting juxtaposition to said first layer of woven fabric, said method comprising the steps of: a) providing a mold having a mold cavity which is configured in the shape of said article, and which has an inlet through which a flowable plastic material may be injected into said mold; b) precutting a quantity of said fabric to the desired configuration of said first layer; c) inserting said first layer of fabric into said mold cavity; d) injecting a quantity of flowable plastic through said inlet and into said mold so as to form said second layer of plastic in abutting juxtaposition to the first layer of fabric; causing said flowable plastic to stiffen and become fused to first layer of fabric; and, removing said article from said mold.