Abstract: The present concept is a method of attaching soles which minimizes delamination of the sole. It includes the steps of molding a sole together with a bond material by placing the bond material onto the sole material in the mold, and then adhering a bottom side of a bond material to the inside portion of the sole, in the mold by heating the mold to a pre-selected temperature and for a pre-selected amount of time. The bond material includes a hot melt polyurethane reactive film adhesive on a top side and a barrier material on the bottom side. Finally attaching the sole with bond material to an upper.

Abstract: A resilient motor mounting system for use with electric motors including a resilient motor mount including at least two resilient vanes moveable between a collapsed position and an extended position, wherein each vane including a fixed end and a free end, wherein the fixed end rigidly attached to the motor, wherein each vane projecting radially away from the motor such that the free end for resiliently biased against a mounting surface thereby securely holding the motor in a desired stationary position. Each vane preferably defining a curved shape such that the radius of curvature is increased to urge the vane into the collapsed position and the radius of curvature is decreased as the vane is released into the extended position.

Abstract: A toe box protector, or a metatarsal protector, or a combined protector for safety footwear are molded from plastics material either integrally or as separate parts. Each protector part comprises a body of generally U-shaped cross section provided at the central part of its top outer surface with a force receiving part that overlies the central part with its lower surface spaced from the central part and of concave shape toward the central part, thereby forming an arcuate air space at this location. In an integrally molded structure each force receiving part has two transversely spaced integral junctions with the respective body; alternatively they are molded separately and the force receiving part has longitudinal edges that engage two mutually facing, spaced surfaces on the body part.

Abstract: A metatarsal protector for footwear consists of a body molded from resilient plastics material, thus facilitating walking and kneeling, the material being sufficiently flexible that it can be molded flat and bent to the required saddle shape when it is incorporated into the footwear close against the upper inner surface. The range of hardness required for the material is comparatively narrow, so that it is sufficiently flexible, but can still meet certification requirements, and as measured by a Durometer A test is between 35 and 50 Shore. The protector comprises a plurality of integral ridged projections protruding from one surface, forming between themselves a corresponding plurality of open-mouthed recesses, each of which is surrounded by a single projection (e.g. giving a circular recess) or by a plurality thereof intersecting one another (e.g. giving rectangular or triangular recesses). When an impact force is applied to the metatarsal region the resilient material deforms and absorbs the force.

Abstract: A metatarsal protector for footwear consists of a body molded from resilient plastics material, thus facilitating walking and kneeling, the material being sufficiently flexible that it can be molded flat and bent to the required saddle shape when it is incorporated into the footwear close against the upper inner surface. The range of hardness required for the material is comparatively narrow, so that it is sufficiently flexible, but can still meet certification requirements, and as measured by a Durometer A test is between 35 and 50 Shore. The protector comprises a plurality of integral ridged projections protruding from one surface, forming between themselves a corresponding plurality of open-mouthed recesses, each of which is surrounded by a single projection (e.g. giving a circular recess) or by a plurality thereof intersecting one another (e.g. giving rectangular or triangular recesses). When an impact force is applied to the metatarsal region the resilient material deforms and absorbs the force.

Abstract: Molded boot and shoe heels are made by injecting a foamable plastics molding material into a heel mold and thereafter injecting a pressurized gaseous fluid into the heel body after it has formed an outer skin against the mold inner surfaces but before it has fully set in order to displace and compress the foaming material and form within the heel at the point of injection at least one enclosed hollow chamber which provides a different degree of resilience to heel strike forces at the location of the chamber. A plurality of closely adjacent chambers may be provided to obtain the same effect, particularly when the heel is shallow. A preformed member may be molded into the heel to form the heel outer surface and ensure a minimum heel wall thickness at this location. The heel may be molded integrally with a sole part. The enclosed chamber may be vented to the ambient atmosphere or it may be sealed.

Abstract: A toe protector, or a metatarsal protector, or a combined toe and metatarsal protector for safety footwear are molded from plastics material either integrally or separately and then attached to one another for storage and incorporation into the finished footwear. Each part of the respective protector comprises a generally U-shaped body provided at the central part of its top outer surface with two mutually facing, spaced surfaces extending outward therefrom and bounding between them a central part of the top portion. A force receiving plate overlies the respective central part with its lower surface spaced from the central part, is of concave shape toward the central part, and has two spaced edges engageable with the two surfaces. In an integral structure the adjacent surfaces and edges are constituted by corresponding integral junctions.

Abstract: In the molding of boot and shoe heels a foamable plastics molding material is injected into a heel mold and a pressurized gaseous fluid is injected into the heel body after it has formed an outer skin against the mold inner surfaces but before it has fully set in order to displace and compress the foaming material and form within the heel at least one enclosed hollow chamber which provides a different degree of resilience to heel strike forces at the location of the chamber. A plurality of closely adjacent chambers may be provided to obtain the same effect, particularly when the heel is shallow. A preformed member may be placed in the mold to form the heel outer surface and ensure a minimum heel wall thickness at this location. The invention also includes apparatus for making such heels, and the heels when so made. The molded body may comprise a sole with an integral heel part. The enclosed chamber may be vented to the ambient atmosphere or it may be sealed.

Abstract: A safety shoe including a metatarsal guard comprising a molded plastic arch extending across the metatarsal area supported at each of its ends on the sole and consisting of a number of ribs hinged to each other, the whole being laminated into the upper of the shoe.