Abstract: A protective plastic toe cap for shoes includes a construction incorporating three important minimum dimensions. These dimensions include side wall thickness, the radius of the transition between the walls and the bottom flange, and the bottom flange width. Careful selection of the plastic resin materials based on certain minimum physical properties is also disclosed.

Abstract: A protective plastic toe cap for shoes includes a construction incorporating three critical minimum dimensions. These dimensions include side wall thickness, the radius of the transition between the walls and the bottom flange, and the bottom flange width.

Abstract: A toe cap for a protective shoe is injection molded utilizing a fiber-filled plastic resin having a high loading of relatively long fibers. A preferred material is glass-filled polyurethane having fibers predominantly of a length in the range of 0.25 inch (6 mm) and 1 inch (25 mm). The resin injection gate is positioned to provide injection of the fiber-filled plastic material directly adjacent the rear edge of the toe cap, preferably between the roof of the cap and the lower edge of one wall. The gate has a minimum dimension of 0.100 inch (2.5 mm). The gate location and size results in a lateral orientation of the fibers in the injected plastic material across the roof of the toe cap to substantially enhance the strength thereof.

Abstract: A toe cap for a protective shoe is injection molded utilizing a fiber-filled plastic resin having a high loading of relatively long fibers. The toe cap is constructed to provide a controlled vertical collapse of the body under a vertical load imposed on the roof by providing a roof section of relatively higher strength than the front and side walls of the toe cap. The front and/or side walls are provided with regions of substantially reduced cross section, as compared to the roof section, allowing the walls to close vertically and collapse in a hinge-like manner, while the relatively stronger roof substantially retains its original shape. A specially positioned and shaped gate allows the fiber-filled resin to be injected to form the toe cap in a manner resulting in the lateral orientation of the fibers across the roof to substantially enhance the strength thereof.