METATARSAL PROTECTIVE ARCH FOR ITEM OF FOOTWEAR

Abstract

A metatarsal protective arch comprising a pad body. A shielding arch member is on a top surface of the pad body. The shielding arch member has a greater hardness than the pad body. The pad body and the shielding arch member concurrently form an arch configured to straddle at least part of a metatarsal region of a foot. The metatarsal protective arch is configured to be positioned in a foot-receiving cavity of an upper of an item of footwear.

Description

FIELD OF THE APPLICATION

The present application relates to footwear and, more specifically, to safety footwear of the type used to protect the feet of a user, for example in the construction industry, in warehouses, in manufactures, etc.

BACKGROUND OF THE ART

Safety footwear is often required as protective equipment, when a wearer is exposed to impacts, for example in the construction industry, in warehouses, in manufactures, etc. A primary function of safety footwear, such as safety boots or shoes, is to protect the foot against impacts. Accordingly, numerous features have been added to footwear, to provide various protective functions. Examples include some items of footwear equipped with additional sole puncture resistance, the presence of a toe cap, plates or guards covering the metatarsal region of the item of footwear to shield the top of the foot from impacts.

However, the addition of numerous protective components on items of footwear may occasionally be difficult to reconcile with other design properties associated to footwear, such as weight and flexibility. Indeed, some wearers may look for footwear that is comfortable, lightweight and that does not hamper foot movement in the walking action.

SUMMARY OF THE APPLICATION

It is therefore an aim of the present invention to provide items of footwear that addresses issues related to the prior art, in the context of metatarsal protection.

Therefore, in accordance with a first aspect of the present disclosure, there is provided a metatarsal protective arch that may include a pad body; and at least one shielding arch member connected to the pad body; wherein the shielding arch member has a greater hardness than the pad body; wherein the pad body and the at least one shielding arch member concurrently form an arch configured to straddle at least part of a metatarsal region of a foot; and wherein the metatarsal protective arch is configured to be positioned in a foot-receiving cavity of an upper of an item of footwear.

In accordance with another aspect of the present disclosure, there is provided an item of footwear comprising: an upper mounted to a sole, the upper and the sole forming a foot-receiving cavity; and the metatarsal protective arch as described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an item of footwear with a metatarsal protection arch in accordance with the present disclosure;

FIG. 2 is an assembly view of a metatarsal protection arch in accordance with a first embodiment of the present disclosure;

FIG. 3 is a perspective view of a metatarsal protection arch in accordance with a second embodiment of the present disclosure;

FIG. 4 is a top view of a metatarsal protection arch in accordance with a third embodiment of the present disclosure;

FIG. 5 is a cross-sectional view of the a metatarsal protection arch in accordance with a fourth embodiment of the present disclosure;

FIG. 6 is a perspective view of a metatarsal protection arch in accordance with a fifth embodiment of the present disclosure;

FIG. 7 is a perspective view of a metatarsal protection arch in accordance with a sixth embodiment of the present disclosure; and

FIG. 8 is an underside perspective view of the metatarsal protection arch of FIG. 7; and

FIG. 9 is a cross-sectional view showing the metatarsal protection arch against a floor of an item of footwear.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, and more particularly to FIG. 1, an item of footwear having a metatarsal protection arch in accordance with the present disclosure is generally shown at 10. The item of footwear 10 is illustrated as a boot, but could also be a shoe or any type of footwear featuring a metatarsal protection arch 20 as described hereinafter. Moreover, the boot 10 is shown with laces. However, it is understood that the boot 10 may comprise any suitable attachment means such as Velcro®, elastics, straps or the like during normal use. Although the expression “boot” is used, the item of footwear 10 may be known as a work boot, construction boot, hiking boot among other possible nomenclatures.

The boot 10 has an upper 11 that constitutes the top portion of the boot 10. The upper 11 therefore defines the foot-receiving cavity of the item of footwear 10. The upper 11 covers a top portion and sides of the foot and, in some cases, a portion of the ankle and shin. For simplicity, other known components such as the tongue, and eyelets, as well as decorative or structural parts of the upper 11 are illustrated but not detailed. The upper 11 may be made from a natural or synthetic leather, different polymers and composites, among numerous other possible materials or combinations of material.

The boot 10 further comprises a sole, for instance constituted of an outsole 12 and a midsole 13. However, while two distinct layers are shown in FIG. 1, a single sole layer or more than three sole layers may be present. The sole is the interface of the boot with the ground and its footprint may have any appropriate patterns or lugs to provide friction and/or purchase to the wearer. In the illustrated embodiment, the midsole 13 joins the outsole 12 to the upper 11. As observed in FIG. 1, the sole has a portion projecting from an upper surface of its foot-facing side and extending upwardly at a front portion of the boot 10 and forms a concave sole shell 14 encapsulating a front portion of the boot 10. The concave sole shell 14 is illustrated as being monolithically part of the sole, as observed from the lines showing that both the outsole 12 and the midsole 13 may be part of the concave sole shell 14. The figures illustrate that the concave sole shell 14 may have a portion that is seamlessly part of the outsole 12, and another portion that is seamlessly part of the midsole 13, as a result of a molding of the outsole 12 as a single piece, and the subsequent direct-attach injection of the midsole 13 between the upper 11 and the outsole 12, such that the concave sole shell 14 encapsulates a front portion of the upper 11. The concave sole shell 14 is optionally. Hence, the sole 12/13 is overmolded or molded by direct injection with the concave sole shell 14 onto the upper 11, to use other expressions describing the direct-attach molding, according to an embodiment. Other manufacturing processes are contemplated, such as stitching, gluing, cementing, etc, in accordance with other methods. The direct-attach process may be in numerous steps, including the molding of the outsole 12, the positioning of the upper 11 and the outsole 12 in a mold, with a space between, and the subsequent injection of the midsole 13 in the space between the upper 11 and the outsole 12. This may require some forms of automation or manipulations, and adapted tooling, considering that the upper 11 must be inserted in the outsole component of the concave sole shell 14, prior to the injection of the midsole 13 to direct-attach the upper 11, the outsole 12 and the midsole 13.

In the direct-attach process, the outsole 12 may be made of a rubber or other polymers, with different properties, such as tear resistance, corrosion resistance, flexing endurance, adherence, etc. The midsole 13, on the other hand, is made of a polymer such as polyurethane, which is known to form a permanent bond to given materials it interconnects. Polyurethane also provides the benefits of lightness, flexibility and waterproofness to the item of footwear. In the present embodiment, the polyurethane or equivalent of the midsole 13 bonds the upper 11 to the outsole 12. The midsole 13 may also provide some cushioning effect by having greater compliance than the outsole 12. The junction between the upper 11 and the sole is delineated by the junction lines 15 and 16. The junction line 15 is between the outsole 12 and the midsole 13, whereas the junction line 16 is between the midsole 13 and the upper 11. In the illustrated embodiment, there is no seam line in the sole, other than the junction 15 between the outsole 12 and the midsole 13, due to the monolithic construction of the outsole 12 (with its concave cap portion) and due to the monolithic construction of the midsole 13 (with its concave cap portion). Stated differently, the outsole 12 is a single piece resulting from its manufacturing (molding or heat-pressing), and does not have any adhesive between two distinct parts manufactured separately. Likewise, the midsole 13 is a single integrally-formed piece resulting from the direct-attach injection process. In other embodiments, the soles 12/13 may be cemented, vulcanized or stitched. The construction configuration provided above is merely provided as an example of how a given type of footwear 10 can be constructed, but numerous other types of footwear 10 may have the metatarsal protection arch 20 described below.

Numerous other components may be present in the item of footwear 10. For example, a protective toe-cap may optionally be present and may be covered by the material of the upper 11, and that of the concave sole shell 14 of the sole if present. The protective toe-cap may be defined by a shell made of a hard material to cover the wearer's toes and protect them from impacts.

The upper may be constituted of different layers, including an outer layer. The upper may also comprise a lining layer forming the inner surface of the boot 10. A strip may be at the end of the protective toe-cap 18 so as to form a smooth transition between the different components of the upper.

At its interface with the bottom of the foot, the boot 10 may have different layers including an insole board lying on top of a textile layer that covers the midsole 13. The insole board may be made of any appropriate material, including leather or various polymers. A removable sock liner may cover the insole board for hygienic reasons. These components may all be optional or sold separately. If present, the removable sock liner may provide some resilience and padding for the foot, the sock liner being, for example, the most compliant part of the underside of the boot. The sock liner may be a composite of laminated layers and may include a textile or fabric thereon.

Referring concurrently to FIGS. 1 and 2, an embodiment of the metatarsal protection arch is shown at 20. The metatarsal protection arch 20 may be located inside the upper 11, i.e., instead the foot-receiving cavity, so as not to be visible from an exterior of the item of footwear 10. In another variant, the metatarsal protection arch 20 is concealed between the outer layer of the upper 11 and the inner lining of the upper 11, with the inner lining defining the inner surface of the upper 11 in the foot-receiving cavity.

The metatarsal protection arch 20 is shown having a pad body 21. The pad body 21 may be said to be the main component of the metatarsal protection arch 20 in terms of size. The pad body 21 has an arch geometry so as to straddle the metatarsal region of a user's foot. The pad body 21 may span a sufficient arch shape such that its ends may come into abutment with the floor the boot 10, i.e., the surface upon which the foot lays when the boot 10 is worn, whether this surface is the sock liner, the insole or insole board, a footbed, etc. However, it is not necessary that the ends of the pad body 21 contact the interior bottom of the boot 10. In a variant, the metatarsal protection arch 20 floats (i.e., is suspended, hovers), in that its undersurface and its ends do not contact other structural parts of the item of footwear 10, for the metatarsal protection arch 20 to rest on the user's foot, with or without the inner lining being present.

In an embodiment, the pad body 21 is supple polymer base, allowing flexibility at the ball area of the foot during the gait cycle. For example, the polymer base may be constituted of polyurethane at a density of 0.45±0.05 g/cm³, though the density may be lower or greater. The hardness of the polyurethane may be between Shore A 35-40, though the hardness may be lower or greater. As an alternative to polyurethane, silicone rubber may be used, as silicone rubber may be even more supple or flexibility for a similar weight or density. Silicone rubber may exhibit lower breathability than polyurethane. As yet another alternative to polyurethane, a thermoplastic polyurethane (TPU) rubber may be used. TPU rubber may be even more supple or flexibility for a similar weight or density as polyurethane, and may have greater shock-absorption capacity than polyurethane. TPU rubber may exhibit lower breathability than polyurethane.

Referring to FIG. 2, the geometry of the pad body 21 is defined as having a foremost toe portion 21A, a central metatarsal portion 21B and a tapered ankle portion 21C, as a possibility among others. Stated differently, this geometry is an option. The central metatarsal portion 21B is configured to be located most over the metatarsal region of the foot. The foremost toe portion 21A may be over the phalanges, with a junction between the foremost toe portion 21A and the central metatarsal portion 21B generally aligned with the toe-off joint of the foot. Accordingly, as the foremost toe portion 21A is of a smaller width than the central metatarsal portion 21B, less resistance force is present at the transition from the midstance phase and the propulsive phase (i.e., toe-off), than if the foremost toe portion 21A were as wide as the central metatarsal portion 21B.

The presence of the tapered ankle portion 21C allows the pad body 21 to protect the front of the ankle and optionally part of the shin. Its reduced width relative to the central metatarsal portion 21B may be beneficial so as not to increase the ankle volume (i.e., the combination of the human ankle and the tapered ankle portion 21C) vis a vis the ankle opening in the upper.

Referring to FIG. 2, the pad body 21 is shown as having aeration holes 22. The aeration holes 22 are said to be for aeration, as they may be empty and may thus have air. The holes 22 may also be referred as vent holes. The holes 22 may extend from a bottom surface to a top surface, and may also define passages for sweat to escape.

A shielding arch member 23 may be provided on a top surface of the pad body 21, and may have a geometry conforming to that of the pad body 21. While it is illustrated on a top surface of the pad body 21, the shielding arch member 23 may be located in the underside surface of the pad body 21, or inside the pad body 21. The shielding arch member 23 is made of a more rigid than that of the pad body 21, and may be more apt at offering shock resistance, acting as a hard shell. The shielding arch member 23 has a size that is smaller than that of the pad body 21, such that only a portion of the top surface of the pad body 21 is covered by the shielding arch member 23. In a variant, the shielding arch member 23 is entirely located in the central metatarsal portion 21B of the pad body 21 if the pad body 21 has different portions, as described above. The shielding arch member 23 may be made of Nylon 6 or Nylon 66, as a first variant. Other materials that can be used include TPU at a higher density and hardness than a TPU rubber that could be used for the pad body 21.

The shielding arch member 23 may be secured to the pad body 21 in any appropriate way. For example, a co-molded joint, overmolding or like direct-attach joint may be present between the pad body 21 and the shielding arch member 23. The joint may result from a two-step molding process, with one of the pad body 21 and the arch member 23 molded first, and the other of the pad body 21 and arch member 23 molded over the part that is molded first. In a variant, the arch members 23 are interconnected to facilitate the overmolding, with the interconnection optionally being broken off once molding is completed. This may be known as overmolding. As an alternative, an adhesive, glue, cement may be present between the pad body 21 and the shielding arch member 23. Stitching or sewing may also be used, additionally or alternatively. Hence, as a possibility, the pad body 21 and the shielding arch member 23 are integrally connected.

As observed, the holes 22 may extend through the shielding arch member 23, such that at least some of the holes 22 may be in both the pad body 21 and the shielding arch member 23. In a variant, as illustrated in FIG. 2, the holes 22 that are in both the pad body 21 and shielding arch member 23 may be localized on the end regions of the shielding arch member 23. As the shielding arch member 23 defines the primary shock resistance component of the metatarsal protection arch 20, it may be desired to limit any surface disruption therein. This being said, there could be some vent holes 22 in a central segment of the shielding arch member 23. Moreover, there may be some prominent edges on the top surface of the shielding arch member 23. The embodiment of FIGS. 3 to 5 feature such prominent edges as an example, which similar prominent edges may be present in the embodiment of FIG. 2, extending along the arch member 23. The prominent edge(s) is (are) optional.

Referring to FIG. 2, an additional layer 24 may optionally be provided on the underside of the pad body 21. The additional layer 24 may be a textile or fabric, such as a cotton layer. The additional layer 24 may be provided to assist with the breathability of the metatarsal protection arch 20. The fabric layer 24 may be stitched, glued, cemented or connected in any appropriate way. As the metatarsal protection arch 20 may be embedded in the upper 11, the fabric layer 24 may be optional. As a possibility, the metatarsal protection arch 20 is used as an add-on component that is not an integral part of the item of footwear 10. In such an arrangement, the fabric layer 24 may be useful for sanitary reasons.

In use, when the top of the boot 10 receives an impact, the shielding arch member 23 will protect the metatarsal region of the foot from the impact as it acts as a hard shell. The arch member 23 may deflect the impact, especially if the arch member 23 has a prominent edge. The pad body 21 may elastically compress so as to absorb the impact, via a possible deceleration. The pad body 21 may also distribute the impact force via its greater surface than that of the arch member 23. In a configuration, the shielding arch member 23 may have its ends sit on the sole, foot bed, etc such that the impact force may also be transmitted to the sole, thereby bypassing the user's foot. The pad body 21 is made of a resilient and flexible material that will offer some protection while not impeding movement of the foot in the walking. The shielding arch member 23 may have a reduced width relative to the pad body 21, so as not to hamper the dynamics of the foot while a user walks.

Referring to FIG. 3, another embodiment of the metatarsal protection arch 20 is shown, and may have similar components as the metatarsal protection arch 20 of FIG. 2, whereby like reference numerals will be used to designated like components. The shielding arch member 23 however differs, in that it features two or more arch portions 30 (three shown), separated by hinge portions 31. The arch portions 30 and the hinge portions 31 may be a monoblock piece. The narrowing defined by the hinge portion(s) 31 relative to the arch portions 30 it connects may enable more flexibility of the shielding arch member 23 of FIG. 3 at the hinge portion(s) 31. The flexibility may be in the elastic range region during the walking cycle, such that the metatarsal protection arch 20 of FIG. 3 may cover a substantial portion of the metatarsal region of the foot, and yet adapt to the walking cycle.

Still in FIG. 3, it can be observed that the pad body 21 may optionally have a contour that emulates that of the shielding arch member 23, for the same purpose. As another possible feature, as can be seen at A, the pad body 21 may have a greater thickness in a centerline of the foot, the thickness reducing gradually in both the medial and lateral directions. The centerline may be known as the cardinal longitudinal axis of the foot, may be described as the anterior-posterior axis of the foot as well. As a result, more padding may be present along the centerline of the foot, i.e., the prominent part of the foot that may be more exposed to impacts.

Referring to FIG. 4, another embodiment of the metatarsal protection arch 20 is shown, and may have similar components as the metatarsal protection arch 20 of FIG. 2 and of FIG. 3, whereby like reference numerals will be used to designated like components. The shielding arch member 23 however differs, in that it features two or more arch portions 40 (three shown), separated by hinge portions 41, that are webs of material, that may be separated by slits 42. Moreover, larger vent holes 43 may be defined in the pad body 21 in register with the slits 42, and may help reduce material resistance to deformation. The arch portions 40 and the hinge portions 41 may be a monoblock piece. The relatively small size of the webs 41 may enable even more flexibility of the shielding arch member 23 at the webs 41, in comparison to other embodiments. Again, the flexibility may be in the elastic range region during the walking cycle, such that the metatarsal protection arch 20 of FIG. 4 may cover a substantial portion of the metatarsal region of the foot, and yet deformably adapt to the walking cycle.

FIG. 5 therefore shows how any one of the metatarsal protection arches 20 can define hinge zones intermittent with protective zones, so as to combine impact shielding and walking cycle adaptability. Four of the hinge zones are shown, but as little as one could be present, or none at all as in FIG. 2. The presence of hinge zones may allow the shielding arch member 23 to cover a greater surface of the foot, due to its capacity to deform. The metatarsal protection arch of FIG. 5 also shows prominent edges 50 that can be present in the various metatarsal protection arches 20 described herein.

Referring to FIG. 6, another variant of the metatarsal protection arch 20 is shown. The metatarsal protection arch 20 may have similar components as the metatarsal protection arch 20 of FIG. 2-5, whereby like reference numerals will be used to designated like components. The metatarsal protection arch 20 of FIG. 6 may have a pair of straps 60, looped and closed by eyelets 61. The straps 60 may be passed in slits 62 that may for instance be in the hinge zones, upper quarter or eyestays. The eyelets 61 would project out of the upper 11 (e.g., via openings such as slits), for laces of the boot 10 to pass through the eyelets 61. Accordingly, the metatarsal protection arch 20 of FIG. 6 would be supported by and connected to the laces, as one possible way to secure the metatarsal protection arch 20 to the boot. The straps 60 and eyelets 61 are a convenient way to achieve this, as the eyelets 61 may act as rivets for a closed loop of strap. However, other techniques of assembly are considered, including bonding, sewing, stitching, etc. As alternative to straps, other attachment means can be used, such as laces, Velcro®, tape, clips.

Referring to FIGS. 7, 8 and 9, another variant of the metatarsal protection arch 20 is shown. The metatarsal protection arch 20 may have similar components as the metatarsal protection arch 20 of FIG. 2-6, whereby like reference numerals will be used to designated like components. The metatarsal protection arch 20 of FIGS. 7 and 8 is shown having the pad body 21. The pad body 21 may be said to be the main component of the metatarsal protection arch 20 in terms of size. The pad body 21 has an arch geometry so as to straddle the metatarsal region of a user's foot. The pad body 21 may span a sufficient arch shape such that its ends may come into abutment with the floor F the boot 10, i.e., the surface upon which the foot lays when the boot 10 is worn. This is for instance illustrated in FIG. 9. However, it is not necessary that the ends of the pad body 21 contact the interior bottom of the boot 10. In a variant, the metatarsal protection arch 20 floats (i.e., is suspended, hovers), in that its undersurface and its ends do not contact other structural parts of the item of footwear 10, for the metatarsal protection arch 20 to rest on the user's foot, with or without the inner lining being present.

In an embodiment, the pad body 21 is supple polymer base, allowing flexibility at the ball area of the foot during the gait cycle. For example, the polymer base may be constituted of polyurethane at a density of 0.45±0.05 g/cm³, though the density may be lower or greater. The hardness of the polyurethane may be between Shore A 35-40, though the hardness may be lower or greater, and can be alternatively on the Asker C scale, as between 30-60, inclusively, though this is merely an example. As an alternative to polyurethane, silicone rubber may be used, as silicone rubber may be even more supple or flexibility for a similar weight or density. Silicone rubber may exhibit lower breathability than polyurethane. As yet another alternative to polyurethane, a thermoplastic polyurethane (TPU) rubber may be used. TPU rubber may be even more supple or flexibility for a similar weight or density as polyurethane, and may have greater shock-absorption capacity than polyurethane. TPU rubber may exhibit lower breathability than polyurethane. Other materials include expanded rubber, EVA.

Still referring to FIGS. 7 and 8, the geometry of the pad body 21 is defined as having an optional foremost toe portion 21A and a central metatarsal portion 21B. The foremost toe portion 21A and the central metatarsal portion 21B may be interconnected by a throat portion, that is a local narrowing N1 of the pad body 21, hence acting as a hinge between the foremost toe portion 21A and the central metatarsal portion 21B. Ankle portion(s) 21C may be present, and may be connected or not to the remainder of the pad body 21, such as by narrowings N2 and N3. The upper most ankle portion 21C may have an arcuate clearance, as it may be opposite a shin or upper ankle. It can be observed that the narrowings N1, N2 and/or N3 may optionally include a channel in the undersurface of the metatarsal arch portion 20, to contribute to the flexibility of the metatarsal arch portion 20 at N1, N2 and/or N3. The channels extend in a medio-lateral direction.

The central metatarsal portion 21B is configured to be located most over the metatarsal region of the foot. The foremost toe portion 21A may be over the phalanges, with a junction between the foremost toe portion 21A and the central metatarsal portion 21B generally aligned with the toe-off joint of the foot. Accordingly, as the foremost toe portion 21A is of a smaller width than the central metatarsal portion 21B, less resistance force is present at the transition from the midstance phase and the propulsive phase (i.e., toe-off), than if the foremost toe portion 21A were as wide as the central metatarsal portion 21B. As observed from FIG. 8, slots 21′ may optionally be present in the underside surface of the pad body 21. The slots 21′ may be aligned with a longitudinal direction of the foot, and may also be referred to as channels. These slots 21′ may contribute to air circulation or moisture evacuation.

Two or more separate shielding arch members 23 may be provided on a top surface of the pad body 21, and may have a geometry conforming to that of the pad body 21. The shielding arch members 23 are made of a more rigid than that of the pad body 21, and may be more apt at offering shock resistance, acting as a hard shell. The shielding arch members 23 do not contact each other, and are interconnected by webs 21D of the pad body 21. Accordingly, the webs 21D may act as hinges or like joints between the arch members 23. It can be observed that the webs 21D may optionally each include a channel in the undersurface of the metatarsal arch portion 20, to contribute to the flexibility of the metatarsal arch portion 20 at the webs 21D. The channels extend in a medio-lateral direction. In a variant, the arch members 23 are as long or longer than the pad body 21, such that end(s) of one or more of the shielding arch members 23 may come into contact with a bottom interior surface of the item of footwear (e.g., top surface of the sole, sock liner, insole, etc). The arch members 23 may optionally have a flared outline 23′ to increase their contact surface with the floor F of the item of footwear 10. This may require that the metatarsal protection arch 20 have a geometry specific to an item of footwear and to a size thereof. In such a scenario, the arch members 23 form a cage around a metatarsal region of a foot of a user, such that an impact on the metatarsal protection arch 20 may be distributed to the sole. The shielding arch members 23 may be made of Nylon 6 or Nylon 66, as a first variant. The shielding arch members 23 may have a Shore A hardness of 60-100, though this is merely an example Other materials that can be used include TPU at a higher density and hardness than a TPU rubber that could be used for the pad body 21. Thus, the embodiment of FIGS. 7, 8 and 9, and of other embodiments of the metatarsal protection arch 20, defines a cage or skeleton around a portion of the foot, and the cage or skeleton is articulated between structural members (e.g., via webs 21D), so as not to provide excessive rigidity to the item of footwear in which the metatarsal protection arch 20 is used. As best seen in FIG. 7, the arch members 23 may be embedded in the pad body 21. This may be the result of co-molding or overmolding. While the arch members 23 are shown spaced from one another, they may be interconnected as in the other embodiments. Moreover, the arch members 23 of the metatarsal portion 21B may be interconnected at their extremities, in a symmetric or asymmetric manner. Moreover, the metatarsal protection arch 20 may be positioned outside of the item of footwear 10, on an outer surface of the upper, and may for example abut against the periphery of the sole, as an option.

Therefore, the metatarsal protection arches 20 described herein can generally be described as being multi-density internal metatarsal protector. In some embodiments, the metatarsal protection arches 20 may be regarded as a multi-ribbed protection made a hard shell or like harder material such as nylon, TPU, Pebax®, polypropylene, polycarbonate, etc. with a soft pad body base made of a polyurethane or like foam, EVA, EPP, EPE, etc. The arches 20 may have an Asker C value of 60±5. The metatarsal protection arches 20 may have different configurations, such as hinges, slits, etc. to increase flexibility during a walking cycle. The slits or hinges may also be with a co-injected/co-molded textile reinforcement material. In a variant, the upper 11 is part of an outbossed vamp shaped to insert the internal metatarsal protector putting forth the protection and concealing it in a way to reduce the pressure on the metatarsal bones. The metatarsal protection arch 20 may comply with the CSA Z195 standard and/or the ASTM F2413 standard if appropriately sized, by limiting its downward movement within standard thresholds upon sustaining an impact.

The expression “arch” is used herein to designate the shape of the metatarsal protection arch 20 when seen from a front of a wearer's foot. As the arch 20 straddles the metatarsal region of the foot, it is arcuate and cab thus be said to form an arch.

In accordance with another variant of the present disclosure, there is provided a method for adding metatarsal protection in an item of footwear, such as the item of footwear 10. The method may include identifying an appropriate metatarsal protection arch 20 as a function of the size and/or model and/or dimensions of the item of footwear 10. The item of footwear 10 may then optionally be loosened, such as by loosening the laces or other attachment system (e.g., Velcro®, Boa®, etc) and by pulling the tongue forwardly. The metatarsal protection arch 20 may then be inserted via the foot opening of the item of footwear 10, and moved toward a front of the item of footwear 10, until the ends of the arch members 23 of the metatarsal portion 21B come into contact with the floor F of the item of footwear 10, and the upper portion of the metatarsal protection arch 20 can no longer move forward as it contacts the inner surface of the upper. If undone, the tongue and laces or like attachment system may then be tightened.

The metatarsal protection arch 20 may generally be described as having a pad body; and at least one shielding arch member connected to the pad body; wherein the shielding arch member has a greater hardness than the pad body; wherein the pad body and the at least one shielding arch member concurrently form an arch configured to straddle at least part of a metatarsal region of a foot; and wherein the metatarsal protective arch is configured to be positioned in a foot-receiving cavity of an upper of an item of footwear.

Claims

1. A metatarsal protective arch comprising: a pad body; andat least one shielding arch member connected to the pad body;wherein the shielding arch member has a greater hardness than the pad body;wherein the pad body and the at least one shielding arch member concurrently form an arch configured to straddle at least part of a metatarsal region of a foot; andwherein the metatarsal protective arch is configured to be positioned in a foot-receiving cavity of an upper of an item of footwear.

2. The metatarsal protective arch according to claim 1, wherein the pad body is a polyurethane.

3. The metatarsal protective arch according to claim 2, wherein the polyurethane has a density of 0.45±0.05 g/cm3.

4. The metatarsal protective arch according to claim 1, wherein the pad body has a hardness of Shore A 35-40.

5. The metatarsal protective arch according to claim 1, wherein the shielding arch member is made of a TPU, Pebax®, nylon, polypropylene or polycarbonate.

6. The metatarsal protective arch according to claim 1, wherein the pad body and the shielding arch member have different densities.

7. The metatarsal protective arch according to claim 1, including vent holes extend through the metatarsal protective arch.

8. The metatarsal protective arch according to claim 1, including at least two of the shielding arch member, separated by a hinge portion.

9. The metatarsal protective arch according to claim 8, wherein the shielding arc member and the hinge portion are made of a monoblock body.

10. The metatarsal protective arch according to claim 8, wherein the hinge portion is a narrowing in the pad body between adjacent ones of the shielding arch member.

11. The metatarsal protective arch according to claim 1, including attachment means for attachment of the metatarsal protective arch to an item of footwear such that the metatarsal protective arch is suspended.

12. The metatarsal protective arch according to claim 11, wherein the attachment means are straps.

13. The metatarsal protective arch according to claim 1, wherein the at least one shielding arch member is on a top surface of the pad body.

14. The metatarsal protective arch according to claim 13, wherein the at least one shielding arch member is overmolded with the pad body.

15. The metatarsal protective arch according to claim 1, wherein ends of one or more of the at least one shielding arch member are configured to contact a floor of the item of footwear.

16. The metatarsal protective arch according to claim 15, wherein the ends of the the at least one shielding arch member flare toward the floor of the item of footwear.

17. An item of footwear comprising: an upper mounted to a sole, the upper and the sole forming a foot-receiving cavity; andthe metatarsal protective arch according to claim 1.

18. The item of footwear according to claim 17, wherein the metatarsal protective arch is located in the foot receiving cavity.