Safety footwear having metatarsal guard, and methods

Abstract

A metatarsal guard inserted in the upper of a safety shoe is made of plastic and defines an arch extending from the sole of the shoe on one side of the wearer's instep to the sole on the other side of the wearer's instep. A rear portion of the metatarsal guard includes at least one longitudinal tongue extending away from the toe portion of the guard, preferably three tongues. An appropriately sized metatarsal guard is used for each size of footwear. The guard is shaped and size by the last used to make the footwear.

What is claimed:  
     
         1 . A method of making a safety footwear, the safety footwear comprising a sole, an upper including a first layer and a second layer, and a metatarsal guard positioned between the first and second layers of the upper, the method comprising the steps of: 
 (a) forming a metatarsal guard having a shape determined by a first last;    (b) building the safety footwear on a second last, wherein the first last and the second last have the same shape.    
     
     
         2 . The method according to  claim 1 , wherein the step of forming a metatarsal guard having a shape determined by a first last comprises: 
 (a) molding a sheet of material to the first last to provide the metatarsal guard.    
     
     
         3 . The method according to  claim 1 , wherein the step of forming a metatarsal guard having a shape determined by a first last comprises: 
 (a) injection molding a mass of material using a mold having been shaped by the first last.    
     
     
         4 . The method according to  claim 1 , wherein the step of building the safety footwear on a second last comprises: 
 (a) providing the sole;    (b) positioning the metatarsal guard between the first layer and the second layer of the upper; and    (c) attaching the upper to the sole.    
     
     
         5 . The method according to  claim 4 , wherein the step of positioning the metatarsal guard between the first layer and the second layer of the upper is done prior to the step of attaching the upper to the sole.  
     
     
         6 . The method according to  claim 4 , the safety footwear further comprising a safety toe box, the method further comprising: 
 (a) positioning the toe box between the first layer and the second layer of the upper.    
     
     
         7 . The method according to  claim 1 , wherein the first last and the second last are the same last.  
     
     
         8 . A method of making a metatarsal guard, the method comprising: 
 (a) shaping a flat sheet of plastic by a mold, the mold having a shape and size of a last, the last being used to construct footwear into which the metatarsal guard will be incorporated.    
     
     
         9 . The method according to  claim 8 , wherein the step of shaping a flat sheet of plastic by a mold comprises: 
 (a) heating the flat sheet of plastic to the shape of the last.    
     
     
         10 . A metatarsal guard made by the process of: 
 (a) shaping a flat sheet of plastic by a mold, the mold having a shape and size of a last, the last being used to construct footwear into which the metatarsal guard will be incorporated.    
     
     
         11 . A method of making a plurality of safety footwear, the plurality of safety footwear being similar except for their size, the plurality comprising a first footwear having a first size, a second footwear having a second size different than the first size, and a third footwear having a third size different than each of the first size and the second size, the method comprising: 
 (a) making the first footwear on a first last, comprising the steps of: 
 (i) forming a first metatarsal guard having a shape determined by a second last, the second last having a shape similar to a shape of the first last;  
 (ii) building the first footwear on the first last;  
   (b) making the second footwear on a third last, comprising the steps of: 
 (i) forming a second metatarsal guard having a shape determined by a fourth last, the fourth last having a shape similar to a shape of the third last;  
 (ii) building the second footwear on the third last;  
   (c) making the third footwear on a fifth last, comprising the steps of: 
 (i) forming a third metatarsal guard having a shape determined by a sixth last, the sixth last having a shape similar to a shape of the fifth last;  
 (ii) building the third footwear on the fifth last.  
   
     
     
         12 . The method according to  claim 11 , wherein the first footwear has a first size, the second footwear has a second size, and the third footwear has a third size.  
     
     
         13 . A unitary metatarsal guard comprising a unitary, non-segmented body defined by a front edge, a continuous inner edge, a continuous outer edge, and a back edge, the body comprising an impact-absorbing portion having a thickness of about 0.065 to 0.075 inches, and a first tongue, a second tongue, and a third tongue, each of the tongues extending longitudinally from the impact-absorbing portion and defined by the back edge, with the body made from a polymeric material from the group of acrylonitrile-butadiene-styrene, polycarbonate, high density polyethylene, high density polypropylene, and acrylic polyvinyl chloride alloy plastic.