Protective footwear and method of forming the same

Abstract

Formfitting footwear including a stretchable sleeve to be worn on a human foot, the sleeve having a first end and a second end opposite the first end. Toe openings are disposed at the first end of the elastic sleeve. A footpad is disposed at the first end of the elastic sleeve adjacent the toe openings, the footpad including an inner layer of at least one of shock absorbing material and cushioning material and an outer layer that contacts a ground surface.

1 . Formfitting footwear comprising: 
 a stretchable sleeve to be worn on a human foot, the sleeve having a first end and a second end opposite the first end;    toe openings disposed at the first end of the elastic sleeve;    a footpad disposed at the first end of the elastic sleeve adjacent the toe openings, the footpad comprising an inner layer of at least one of shock absorbing material and cushioning material and an outer layer that contacts a ground surface.    
   
   
       2 . The formfitting footwear of  claim 1 , further comprising an elastic portion formed around the second end of the stretchable sleeve that prevents the stretchable sleeve from falling towards a wearer's toes.  
   
   
       3 . The formfitting footwear of  claim 1 , wherein the inner layer of the footpad is made of a foam material.  
   
   
       4 . The formfitting footwear of  claim 3 , wherein the foam material is polyurethane foam.  
   
   
       5 . The formfitting footwear of  claim 1 , wherein the inner layer of the footpad is made of a gel material.  
   
   
       6 . The formfitting footwear of  claim 1 , wherein the thickness of the inner layer is in the range of about 0.25 mm to about 3.0 mm.  
   
   
       7 . The formfitting footwear of  claim 1 , wherein the outer layer is made of a material from the group consisting of smooth leather, suede leather, synthetic leather, moldable polymers and elastomers.  
   
   
       8 . The formfitting footwear of  claim 1 , wherein the outer layer is textured to enhance traction.  
   
   
       9 . The formfitting footwear of  claim 8 , wherein the textured footpad comprises one or more of the following: ridges, grooves and dimpling.  
   
   
       10 . The formfitting footwear of  claim 1 , further comprising a toe piece that forms the toe openings.  
   
   
       11 . The formfitting footwear of  claim 1 , wherein the footpad further comprises a moisture-absorbing layer.  
   
   
       12 . The formfitting footwear of  claim 1 , wherein the stretchable sleeve comprises a cut-out portion to which the toe portion is attached.  
   
   
       13 . The formfitting footwear of  claim 1 , wherein the stretchable sleeve comprises a cut-out portion to which the footpad is attached.  
   
   
       14 . A method of forming formfitting footwear comprising: 
 providing a sheet of stretchable material, the sheet having a first longitudinal end portion, a second longitudinal end portion, a first lateral end portion and a second lateral end portion;    forming toe openings at the first longitudinal end portion of the sheet;    attaching a footpad to the first longitudinal end portion of the sheet adjacent to the toe openings;    folding the sheet such that the first lateral end portion overlaps the second lateral end portion with the footpad disposed between the first and second lateral end portions;    permanently attaching the first lateral end portion to the second lateral end portion so as to form a sleeve with the footpad disposed within the sleeve; and    turning the sleeve inside out such that the footpad is disposed outside the sleeve.    
   
   
       15 . The method of  claim 14 , further comprising attaching an elastic portion to the second longitudinal end portion of the sheet.  
   
   
       16 . The method of  claim 14 , wherein the step of forming toe openings comprises attaching a toe piece to the sheet.  
   
   
       17 . The method of  claim 14 , wherein the step of attaching a footpad comprises attaching to the sheet an inner layer of at least one of shock-absorbing material and cushioning material and an outer layer that contacts a ground surface during use.  
   
   
       18 . The method of  claim 17 , wherein the step of attaching a footpad further comprises attaching to the sheet a moisture-absorbing layer.