Soft toe post with reinforcement

Abstract

A footwear product includes an upper strap assembly coupled to a sole assembly using a toe post. The toe post includes a soft shell that is at least partially disposed over a reinforcement element.

What is claimed is: 
     
         1 . A toe post, comprising:
 a reinforcement element, the reinforcement element comprising a first material; and   a soft shell disposed over at least a portion of the reinforcement element, the soft shell comprising a second material different from the first material.   
     
     
         2 . The toe post of  claim 1 , wherein the first material comprises nylon. 
     
     
         3 . The toe post of  claim 1 , wherein the second material comprises a thermoplastic elastomer material. 
     
     
         4 . The toe post of  claim 3 , wherein the thermoplastic elastomer material comprises a styrenic block copolymer material. 
     
     
         5 . The toe post of  claim 1 , wherein the first material is bonded to the second material. 
     
     
         6 . The toe post of  claim 1 , further comprising an attachment interface of the reinforcement element defined by an aperture in the soft shell. 
     
     
         7 . A method of constructing a toe post, the method comprising:
 injecting a first material into a first mold cavity to create a reinforcement element;   removing the reinforcement element from the first mold cavity;   placing the reinforcement element within a second mold cavity; and   injecting a second material into the second mold cavity to create a soft shell that is disposed over at least a portion of the reinforcement element, wherein the second material bonds to at least a portion of an outside surface of the reinforcement element.   
     
     
         8 . The method of  claim 7 , wherein the second mold cavity includes pins that hold the reinforcement element in a position within the second mold cavity. 
     
     
         9 . The method of  claim 8 , wherein the reinforcement element comprises a fin assembly and, wherein inserting the pins comprises orienting the pins substantially perpendicularly to the fin assembly. 
     
     
         10 . The method of  claim 9 , wherein inserting the pins comprises placing the pins such that an engagement end of each pin engages a surface of the fin assembly. 
     
     
         11 . The method of  claim 9 , wherein inserting the pins comprises placing the pins through corresponding apertures defined within the fin assembly. 
     
     
         12 . The method of  claim 7 , wherein the second material bonds to a portion of an outside surface of the reinforcement element such that an attachment interface surface of the reinforcement element is exposed. 
     
     
         13 . The method of  claim 7 , wherein the second material bonds to an entirety of the outside surface of the reinforcement element. 
     
     
         14 . The method of  claim 7 , wherein the first material comprises nylon. 
     
     
         15 . The method of  claim 7 , wherein the second material comprises a thermoplastic elastomer material. 
     
     
         16 . The method of  claim 15 , wherein the thermoplastic elastomer material comprises a styrenic block copolymer material. 
     
     
         17 . A method of constructing a footwear product, the method comprising:
 creating a toe post, the toe post including a soft shell that is disposed over at least a portion of a reinforcement element, wherein the toe post comprises an anchor at a first end thereof, an attachment section, and a shaft disposed between the anchor and the attachment section;   coupling the toe post to a sole assembly, the sole assembly having a forefoot portion and an aperture that is defined through the forefoot portion from a lower surface of the sole assembly to an upper surface of the sole assembly, wherein coupling the toe post to the sole assembly comprises inserting the toe post through the aperture such that an upper surface of the anchor engages the sole assembly and at least a portion of the shaft is disposed through the aperture; and   attaching a front portion of an upper strap assembly to the attachment section of the toe post.   
     
     
         18 . The method of  claim 17 , further comprising attaching a rear portion of an upper strap assembly to the sole assembly. 
     
     
         19 . The method of  claim 17 , wherein the attachment section of the toe post comprises an attachment interface surface of the reinforcement element. 
     
     
         20 . The method of  claim 19 , wherein attaching the front portion of the upper strap assembly to the attachment section of the toe post comprises adhering the front portion of the strap assembly to the attachment interface surface of the reinforcement element.