Abstract:
A shoe toe cap for protecting a toe end of a shoe is disclosed. The shoe toe cap has various layers adhered together to form a single piece for use on the shoe toe cap. Adhesive film layers and polyurethane film layers are combined to form the inventive shoe toe cap. A lowermost adhesive film layer is temporarily or permanently adhered to the toe end of the shoe. A series of polyurethane film layers are adhered on top of the lowermost adhesive film layer. The shoe toe cap is abrasion and creep resistant and increases the life of the shoe.

Description:
CROSS REFERENCE TO RELATED APPLICATION(S) 
       [0001]    This is a non-provisional patent application based on co-pending U.S. Provisional Patent Application Ser. No. 62/077,991 (Attorney Docket No. LD-14-1) previously titled “Shoe Toe Cap”, filed on Nov. 11, 2014, the priority of which is hereby claimed and the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to a protector used for the protection of a shoe. More particularly, the present invention relates to a shoe toe cap which increases the durability of the shoe. 
         [0004]    2. Description of the Related Art 
         [0005]    Various methods have been used in the past to prolong life of the shoes and to protect them from getting damaged. One of the techniques includes the use of a shoe toe cap for footwear. This method is very well documented in the art. The shoe toe cap includes a piece of cloth or polymer or any other suitable material which covers the toe end of the shoe. 
         [0006]    Different types of shoe toe caps used on footwear&#39;s serve different purposes. For e.g. working boots for factory workers are designs to have steel toe cap to ensure safety from heavy tools and machine parts. Shoes designed for athletes have shoe toe caps made of material which protect and extend the life of the cleats. Children while playing, rub their shoes on a street sidewalk, or on a dirt road, especially the toe end of the shoe. Hence toe caps for shoes worn by children are generally abrasion resistant which prevent scuffing and keep the shoes dirt free. An example of children&#39;s shoes with built in toe cap protection method include Converse brand Chuck Taylor shoes with thick latex rubber on the toe end. Generally shoes with toe protection are those which are provided by the manufacturer and are essentially built-in or stitched onto the shoe, such as the Converse brand shoes described. 
         [0007]    Shoe toe cap are made of different fabrics and material like leather, rubber, textiles, etc. Leather is more prone to cracking and wearing while vulcanised rubber is heavy and hard, resistant to wear and tear. Therefore, sports or hiking shoes will have toe caps made of vulcanised rubber while shoes made for day to day use will have toe caps made of leather. 
         [0008]    Various types of shoe toe caps have already been described in the art. U.S. Pat. No 2,380,050 by Karp Jack provides an attachable toe cap for shoes, which is made of plastic material. The toe cap is stitched and then cemented to the shoe welt. There remains a risk of fracturing of the plastic material when the toe end is subjected to pressure. Also as the toe cap is cemented and stitched to the welt, any damage to the toe cap can cause considerable damage to the shoe which can be beyond repair. 
         [0009]    US Publication No 2006/042,125 by Eddie Chen and Phoenix Hsu discloses a light weight, abrasion resistant shoe toe cap. The toe cap is made of composite material having a fabric layer and an abrasion resistant coating layer adhered to the fabric layer. 
         [0010]    WIPO Publication No 2,013,112,022 by Tae Won Sohn and Jung Soo Yoon discloses a toe cap produced from high tenacity fibre sheet. The toe cap has sufficient load carrying capacity and impact resistance. However, the toe cap gets permanently adhered to the shoes, so if the toe cap is damaged or disfigured, it destroys the physical appeal of the shoes. 
         [0011]    In light of the foregoing discussion, there exists a need for an innovative, robust and a durable after-market shoe toe cap which can protect the shoe from scuffing and also gives an attractive appeal to the shoes. Preferably something which does not impact the physical appearance of the shoe as purchased and vet protects the toe end, or the heel end, from damage such as scuffing, tearing, or scratches from abrasions. 
       SUMMARY 
       [0012]    An object of the present invention is to provide a shoe toe cap protector, as an after-market item, which is placed on a toe end of a shoe to extend the life and appearance of the shoe. The inventive shoe toe cap protector can also be used on shoe heels or other items subject to abrasion. 
         [0013]    The shoe toe cap is made of composite materials comprising two or more layers. A layer of an adhesive film which has a backing forms a bottom most layer of the shoe toe cap which is in contact with the toe end of the shoe. A first polyurethane film is adhered on top of the adhesive layer. 
         [0014]    According to another embodiment, the shoe toe cap can also be provided with an additional layer for decorative purpose. The first polyurethane film can optionally be imprinted with a design for decorative purposes. The shoe toe cap is made of a first layer of the adhesive film which is placed on the toe end of the shoe, a second layer of a white or a coloured first polyurethane film with the desired imprint placed on top of the first layer, and followed by a third layer of a second polyurethane film placed over the imprinted layer. All layers adhere to each other forming the shoe toe cap. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0015]    The features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. Embodiments of the present invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the scope of the claims, wherein like designations denote like elements, and in which: 
           [0016]      FIG. 1  shows a schematic perspective view of a shoe with a shoe toe cap; 
           [0017]      FIG. 2 a    shows a section of the shoe toe cap according to an embodiment of the invention; and 
           [0018]      FIG. 2 b    shows a section of the shoe toe cap with the imprinted layer of the polyurethane film according to another embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0019]    As used in the specification and claims, the singular forms “a”, “an” and “the” include plural references unless the context clearly dictates otherwise. For example, the term “an article” may include a plurality of articles unless the context clearly dictates otherwise. 
         [0020]    Those with ordinary skill in the art will appreciate that the elements in the Figures are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions of some of the elements in the Figures may be exaggerated, relative to other elements, in order to improve the understanding of the present invention. 
         [0021]    There may be additional components described in the foregoing application that are not depicted on one of the described drawings. In the event such a component is described, but not depicted in a drawing, the absence of such a drawing should not be considered as an omission of such design from the specification. 
         [0022]    Before describing the present invention in detail, it should be observed that the present invention utilizes a combination of system components which constitutes a shoe toe cap for prolonging the life of a shoe. Accordingly, the components and the method steps have been represented, showing only specific details that are pertinent for an understanding of the present invention so as not to obscure the disclosure with details that will be readily apparent to those with ordinary skill in the art having the benefit of the description herein. 
         [0023]    As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the invention. 
         [0024]    A schematic perspective view of a shoe  100  with a shoe toe cap  102  is shown in  FIG. 1  according to an embodiment of the invention. The shoe toe cap  102  adheres to a toe end  104  of the shoe  100 . The shoe toe cap  102  prolongs the life of the shoe  100 . The shoe toe cap  102  provides high abrasion resistance, high tear strength and prevents scuffing of the material of the shoe  100 . It should be appreciated that the shoe toe cap  102  can also be used to protect any other portion of the shoe  100  such as a heel end of the shoe  100  or other vulnerable areas of the shoe. The shoe toe cap  102  can also be designed to enhance the attractive appeal of the shoe  100  by imprinting it with various designs and colours. 
         [0025]    According to an embodiment the shoe toe cap  102  is specifically designed as an after-market product. However, it should be appreciated that the application of the shoe toe cap  102  is not limited so as to be used only as an after-market item. It can also be placed on a shoe before it is finally constructed and hence can be a “before market” application item. It should also be appreciated that the use of the shoe toe cap  102  is not restricted to shoes and footwear. The shoe toe cap  102  can also be used to protect other items such as carry bags, luggage, transport boxes, briefcases, and purses which are prone to abrasion and scuffing. 
         [0026]    A sectional view of the shoe toe cap  102  is shown in  FIG. 2 a    and  FIG. 2   b.  The shoe toe cap  102  includes a first layer  106  and a second layer  108  as shown in  FIG. 2 a    according to an illustrative embodiment of the invention. The first layer  106  is an adhesive film  106  which has a backing for ease in transport and handling. The second layer  108  is a first polyurethane film  108 . The first layer  106  is adhered on top of the toe end  104  of the shoe  100 . The second layer  108  is adhered on the top of the first layer  106 . 
         [0027]    According to another embodiment of the invention, the shoe toe cap  102  is provided with an imprinted layer as shown in  FIG. 2   b.  The shoe toe cap  102  with imprint comprises at least three layers. The imprinting is optional and is done primarily to enhance the attractive and aesthetic appeal of the shoe  100 . The three layers include the first layer  106  of the adhesive film  106 , the second layer  108  of the first polyurethane film  108  having a design thereon, and a third layer  110  the third layer is preferably clear to not alter the imprint, or it can also be imprinted to accompany the first layer imprint on the shoe. Generally, the second layer  108  is imprinted with a design for decorative purposes. The second layer  108  has a white or a coloured backing onto which a design is imprinted. The backing can be made of polyurethane or a number of other thin films which are suitable for imprinting. 
         [0028]    The third layer  110  is adhered on the top of the second layer  108  as shown in  FIG. 2   b.  The third layer  110  is a second polyurethane film  110 . The third layer  110  is adhered on top of the imprinted second layer  108  so as to ensure that the design is not impaired or scrubbed away in event of scuffing of the shoe  100 . It should be appreciated that the term first layer  106  and the term adhesive film  106  can be interchangeably used throughout the course of this disclosure. It should also be appreciated that the term second layer  108  and the term first polyurethane film  108  can be interchangeably used throughout the course of this disclosure. It should also be appreciated that the term third layer  110  and the term second polyurethane film  110  can be interchangeably used throughout the course of this disclosure. In another embodiment, the shoe toe cap  102  can be made of more than three layers. Optionally for example, an adhesive layer can be placed between the two polyurethane films to allow for greater adhesion and scuff protection. 
         [0029]    According to an embodiment of the present invention, the first polyurethane film  108  and the second polyurethane film  110  are preferably made of aliphatic polyurethane as they tend to be more durable, less yellowing, and longer lasting than the aromatic or other polyurethanes. The use of any other suitable materials for preparing the first polyurethane film  108  and the second polyurethane film  110  is well within the scope of this invention. The adhesive film  106 , the first polyurethane film  108  and the second polyurethane film  110  are transparent so that the shoe design is not impacted, and the aesthetic feature of the invention remains. Also if a user desires an imprinted design for the shoe toe cap  102 , the user can see the design on the first polyurethane film  108 . However, as mentioned above, the second polyurethane film can also be imprinted. 
         [0030]    The shoe toe cap  102  can either be temporarily adhered or permanently adhered to the toe end  104  of the shoe  100 . The shoe toe cap  102  is placed on the top layer of the toe end  104  of the shoe  100  and an outline of the toe end  104  of the shoe  100  is traced on the shoe toe cap  102 . The shoe toe cap  102  is cut as per the outline traced. A backing paper covering the adhesive film  106  is removed and the shoe toe cap  102  is adhered to the toe end  104  of the shoe  100 . It is preferable but not mandatory to apply heat, with a blow dryer or iron, while applying pressure to the toe cap. 
         [0031]    In an alternate description, when the shoe toe cap  102  is used without an imprinted design, there are at least two layers present to form the shoe toe cap  102 : the first layer  106  being an adhesive which sticks to the toe end  104  of the shoe  100 , and the second layer  108  which is a polyurethane and sticks to the first layer  106 . When the shoe toe cap  102  is used with an imprint, there are at least three layers present: the first (adhesive) layer  106  which sticks to the toe end  104  of the shoe  100 , the second (polyurethane) layer  108  having an imprint thereon which sticks to the first layer  106  and the third (clear polyurethane) layer  110  which sticks to the second layer  108 . Again, multiple layers can be used and imprinted as desired. 
         [0032]    In yet another embodiment of the present invention the shoe toe cap include a second adhesive layer (not shown) placed between the second layer  108  and the third layer  110 . 
         [0033]    The shoe toe cap  102  of the present invention can be used on shoes made of a variety of different fabrics. Examples include Nylon (89% nylon, 17% metallic), Polyester (100%), Leather, Linen (100%), Cotton (100%), Rayon and Vinyl (100%). It should be appreciated the shoe toe cap  102  can also be used on fabrics or textiles suitable for shoes or shoe construction, other than the above mentioned examples. The shoe fabric can be anything which the polyurethane and adhesive will stick and remain on the shoe for protection of the toe cap. Laboratory testing for tensile strength, creep and taber abrasion has been conducted on the seven fabrics mentioned above after they were adhered to the shoe toe cap  102 . Each fabric adhered to the shoe toe cap  102  was treated as a separate specimen and was individually tested. Results indicated that the inventive toe cap protected the fabric from scrapes, scuffs, and abrasion while remaining adhered throughout. 
         [0000]    Tables 1-4 attached herein show the samples as submitted and as tested. Portions of the data are reproduced within the body of the specification for ease of review. 
         [0034]    The tensile strength test (tables 2 and 3) for each of the specimen was conducted under conditions before and after applying heat at 60 degree Celsius. Each specimen was subjected to 180° peel at a constant rate of 50 mm/minute under both the conditions. The results of the tensile strength test before heating and after heating are as follows: 
       Tensile Strength Testing, Before Heating Sample 
       [0035]      
         [0000]    
       
         
               
               
               
             
               
               
               
             
           
               
                   
               
               
                   
                   
                 Peel Strength 
               
               
                 Before Heating 
                 Peak Load (lbf) 
                 (lbf/in) 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 89% Nylon 17% 
                 1.46 
                 0.992 
               
               
                 Metallic 
                   
                   
               
               
                 100% Polyester 
                 1.86 
                 1.229 
               
               
                 Leather 
                 2.573 
                 2.159 
               
               
                 100% Linen 
                 1.08 
                 0.664 
               
               
                 100% Cotton 
                 5.13 
                 3.068 
               
               
                 Rayon 
                 2.415 
                 2.156 
               
               
                 100% Vinyl 
                 2.426 
                 1.965 
               
               
                   
               
             
          
         
       
     
       Tensile Strength Testing, After Heating Sample 
       [0036]      
         [0000]                                                          Peel Strength       After Heating (60° C.)   Peak Load (lbf)   (lbf/in)                                89% Nylon 17%   2.236   1.691       Metallic               100% Polyester   2.777   1.879       Leather   1.882   0.931       100% Linen   1.494   1.128       100% Cotton   5.014   2.809       Rayon   3.995   3.065       100% Vinyl   1.791   1.449                    
For tensile strength, it was found the strength increased after heating for nylon, polyester, linen, and rayon. The tensile strength decreased after heating for leather, cotton and vinyl.
 
         [0037]    The creep test for each of the specimen was conducted under conditions subjected to oven aging at 40° C. and by increasing the temperature by 10° C. every hour until it reaches 60° C. It was observed that for all specimens there was no creepage of the shoe toe cap  102  which was adhered to the fabric or material. Creep data is shown in Table 1. The taber abrasion test for each of the specimen was conducted under conditions subjected to abrasion testing using a 500 g load and CS-10 wheels for 250 cycles. It was observed that no specimen exhibited wear through the shoe toe cap  102  to the material. Taber abrasion data is shown in Table 4. 
         [0038]    For the present examples and data collected, fabrics as discussed above were employed. The adhesive used was a 3M Company supplied adhesive number 9472LE which is employed on the adhesive transfer tape and has a low surface energy acrylic adhesive providing high bond strength to most surfaces. It was found to be suitable for fabrics having light contamination with machine oil parts such as found on after-market shoes of cloth or leather or synthetic fabrics. 
         [0039]    It was found to have excellent to good adhesion onto the surfaces employed. The technical data for adhesive 300LSE and in particular number 9472LE can be found on the 3M website, herein incorporated by reference. Film 9472LE has a 5.2 mil (132 micron) thickness, 58# polycoated kraft liner, the adhesive is solvent free and acrylic based. This adhesive has: good bond strength, humidity resistance after exposure for 7 days at 90 F (32 C) and 90% humidity, water has no appreciable effect on the bond strength after 100 hours at room temperature, the bond is maintained, chemical resistance to oil, mild acids and alkalis, and has a lower service temperature to about −40 F (−40 C). 
         [0040]    The polyurethane used was as supplied by API (American Polyfilm, Inc.) of Branford, Conn., USA. It was supplied as PN 1001, aliphatic polycaprolactone-base polyurethane, having the following values: 
       Polyurethane PN 1001 Specification 
       [0041]      
         [0000]    
       
         
               
               
               
               
             
           
               
                   
                   
               
               
                   
                   
                 Test Values 
                 ASTM Method 
               
               
                   
                   
               
             
             
               
                   
                 Durometer 
                 92A 
                 D2240 
               
               
                   
                 Specific gravity 
                 1.12 
                 D792 
               
               
                   
                 Elongation at break  
                 380% 
                 D412 
               
               
                   
                 Tensile strength at 
                 6000 psi 
                 D412 
               
               
                   
                 break 
                   
                   
               
               
                   
                 100 o/o Modulus 
                 1000 psi 
                 D412 
               
               
                   
                 300 o/o Modulus 
                 4500 psi 
                 D412 
               
               
                   
                 Tear strength 
                  460 psi 
                 D624 
               
               
                   
                 Melt range 
                 195-250° F. 
               
               
                   
                   
               
             
          
         
       
     
         [0042]    The polyurethane film was reported to have exceptional clarity, good UV stability and high hydrolysis resistance per API. 
         [0043]    The present invention has been described herein with reference to a particular embodiment for a particular application. Although selected embodiments have been illustrated and described in detail, it may be understood that various substitutions and alterations are possible. Those having ordinary skill in the art and access to the present teachings may recognize additional various substitutions and alterations are also possible without departing from the spirit and scope of the present invention, and as defined by the following claim.