Patent Publication Number: US-10786044-B2

Title: Footwear with protective toe guard and related method

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to footwear, and more particularly to safety footwear including protective toe guards. 
     The human foot includes many bones that can be subject to crushing forces when impacted by falling or dropped items. For example, the foot includes multiple elongated metatarsal bones in the instep region, which are further connected to phalanges associated with the toes. These bones are particularly vulnerable to fracture when impacted by falling objects. In the United States, over 100,000 individuals are injured annually due to such accidents, some being severely incapacitated or maimed. 
     Many manufacturers produce footwear designed to prevent injury to the toe region and instep region in general. Such footwear typically includes a protective toe element, usually in the form of a rigid metal shield placed over the toe region, such as a steel toe. The steel toe usually rests on top of a midsole, and is concealed by a fabric or leather cover that matches the remainder of the footwear. The metal shield can include a bottom that projects upward from the top of a midsole or an outsole to form an abrupt edge located under the base of the wearer&#39;s toes. Typically, a footbed or insole is placed over this edge so it is not perceivable to a wearer of the footwear. Over time however, the footbed or insole may thin, so the edge becomes noticeable to the wearer due to the edge engaging the wearer&#39;s toes or forefoot. Further, with the bottom of the steel toe above the midsole, it frequently is difficult to fully conceal the upwardly projecting edge. This can cause discomfort to the wearer, along with a stiff construction used to attach the steel toe to the midsole. 
     Accordingly, there remains room for improvement in the field of protective toe elements that protect the phalanges, and optionally metatarsal bones of a wearer&#39;s foot from forceful impacts, and simultaneously provides comfort, flexibility and ease of manufacture in an aesthetically pleasing package. 
     SUMMARY OF THE INVENTION 
     Footwear is provided including a protective toe element in the form of a rigid protective toe guard nested in a recess defined by a sole component so that the toe guard is of a low profile and has an at least partially closed bottom which cleanly transitions to an upper surface of the sole component. The footwear and its components provide impact and crushing force resistance, yet the footwear is low profiled and flexible enough to provide enhanced mobility and comfort to a wearer. 
     In one embodiment, the footwear includes an upper having an inner portion. The inner portion can be of a Strobel construction. For example, the inner portion can include a liner or other fabric portion that extends within and generally closes a void for a wearer&#39;s foot. The bottom of the liner can be closed with a Strobel board, which can be a full or partial Strobel board extending from the toe region toward the heel region of the footwear. The Strobel board can be flexible and of a minimal thickness, for example about 0.25 mm to about 2.5 mm, or other thicknesses depending on the application. 
     In another embodiment, the Strobel board can rest on the top and/or be in contact with an upper surface of the bottom wall of the toe guard. The Strobel board also can rest atop and/or can be in contact with an upper surface of the sole component. In this manner, the transition between the bottom wall of the toe guard and the sole component&#39;s surface can be imperceptible to a wearer of the footwear, and does not reflect through or otherwise create an abrupt transition noticeable through the Strobel board. Optionally, a footbed can be placed atop the Strobel board and can be of a similar size and shape. This footbed also can fit within the interior of the toe guard. 
     In still another embodiment, the inner portion of the upper attached to the Strobel board can form a closed toe box of the inner portion. The toe box can be disposed within the interior of the toe guard, optionally so that the wearer&#39;s foot cannot contact the interior surfaces of the toe guard. 
     In another embodiment, the upper can include an outer portion. This outer portion can extend over at least a portion of the inner portion and can be constructed from more durable material than the material of the inner portion. The outer portion can extend forwardly over an exterior of the toe guard and conceal it within the footwear. 
     In still another embodiment, the toe guard can include an outer perimeter. Adjacent the other perimeter, the toe guard can define a peripheral recess. A peripheral allowance of the outer portion can be nested at least partially within the peripheral recess of the toe guard. In this manner, the peripheral allowance of the outer portion can be secured within a portion of the toe guard. With a peripheral allowance in this recess, the overall profile of the toe guard can be lowered in the footwear. 
     In even another embodiment, the sole component, which can be a footbed, an insole, a midsole, and outsole, or any combination of the foregoing or other cushioning element underfoot, can include a toe guard recess that is configured to receive the toe guard and set it at a particular depth below an upper surface of the sole component. In this manner, the bottom of the toe guard nests within the recess so that the upper surface of the bottom wall is flush with or slightly above or below the upper surface of the sole component to provide a clean, smooth transition between the bottom wall and the upper surface, and optionally to lower the overall profile of the toe guard in the toe region of the footwear. 
     The footwear of the current embodiments provides a protective toe guard that is exceptionally low profiled, flexible and comfortable to wear. With its low profiled, rigid toe guard, the footwear is not overly bulky or aesthetically displeasing. The interior of the footwear is more comfortable due to its clean and imperceptible transition between the rigid toe guard bottom wall and the upper surface of the sole. Due to the clean transition, the footwear also can include a Strobel construction, with a Strobel board overlaying the bottom wall and upper surface of the toe guard&#39;s bottom wall. Where the toe guard includes a peripheral wall recess, an exterior cover can be cleanly associated with the toe guard, and can minimize bulkiness. In addition, the well-fitted, low profile toe guard renders the footwear exceptionally flexible, allowing the foot to follow a more natural range of motion during a gait cycle of the wearer. 
     These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings. 
     Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of footwear of a current embodiment including a toe guard and associated features; 
         FIG. 2  is a sectional view of the footwear, the toe guard, an inner portion of the upper having a Strobel construction and a sole; 
         FIG. 3  is a close-up sectional view of the toe guard and its interface with the sole and outer portion of the upper; 
         FIG. 4  is another sectional view of the toe guard, and in particular, its peripheral recess within which a peripheral allowance of the outer portion of the upper is at least partially disposed; 
         FIG. 5  is a rear perspective view of the toe guard; 
         FIG. 6  is a bottom view of the toe guard with the peripheral allowance being installed in the peripheral recess of the toe guard; 
         FIG. 7  is an exploded view showing assembly of the footwear; 
         FIG. 8  is a perspective view of the first alternative embodiment of the footwear including a modified toe guard having an integral shank extending therefrom; and 
         FIG. 9  is a side exploded view of the first alternative embodiment view of the footwear showing assembly of the footwear with the toe guard plus integral shank. 
     
    
    
     DESCRIPTION OF THE CURRENT EMBODIMENTS 
     An article of footwear in accordance with the current embodiment is shown in  FIGS. 1-7  and generally designated  10 . The footwear includes an upper  20  that is joined with a sole  30 . The footwear  10  also includes a protective toe element in the form of a toe guard  50 . 
     The toe guard  50  generally can be cup shaped, and thus also referred to sometimes as a toe cup, to receive the toes WT of the wearer&#39;s foot WF when the wearer&#39;s foot is placed within the internal void  16  of the footwear  10 . The toe guard  50  also can include a bottom wall  50 B that is configured to be placed at least partially under the wearer&#39;s toes WT when the wearer&#39;s foot is placed within the footwear void  16 . The bottom wall  50 B can include an upper surface  50 BU and a lower surface  50 LS opposite the upper surface. The upper surface generally can be configured to face toward the wearer&#39;s toes WT, while the lower surface can face away from the wearer&#39;s toes WT underfoot. The footwear also includes the sole  30 , which can be in the form of a midsole, an outsole, a footbed, or any other sole component and/or cushion element that is configured to be placed underfoot of the wearer in the footwear. The sole is configured to define a recess  30 R in the forefoot region  17 , and more particularly, the recess  30 R can be defined in the toe region  14  of that forefoot region  17  of the footwear  10 . This recess  30 R can be of a depth sufficient so that when the toe guard  50  is placed in the recess  30 R, the upper surface  50 BU of the bottom wall of the toe guard  50  is flush with or otherwise at a common level as the upper surface  30 US of the sole  30 . Optionally, the bottom wall upper surface  50 BU can lay substantially within the same plane P as the upper surface  30 US of the sole  30 . In turn, this can provide a clean and smooth transition between those two surfaces. Accordingly, when a Strobel assembly  70  having a Strobel board  75  is placed such that its toe box  70 TB is within the interior  50 I of the toe guard  50 , the Strobel board  75  lays atop a smooth surface, without any abrupt edges, bridges or underfoot anomalies that may be perceived by the wearer of the footwear. 
     As mentioned above, the toe guard  50  also can define a peripheral recess  50 PR that extends at least partially around an outer perimeter of the toe guard. This peripheral recess can receive therein, as shown in  FIG. 6 , at least a portion of a peripheral allowance  80 PA of an outer portion  80  of the upper  20 . In turn, this can enable the toe guard to be placed lower and at least partially in the sole  30 . 
     Although the current embodiments are illustrated in the context of a working boot or safety shoe, they may be incorporated into any type or style of footwear, including performance shoes, hiking shoes, trail shoes and boots, hiking boots, all-terrain shoes, barefoot running shoes, athletic shoes, running shoes, sneakers, conventional tennis shoes, walking shoes, multisport footwear, casual shoes, dress shoes or any other type of footwear or footwear components. It also should be noted that directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. Further, the terms “medial,” “lateral” and “longitudinal” are used in the manner commonly used in connection with footwear. For example, when used in referring to a side of the shoe, the term “medial” refers to the inward side (that is, the side facing the other shoe) and “lateral” refers to the outward side. When used in referring to a direction, the term “longitudinal direction” refers to a direction generally extending along the length of the shoe between toe and heel, and the term “lateral direction” refers to a direction generally extending across the width of the shoe between the medial and lateral sides of the shoe. The use of directional terms should not be interpreted to limit the invention to any specific orientation. 
     Further, as used herein, the term “arch region” (or arch or midfoot) refers generally to the portion of the footwear or sole assembly corresponding to the arch or midfoot of the wearer&#39;s foot; the term “forefoot region” (or forefoot) refers generally to the portion of the footwear forward of the arch region corresponding to the forefoot (for example, including the ball and the toes) of a wearer&#39;s foot; and the term “heel region” (or heel) refers generally to that portion of the footwear rearward of the arch region corresponding to the heel of the wearer&#39;s foot. The forefoot region  17 , arch region or mid-foot region  18  and heel region  19 , as well as the toe region  14  within the forefoot region  17 , generally are identified in  FIG. 1 . However, it is to be understood that delineation of these regions may vary depending upon the configuration of the sole assembly and/or footwear. 
     As mentioned above, the phalanges and other nearby bones can be broken when impacted by objects dropped on the wearer&#39;s toes from above. Thus, the toe guard  50  herein enhances protection for these bones in the toe region  14 , and more generally, the forefoot region  17 . 
     For purposes of disclosure, the embodiments herein are described in connection with footwear in the form of a work boot  10  having an upper  20 , which as mentioned above, optionally can include a Strobel construction. The upper  20  is joined with the outsole  30 . The joining of the outsole  30  and the upper  20  can be accomplished using adhesives, cement, injection molding, pour molding or any other technique used to join an upper and outsole. As illustrated, the Strobel board or insole board  75  can be positioned immediately adjacent the sole  30 . 
     As shown in  FIGS. 1, 2 and 5 , the upper  20  optionally includes different portions. For example the upper  20  can comprise an exterior portion  80  which covers an interior portion  70 . The exterior portion  80  can be constructed from multiple different panels of a durable wear resistant material, such as leather, rubber, silicone, thermoplastic polyurethane elastomer (TPU), canvas, Kevlar® (a type of para-aramid fiber), plastic and other materials and fabrics. This outer portion  80  can generally extend through the heel region, arch region and forefoot region. A portion of this outer portion  82  also can extend over and adjacent the toe guard  50  and a corresponding toe box  70 TB of the inner portion  70 . The outer portion  80  also can include a peripheral allowance  80 PA that can extend around the lowermost portion of the outer portion  80  of the upper  20 . Generally, this peripheral allowance  80 PA can form a bottom opening  83  which corresponds to the general shape of the sole of the footwear. 
     In most cases, the peripheral allowance and its internal edge  84  can be concealed under a portion of the sole and/or the toe guard as described further below. Further, the peripheral allowance  80 PA, as shown in  FIG. 3 , can be at least partially concealed by flange  32  of the sole  30 . This flange  32  can extend upwardly a preselected distance above the bottom wall  50 B of the toe guard  50 . Optionally this distance D 1  can be approximately 0.25 mm to 25 mm or more, depending on the particular application. 
     Other portions of the sole also can extend upwardly, adjacent the peripheral allowance and/or sidewalls of the exterior portion  80  of the upper. For example, as shown in the heel region  19  of  FIG. 1 , a rearward flange  33  can extend upward, adjacent a sidewall of the exterior portion  80  of the upper for preselected distance similar to that noted above. 
     As mentioned above, the upper  20  also can include an inner portion  70 . This inner portion can be in the form of a liner joined with a board to generally form a Strobel construction. The Strobel construction defines a foot-receiving upper interior  21  and can be closed on its bottom or lowermost portion by a Strobel board, an insole board, sock liner  75  or other similar component. The Strobel board  75  can include an upper surface  75 US and opposing lower side  75 LS. The upper surface  75 US can face upward toward the interior  21  of the footwear. The lower surface  75 LS can face downward toward and can generally contact and/or be secured to the sole  30  with adhesives or other materials. The Strobel board can be a flexible but somewhat rigid piece or sheet of material in the shape of the bottom of a foot that is sewn around its peripheral edges to a second lower peripheral allowance  70 PA of the inner portion  70 . The sewing can be achieved via a stitching  70 S that extends through both the peripheral allowance  70 PA and the outer perimeter edge  75 E of the Strobel board  75 . Although not shown, the footwear  10  can include a footbed and/or other upper components with the footbed fitted into the upper  10 . 
     The sole  30  can be disposed below the upper  20  and any optional midsole included in the sole. The sole  30  can be constructed from one or more materials. The sole  30  can be constructed from rubber and can include lugs, tread, or other gripping elements. Alternatively, it can be constructed from a thermoplastic polyurethane elastomer (TPU), nylon or other polymer blend that includes nylon and/or TPU. Of course, the outsole can be constructed from any relatively wear resistant polymer, elastomer and/or natural or synthetic rubber or other materials capable of providing the desired functional characteristics. Other materials such as fiber-reinforced polymers can be used. These can include epoxy, polyethylene, polyester, thermosetting plastic reinforced with carbon, glass and/or aramid fibers. 
     The footwear  10  of the current embodiment includes the rigid protective toe element or toe guard  50 . This element can be a steel toe, but of course can be constructed from other materials. For example, it can be constructed from rigid polymeric materials and/or composites of sufficient thickness to deflect forces and/or loads from objects dropped on the toe. The rigid toe guard  50  can be configured to extend throughout the toe region  14  of the wearer&#39;s foot generally extending rearwardly toward the heel region  19  of the foot, but located substantially within the forefoot region  17  ( FIG. 1 ) of the footwear  10 . 
     With reference to  FIGS. 3-5 , the toe guard  50  will now be described in further detail. As mentioned above, the toe guard  50  includes an interior  50 I within which the wearer&#39;s toes WT can be disposed as the footwear is in use. The toe guard  50  generally can include multiple walls that face inwardly toward the interior  50 I. These walls can include the bottom wall  50 B as mentioned above, a sidewall  50 SW and an upper or top wall  50 T. The sidewall  50 SW can extend upwardly from the bottom wall  50 B and joined that bottom wall with the upper wall  50 T. The upper wall  50 T generally extends across the uppermost extremities of the wearer&#39;s toes WT when the footwear is worn. The upper wall  50 T and sidewall  50 SW can form an arch over the toes when extending from the lateral side to the medial side. The sidewall  50 SW, upper wall  50 T and lower wall  50 B can form a cup-shaped opening which corresponds to the interior  50 I of the toe guard  50 . The sidewall  50 SW also can extend forwardly to an apex  50 SWA which can be the forward most portion of the toe guard  50 T. This apex can be a portion of the sidewall  50 SW that is rounded and extends rearward to the rearward edges  50 SWR on opposite sides of the toe guard  50 . These sidewall rearward edges  50 SWR can be tapered, or can terminate at a squared off edge. 
     The upper wall  50 T, as mentioned above, can be partially rounded and can be joined with the top of the sidewall  50 SW. The upper wall  50 T also can include a rearward edge  50 TR that joins with the rearward edges  50 SWR of the sidewalls. All of these edges can lie in a common plane. 
     As shown in  FIGS. 3-6 , the toe guard also includes the bottom wall  50 B. As mentioned above, this bottom wall can include a bottom wall upper surface  50 BU and a bottom wall lower surface  50 LS. These bottom wall upper and lower surfaces can terminate at a rearward edge  50 BR of the bottom wall. This bottom wall rearward edge  50 BR can be in a common plane with the sidewall edges  50 SWR. The rearward edge  50 BR also can be constructed so that it extends generally vertically when the toe guard is included in the footwear. The upper surface  50 BU can transition to the rearward edge  50 BR at a rounded or angled corner  50 BCU. Likewise, the bottom wall lower surface SOLS can transition to the rearward edge  50 BR at a rounded or angled corner  50 BLU. The upper surface and lower surface of the bottom wall can be separated by a vertical distance or thickness D 3 , which can be about 0.1 mm to about 10 mm, more or less, depending on the particular application. Generally, the rearward edge  50 BR can be optionally void of any tapers so that the upper and lower surfaces are joined at a point or along a line. Optionally, there can be separation between the upper and lower surfaces so that the rearward edge  50 BR has some thickness D 3  where it terminates. 
     The rearward edge  50 BR and the bottom wall also can define a void  50 V. This void can be configured so that when a crushing, impact force F is applied to the top surface  50 T of the toe guard, it translates to the sidewalls  50 T and ultimately the bottom wall  50 B, without the bottom wall  50 B buckling or otherwise collapsing upward to further pinch the wearer&#39;s toes between the bottom wall and the upper wall of the toe guard. In some cases, the void  50 V can be structured to enable the bottom wall to fracture slightly and/or dissipate force into the underlying sole  30 . 
     Optionally, the bottom wall rearward edge  50 BR includes a linear portion that transitions to a curved portion  50 C adjacent the void  50 V. That curved portion  50 C transitions back to another linear portion  50 L of the rearward edge  50 BR. Although the void  50 V is shown including a curved peripheral edge  50 VE, that edge can include multiple compound angled, linear walls that join one another to form a generally rounded void. Further, the void  50 V can, as shown in  FIG. 6 , form an apex  50 VA at its forwardmost portion. That apex  50 VA can lay on a common centerline CL of the footwear. In addition, the sidewall apex  50 SWRA of the toe guard  50  also can lay on that common centerline. If desired, the void  50 V can comprise less than 70% of the bottom wall upper surface  50 BU. In other applications, the void  50 V can comprise optionally less than 60%, further optionally less than 50%, even further optionally less than 40%, yet further optionally less than 30%, further optionally less than 20%, and yet further optionally less than 10% of the area of the upper surface  50 BU of the bottom wall  50 B. Although shown as a parabolic or rounded void  50 V, the void can be in the shape of a triangle or a partial polygon depending on the particular application. 
     The toe guard  50 , as mentioned above also can include a peripheral recess  50 PR. This peripheral recess  50 PR as illustrated in  FIGS. 3-7 , can extend from the rearward edge  50 BR of the bottom wall  50 B on a first or medial side of the toe guard all the way to the rearward edge  50 BR on a second or lateral side of the toe guard. This recess  50 PR can include and be defined by a shoulder  50 PRS that intersects a shelf  50 PS. The shelf  50 PS can extend generally outwardly away from the centerline CL of the toe guard. The shelf  50 PS also can be substantially parallel to the upper surface  50 BU and/or the lower surface SOLS of the bottom wall. The shelf can transition to the shoulder  50 PRS at a distance D 4  away from the sidewall  50 SW as shown in  FIG. 6 . This distance D 4  can be optionally at least 0.1 mm, further optionally at least 0.25 mm, even further optionally 1 mm, yet further optionally at least 2 mm, still further optionally at least 3 mm, yet further optionally at least 4 mm, still further optionally 5 or 10, 20 or more millimeters depending on the thickness of the peripheral allowance  80 PA that fits into and is housed within at least a portion of that peripheral recess  50 PR. The shoulder  50 PRS can transition to the bottom surface  50 LS of the bottom wall  50 B. 
     Optionally, the rearward edge can be substantially perpendicular to the bottom wall upper surface  50 BU, as well as the bottom wall lower surface SOLS. Further, the shoulder  50 PRS can be substantially perpendicular to the shelf SOPS and the lower surface SOLS. In some cases, the lower surface SOLS can be separated from the shelf SOPS by distance D 5  as shown in  FIG. 6 . This distance D 5  can be equal to or greater than the thickness T 2  of the peripheral allowance  80 PA. This can enable the peripheral allowance to nest within the peripheral recess  50 PR. The lowermost surface of the peripheral allowance  80 PA also can be flush with or raised relative to the lower surface SOLS. In the completed footwear, this enables the lower surface SOLS of the toe guard  50  to substantially lay the same plane as the exterior surface of the peripheral allowance  50 PA. 
     Although shown as extending around the toe guard adjacent the sidewall  50 SW, the peripheral recess  50 PR optionally can extend in different proportions around the toe guard  50 . For example, the peripheral recess  50 PR can extend only on the lateral and medial sides of the toe guard. In other cases, the peripheral recess may extend rearward from the apex a preselected distance from that apex, and not reach the rearward edge  50 BR of the toe guard  50 . 
       FIGS. 4 and 6  illustrate the fitment of the peripheral allowance  80 PA of the exterior portion  80 , and the bottom wall  50 B of the toe guard  50 . As shown there, the peripheral allowance is nested within the peripheral recess  50 PR of the bottom wall. The thickness T 2  of the peripheral allowance  80 PA can be less than or equal to the distance D 5  of the depth of the peripheral recess  50 PR. Accordingly, when the sole upper surface  30 US is adhered to the lower surface SOLS of the bottom wall, the peripheral allowance  50 PA nests in the recess, and does not produce a bump or abrupt transition along that lower surface SOLS of the bottom wall. In this manner, that peripheral allowance  50 PA is tucked into and neatly joined with the bottom wall in the peripheral recess  50 PR. Optionally, this peripheral allowance  80 PA can be glued, cemented, riveted, fastened, stapled or otherwise joined to the shelf SOPS and/or the shoulder  50 PRS associated with the peripheral recess  50 PR. The sole upper surface  30 US likewise can be cemented, adhered, molded or otherwise joined with the lower surface SOLS of the bottom wall and adjacent the peripheral allowance  80 PA. As shown in  FIG. 4  as well, the sole can include a phalange  32  that extends upwardly along the sides of the exterior portion  80  and above the peripheral allowance  80 PA a preselected distance. Again, this preselected distance can vary depending on the desired protection along the front, sides or rear of the footwear, whenever the flange is located. 
     Further optionally, as shown in  FIG. 5 , the bottom wall  50 B can have varying thicknesses. For example, between the bottom wall upper surface  50 BU and the bottom wall lower surface  50 LS, the bottom wall can be of a thickness D 3  and a second thickness D 6 . The thickness D 3  can be greater than the thickness D 6 , due to the recess  50 PR defined in the bottom wall in the area or region of the thickness D 6 . In some cases, the thickness D 3  can be the same as the thickness D 6 , but in those cases, the upper surface  50 BU can include an upper recess, inward from the shoulder  50 PRS of the peripheral recess. In this case, the central region of the upper surface  50 BU can be sunken within the toe guard. 
     As mentioned above, the toe guard  50  is configured to nest or be disposed at least partially within the recess  30 R defined by the sole  30 . As shown in  FIGS. 3 and 7 , the sole defines the recess  30 R in a forefoot portion  17 , in particular in the toe region  14 , of the footwear. This recess  30 R can extend downward from the upper surface  30 US of the sole  30 . The recess can be disposed rearwardly a distance from the flange  32 . The recess can include an arcuate forward wall  30 F that extends from a medial side of the footwear to the lateral side of the footwear, generally in the toe region  14 . This curved wall can transition to a generally planar and/or linear rearward wall  30 B. This wall can extend laterally from the medial side of the footwear to the lateral side of the footwear generally crossing a centerline or central longitudinal axis CL of the footwear. Optionally the recess  30 R can be of a depth D 7 , which extends downwardly from the upper surface  30 US of the sole to a bottom wall  30 L. The depth D 7  of the recess  30 R can be substantially continuous around the front wall  30 F and the rearward wall  30 B. Of course, in some cases, the depth D 7  can vary depending on the profile of the bottom wall  50 B or the overall height of the toe guard  50 . Optionally, the depth D 7  also can be greater than or equal to the thickness D 3  of the bottom wall. In some cases, the depth D 7  also can be greater than the thickness D 6  of the bottom wall as shown in  FIG. 5 . Generally, with the thickness of the bottom wall  50 B being less than or equal to the depth D 7  of the recess  30 R, defined by the sole, when the toe guard  50  and its bottom wall are placed at least partially in the recess  30 R, the upper surface  50 BU of the bottom wall  50 B can be flush with and in a common plane P with the upper surface  30 US of the sole  30 . 
     When the toe guard is assembled relative to the sole, as shown in  FIG. 3 , the rearward edge  50 BR is adjacent and optionally abuts the back wall  30 B of the recess  30 R. Indeed, in some cases, this abutment and contact between the rearward edge and the back wall can operate as an indexing feature to ensure that the toe guard is properly aligned relative to the remainder of the footwear. Although not shown, in some applications, the back wall  30 B optionally can include a protrusion that extends into the recess  30 R and corresponds to the void  50 V. If this protrusion is included, it can further assist in indexing the and aligning the toe guard with the sole  30 . 
     Optionally, as shown in  FIG. 7 , the upper surface  30 US of the sole  30  can define lateral and medial recesses  30 LR and  30 MR. These recesses can be in communication with and open into the recess  30 R. These recesses can be configured to ramp upward or become a shallower depth transitioning from the recess  30 R rearward toward the heel region. These recesses can be sized to receive at least a portion of the peripheral allowance  80 PA of the exterior portion of the upper. The peripheral allowance can be nested within those lateral and medial recesses to provide a further lower profile to the toe guard and portion of the upper in the forefoot. Although not shown, the lateral and medial recesses can extend rearwardly all the way around the periphery of the sole upper surface  30 US. In turn, this can provide further concealment and nesting of the peripheral allowance in those recesses which can also assist in further lowering the profile of the footwear in the rearward and heel regions. In some cases, these lateral and medial recesses can intersect the rear wall  30 B a location and can be of the same depth D 7  as the recess  30 R itself. In other cases, these lateral and medial recesses can be certain proportions of the depth D 7  of the recess  30 R, depending on the application and the configuration of and thickness of the peripheral allowance. 
     As shown in  FIG. 7 , the recess  30 R defined in the upper surface  30 US of the sole  30  can be positioned inward from the flange  32  a distance D 9 . The recess and its front wall  30 F also can be set inward relative to the exterior sidewall  30 SW of the sole  30  by distance D 8 . These distances, D 8  and D 9 , can be equal to one another. In other cases, the distances can be different from one another, with one greater or lesser than the other. 
     The current embodiment of footwear  10  with its protective toe guard  10  also lends itself well to quick, easy assembly. With reference to  FIG. 7 , the footwear  10  can be assembled as follows. The exterior portion  80  of the upper  20  can be constructed. Various pieces of material, such as leather, canvas, and other materials can be joined together to form that component. Generally, the bottom of the exterior portion  80  includes an opening  83  which is surrounded at least partially by peripheral allowance  80 PA. An internal boot or liner, optionally in the form of the inner portion  70  can be constructed. This construction can be made by joining the inner portion  70  along its peripheral allowance  70 PA with an edge  75 E of a Strobel board  75  using stitching  70 S. This interior portion  70  can be secured to the exterior portion  80  via stitching, cement, fasteners or other attachment mechanisms. 
     The inner portion and exterior portion can be installed on a last (not shown). With the Strobel construction of the interior portion  70  on the last, the exterior portion  80  can be moved upward slightly so as to expose the toe box  70 TB of the interior portion  70 . In some cases, the toe portion  82  can be rolled back up over the instep of the last with the exterior portion in this position, a technician can then push the toe guard  50  onto the toe box  70 TB of the interior portion  70 . In turn, the toe box  70 TB inserts into and is surrounded within the interior  50 I of the toe guard  50 . Optionally, cement can be applied to the Strobel board  75  in the region of the toe box  70 TB before this installation, so the Strobel board can readily join with the upper surface of the bottom wall  50 BU. 
     When the Strobel board sits within the protective toe  50  as shown in  FIG. 3 , Strobel board can contact and be placed first distance D 10  from the sole  30  rearward of the toe guard  50 . Forward of the rearward edge  50 BR of the bottom wall  50 , however, the lower surface  75 LS of the Strobel board  75  can be placed a second distance D 11  from the sole  30 . This distance D 11  is greater than the distance D 10  and different therefrom. Optionally, the distance D 10  can be about 0.0 to about 0.5 mm, while the distance D 11  can be substantially equal to the depth D 3  of the bottom wall as described above. Further optionally, in this construction, the Strobel board  75  can be spaced different distances from the sole in different regions of the footwear. As an example, in the toe region, the Strobel board and its lower surface  75 LS can be placed at a greater distance from the sole  30  in the arch region or heal region of the footwear, where the Strobel board can directly contact and be at an effective zero distance from the sole. 
     With the toe guard  50  installed in the toe box  70 TB, the inner portion  70  and the outer portion  80  can be manipulated so that the peripheral allowance  80 PA is brought downward and extends around the bottom portion of the upper  20 . For example, as shown in  FIG. 6 , the peripheral allowance  80 PA is installed in direction I around the toe guard  50 . The peripheral allowance itself is placed within the peripheral recess  50 PR of the toe guard  50 . This peripheral allowance  80 PA is stretched over this region so that it is placed adjacent the support shell  50 S. Optionally the interior edge  80 PAE is pushed inward so that it abuts against the shoulder  50 PRS of the toe guard  50 . Optionally, this peripheral allowance can be cemented, glued or otherwise tacked or fastened to the toe guard here. The peripheral allowance rearward of the toe box also can be folded inward against the lower peripheral allowance  70 PA of the inner portion  70 . That peripheral allowance  80 PA also can be sewn, glued or otherwise attached to the Strobel board  75 , and in particular, its bottom surface along the edge  75 E. In turn, this can complete the construction of the upper  20 . 
     With the upper so constructed, it may be joined with the sole  30 . To do so, as shown in  FIG. 7 , the Strobel board  75  is placed against the upper surface  30 US of the sole, generally between the flanges  32  and  33  in the toe and heel portions of the footwear. The bottom wall  50 B is also placed within the recess  30 R. In so doing, the lower surface SOLS of the bottom wall engages the bottom surface  30 L of the recess  30 R in rests within it. The rearward edge  50 PR is placed adjacent the rearward wall  30 B of the recess  30 R. In some cases, it can abut and/or be placed immediately adjacent and in contact with that wall. Optionally, cement can be placed in the recess  30 R and over the upper surface  30 US of the sole  30  before placing these items adjacent one another. 
     As shown in  FIGS. 3 and 4 , the flange  32  of the sole can be placed immediately adjacent the forward portion of the toe guard  50  and can conceal the peripheral allowance  80 PA of the outer portion  80  of the upper  20 . Where the lateral and medial recesses or channels  30 LR and  30 MR are present, the peripheral allowance  80 PA of the exterior portion also can be disposed within those voids. 
     The recess  30 R enables the bottom wall  50 B, and in particular, the bottom wall upper surface  50 BU to be leveled with and substantially within a common plane P with the upper surface  30 US of the sole. This in turn enables the Strobel board  75  to be substantially flat and featureless, without any abrupt or noticeable or perceivable edges or ridges underfoot in the region of transition between the bottom wall in the upper surface of the sole. Due to the recess and inner fitment of the toe guard at least partially within the recess, the overall profile in height of the toe guard top wall  50 T above the upper surface  30 US of the sole  30  is diminished when compared to conventional steel toes that are simply placed atop the upper surface of a sole. 
     A first alternative embodiment of the footwear is illustrated in  FIGS. 8 and 9  and generally designated  110 . This embodiment is similar to the above embodiment in function, structure and operation with several exceptions. For example, the toe guard  150  can include a bottom wall  150 B. The bottom wall  150 B also can define a peripheral recess  150 PR. This peripheral recess can conceal and fit within it the peripheral allowance  180 PA similar to the embodiment above. In addition, the toe guard  150  can include a rearwardly extending integral shank  150 S. The shank  150 S can extend a distance D 12  rearward from the rearward edge  150 BR of the bottom wall  150 B. This distance D 12  can vary depending on the application, but it generally extends sufficiently so that the shank  150 S extends into the arch region  118  of the footwear, so that it can be supported under an arch of the wearer in the finished footwear  110 . Optionally, the shank  150  can extend rearward about 5 mm to about 45 mm, further optionally about 8 mm to about 25 mm, and even further optionally about 10 mm to about 20 mm rearward from the rearward edge  150 BR. The shank can be of a width W 2  that is less than the width W 1  of the toe guard  150  as shown in  FIG. 8 . The shank also can be of a thickness T 6  that is less than the thickness or depth D 3  of the bottom wall of the toe guard. Optionally, the shank can be narrower than and thinner than the bottom wall  50 B of the toe guard in some applications. Of course, this can vary depending on the intended use. The shank and bottom wall can define the void  150 V. This void can extend rearward into the forward portion of the shank  150 S as shown. This can lighten the overall weight of the chain and toe guard combination. Additional holes and voids can be defined elsewhere in the shank  150 S depending on the application. 
     Referring to  FIG. 9 , the sole  130 , and in particular the recess  130 , are defined in the upper surface  130 US of the sole and can be modified to accommodate the shank  150 S. For example as illustrated, the upper surface  130 US can define a shank recess  130 SR that extends rearwardly from the toe guard recess  130 R. This shank recess can be of a depth D 13  that is less than or equal to the depth T 6  in some applications. When assembled, the shank  150 S is placed within the recess  130 SR. The upper surface of the shank  150 US generally can be parallel and/or flush with the upper surface  130 US of the sole  130 . In this manner, the rigid components of the toe guard and the shank can be below the upper surface  130 US of the sole and flush with that same surface. Again, this can reduce and/or eliminate the perception of the these components under the Strobel board to a wearer of the footwear  10 . 
     Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s). 
     The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.