A method of constructing footwear includes providing a mold having an inner cavity, injecting an expandable material into the inner cavity, removing the expandable material from the inner cavity such that the material expands to form a footwear-shaped shell having an inner cavity and at least one recessed area offset from an inner surface of the shell, and inserting a chassis within the inner cavity of the expanded shell. The chassis has one or more components adapted to protect a user's foot from injury. The insertion of the chassis within the shell permanently affixes the one or more components within the at least one recessed area of the shell.

A goalie skate assembly has i) a plastic blade mounting member adapted to releasably receive a metal skate blade therein, and ii) a monocoque carbon fiber and resin composite skate boot body for receiving a foot of the user therein. The unitary structure of the skate boot body includes i) a sole portion, ii) a heel portion extending upwardly from the sole portion for receiving a heel of the user therein, iii) a pair of side portions extending upwardly from opposing sides of the sole portion, and iv) a lower portion extending downwardly from a bottom side of the sole portion so as to surround at least a portion of the blade mounting member. A toe cap mounted on the skate boot body includes a molded plastic outer shell and a liner formed of a fiber and resin composite material bonded to an inner surface of the outer shell.

A method of forming an upper for an article of footwear includes providing a first material layer over a shoe last, providing a second material layer over the first material layer such that the first and second material layers adhere to each other at an interface between the first and second material layers, where one or both of the first material layer and second material layer is provided by spray forming a polymer material onto the last. The material layers are removed from the last and turned inside out such that the first material layer includes an exposed surface that forms an exterior surface of the upper.

A microcellular shoe stiffener has at least one adhesive layer coextruded with and carried on a stiffener core. A liquid, such as liquid nitrogen, is introduced into the extruder for the stiffener core to produce a closed cell foam with a gaseous component. The gas reduces the weight and cost of the stiffener with out significantly reducing stiffness and resiliency.

A work shoe, in particular a safety shoe, includes at least one passive protection unit which is intended to passively protect a shoe wearer at least against mechanical and/or electrical loads, and includes at least one active protection unit which has at least one sensor unit which is intended to detect at least one characteristic variable at least in order to enable a protection function and/or a comfort function. The sensor unit is configured at least for detecting at least one person-related characteristic variable and/or at least one environmental characteristic variable.

The present invention is related to a composite laminated structure for shoe stiffeners and preparing method thereof. The composite laminated structure comprises: a fabric core layer, and a hot-melt-adhesive layer covering and interpenetrating the fabric core layer, wherein the fabric core layer comprises a fabric having a fabric count of about 61 to 13 wpi and about 60 to 30 fpi and a weight more than or equal to 100 g/m.sup.2. Preparing methods for said composite laminated structure are very simple processes. With the fabric core layer, proper performances could be achieved with simple hot-melt-adhesives. High level of cheap fillers, such as recycled materials, inorganic fillers or the mixture thereof, could be added while still maintaining excellent split tear strength, resilience and bending stiffness. Thus, the use of virgin materials and the overall cost could be greatly reduced for shoe stiffeners.

A footwear system is disclosed, which includes a shell having an inner cavity and at least one recessed area offset from an inner surface of the shell, and a chassis having one or more components adapted to protect a user's foot from injury. In one embodiment, the chassis is insertable into the inner cavity of the shell, such that the one or more components of the chassis are securely retained (e.g., permanently affixed) within the at least one recessed area of the shell. Methods of forming the aforementioned footwear system using expandable materials are also disclosed.

A ballet pointe shoe has an upper in which a shank insert and/or an elastic loop can removably and replaceably installed without even partial deconstruction of the ballet pointe shoe. Embodiments may have an upper including a tunnel which may extend beneath a toe box, the tunnel having a mouth which is accessible via the foot compartment and by way of which a shank insert can be installed, removed or replaced. In some embodiments an elastic loop may be routed under a portion of the shank insert extending from the mouth of the tunnel. In some embodiments the tunnel may penetrate a shank body under which an elastic loop may be routed. A shank insert and/or elastic loop may be selected from sets of ones having different characteristics. In some embodiments the toe box and shank body may be included in a monolithic foot supporting structure. In some embodiments a shank insert and/or toe box may be reshaped at any time.

Bodywear apparatus configured to be worn by a human user and attachable to footwear of the human user in order to augment the abilities of the lower limbs of the user is disclosed. In another aspect, footwear apparatus configured to be worn by a human user in order to augment the abilities of the lower limbs of the user is disclosed. Such bodywear apparatus and footwear apparatus are configured to reduce the effort a user must exert and improve the user's performance during walking, running, hiking, marching, and various other gaits as well as jumping, hopping, and other activities. In an aspect, bodywear apparatus further includes a supplemental power device configured to further augment the user's abilities by activating during portions of the user's gait cycle.

Bodywear apparatus configured to be worn by a human user and attachable to footwear of the human user in order to augment the abilities of the lower limbs of the user is disclosed. In another aspect, footwear apparatus configured to be worn by a human user in order to augment the abilities of the lower limbs of the user is disclosed. Such bodywear apparatus and footwear apparatus are configured to reduce the effort a user must exert and improve the user's performance during walking, running, hiking, marching, and various other gaits as well as jumping, hopping, and other activities. In an aspect, bodywear apparatus further comprises a supplemental power device configured to further augment the user's abilities by activating during portions of the user's gait cycle.