Boots With Gusset

Abstract

A boot comprises: an outsole and a polymeric upper affixed to the outsole. The upper comprises an upper body and a gusset, which comprises a relaxed position and an expanded position, wherein the gusset moves from the relaxed position to the expanded position to accommodate a wearer's leg upon donning of the boot.

What is claimed is: 
     
         1 . A boot comprising:
 an outsole; and   an upper affixed to the outsole, the upper comprising polymeric upper body and a polymeric gusset comprising a relaxed position and an expanded position, wherein the gusset moves from the relaxed position to the expanded position to accommodate a wearer's leg upon donning of the boot.   
     
     
         2 . The boot of  claim 1 , wherein the gusset comprises one or more pleats. 
     
     
         3 . The boot of  claim 1 , wherein the gusset is integral to the upper body. 
     
     
         4 . The boot of  claim 1 , wherein the gusset is affixed to the upper body. 
     
     
         5 . The boot of  claim 1 , wherein the gusset is self-supporting. 
     
     
         6 . The boot  claim 1 , wherein the gusset is effective to expand a top area of the boot. 
     
     
         7 . The boot of  claim 1 , wherein the gusset in an expanded position upon accommodating a wear's leg expands an edge of the upper body at least one inch. 
     
     
         8 . The boot of  claim 1 , wherein the polymeric upper comprises a thermoplastic polymer. 
     
     
         9 . The boot of  claim 1 , wherein the upper body and the gusset independently comprise a thermoplastic polymer selected from the group consisting of rubber, thermoplastic polyurethane, and polyvinyl chloride. 
     
     
         10 . The boot of  claim 1 , wherein the outsole is polymeric. 
     
     
         11 . The boot of  claim 1 , wherein the outsole comprises one or more integrally-formed features selected from the group consisting of: a toe, a heel, a heel strike, and cleats. 
     
     
         12 . The boot of  claim 1  in the form of a knee boot. 
     
     
         13 . The boot of  claim 1  that is liquid-proof. 
     
     
         14 . A liquid protection knee boot comprising:
 an outsole of a first polymeric material; and   an upper of a second polymeric material, the upper being affixed to the outsole and comprising an upper body, a topline opening defined by an edge of the upper body, and a gusset intersecting the edge of the upper body;   wherein the gusset is effective to expand the edge from a relaxed position to an expanded position to accommodate a wearer's leg upon donning of the boot.   
     
     
         15 . The liquid protection boot of  claim 14 , wherein the gusset comprises one or more pleats. 
     
     
         16 . The liquid protection boot of  claim 14 , wherein the outsole, the upper body, and the gusset independently comprise a thermoplastic polymer selected from the group consisting of rubber, thermoplastic polyurethane, and polyvinyl chloride. 
     
     
         17 . A method of making a boot comprising:
 forming an outsole by injecting a first polymeric material into a first mold cavity;   forming a gusset by injection molding a second polymeric material;   forming an upper body by injecting a third polymeric material into a second mold cavity;   forming an upper comprising the gusset and the upper body; and   affixing the upper to the outsole.   
     
     
         18 . The method of  claim 17 , wherein the second mold cavity comprises one or more surfaces for forming the gusset integrally with the upper body to form the upper, and the second and third polymeric materials are the same. 
     
     
         19 . The method of  claim 17 , the gusset is pre-fabricated in a third mold cavity separate from the second mold cavity, wherein forming the upper comprises injecting the second polymeric material of the upper body around the gusset that is held in the second mold cavity. 
     
     
         20 . The method of  claim 17 , the gusset is pre-fabricated in a third mold cavity separate from the second mold cavity, wherein forming the upper comprises gluing the gusset to the upper body. 
     
     
         21 . A method of providing comfortable boots to wearers, the method comprising:
 donning the boot of one of  claim 1 ; and   expanding the gusset as needed to accommodate the wearer's leg.