U.S. patent application number 09/730398 was filed with the patent office on 2002-06-06 for waterproof shoe.
This patent application is currently assigned to Sympatex Technologies GmbH. Invention is credited to Haderlein, Manfred, Keidel, Karsten, Mulcahy, John J., Pavelescu, Liviu, Van De Ven, Harry.
Application Number | 20020066212 09/730398 |
Document ID | / |
Family ID | 24935170 |
Filed Date | 2002-06-06 |
United States Patent
Application |
20020066212 |
Kind Code |
A1 |
Pavelescu, Liviu ; et
al. |
June 6, 2002 |
Waterproof shoe
Abstract
A waterproof, water vapor permeable shoe having a waterproof,
water vapor permeable functional layer, an upper, and a lining. The
functional layer may be made from a dispersion of a waterproof,
water vapor polymer. The functional layer may only be attached to
the lining at the top opening of the shoe. A method of making a
waterproof, water vapor permeable shoe by forming a waterproof,
water vapor permeable functional layer from a dispersion of a
waterproof, water vapor permeable polymer and then attaching the
functional layer to the lining of the top opening of the shoe.
Inventors: |
Pavelescu, Liviu;
(Wuppertal, DE) ; Keidel, Karsten; (Wuppertal,
DE) ; Haderlein, Manfred; (Haan, DE) ; Van De
Ven, Harry; (Arnhem, NL) ; Mulcahy, John J.;
(Rochester, NH) |
Correspondence
Address: |
OLIFF & BERRIDGE, PLC
P.O. BOX 19928
ALEXANDRIA
VA
22320
US
|
Assignee: |
Sympatex Technologies GmbH
|
Family ID: |
24935170 |
Appl. No.: |
09/730398 |
Filed: |
December 6, 2000 |
Current U.S.
Class: |
36/55 ;
36/45 |
Current CPC
Class: |
A43B 7/125 20130101;
A43B 9/02 20130101 |
Class at
Publication: |
36/55 ;
36/45 |
International
Class: |
A43B 023/00 |
Claims
What is claimed is:
1. A waterproof, water vapor permeable shoe construction
comprising: a waterproof, water vapor permeable functional layer;
an upper; and a lining; wherein the waterproof, water vapor
permeable functional layer is situated between the upper and the
lining and is attached to the lining only at a top portion of the
upper at an opening of the shoe construction where a foot would
enter.
2. The waterproof, water vapor permeable shoe construction of claim
1, wherein the upper is folded over the functional layer and lining
at the top portion of the upper to form the attachment between the
functional layer of the lining.
3. The waterproof, water vapor permeable shoe construction of claim
1, further comprising a sole.
4. The waterproof, water vapor permeable shoe construction of claim
3, wherein the sole is attached to the functional layer and the
upper.
5. The waterproof, water vapor permeable shoe construction of claim
3, wherein the outer perimeter of the sole is sewn to the
functional layer and the dispersion or solution of the waterproof,
water vapor permeable polymer is reapplied to the sewn portions of
the functional layer.
6. The waterproof, water vapor permeable shoe construction of claim
3, wherein the sole is injection molded and the functional layer is
bonded to the sole.
7. The waterproof, water vapor permeable shoe construction of claim
1, wherein an opening, having cut ends, is cut in the bottom of the
functional layer and a seam is formed joining the cut ends of the
opening.
8. The waterproof, water vapor permeable shoe construction of claim
7, wherein portions of the functional layer at the cut ends are
removed before the seam is formed joining the cut ends.
9. The waterproof, water vapor permeable shoe construction of claim
1, wherein the bottom of the functional layer is removed and an
insole is joined to the functional layer.
10. A method of manufacturing a waterproof, water vapor permeable
shoe, comprising: forming a waterproof, water vapor permeable
functional layer in the shape of a sock from a dispersion or
solution of a waterproof, water vapor permeable polymer; inserting
the waterproof, water vapor permeable functional layer into an
interior of a shoe; inserting a lining into the waterproof, water
vapor permeable functional layer; and attaching the waterproof,
water vapor permeable functional layer to the lining only at the
top opening of the shoe.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention relates to a waterproof shoe constructed from
a waterproof, water vapor permeable layer.
[0003] 2. Description of Related Art
[0004] Shoes made from waterproof, water vapor permeable materials
are well known. Waterproof, water vapor permeable shoes may be
manufactured using a variety of materials and processes. Typically,
waterproof, water vapor permeable shoes are manufactured using a
laminate material to impart waterproof, water vapor permeable
characteristics to the shoe. The laminate material is often used in
conjunction with other materials, well known in the art, that
provide the exterior portions (such as, for example, the upper or
the sole) and interior portions of the shoe (such as, for example
the lining). The laminate material used to impart waterproof, water
vapor permeable properties to the shoe is typically made from a
functional layer, which imparts the waterproof, water vapor
permeable characteristics, and at least one more layer of other
materials or textiles.
[0005] The construction of waterproof, water vapor permeable shoes
from a laminate material is very expensive and labor intensive, as
nearly every seam that is sewn in the process of making the shoe
must be resealed to attempt to maintain a waterproof, water vapor
permeable shoe.
[0006] Various types of waterproof, water vapor permeable shoe
designs are known. A first common method is to simply construct the
shoe from known materials in conjunction with waterproof, water
vapor permeable materials (i.e., a waterproof, water vapor
permeable laminate) and perform the aforementioned requisite seam
sealing using a seam sealing tape, glue or other process to
maintain a waterproof shoe design. A second common method to
manufacture waterproof, water vapor permeable shoes is to
manufacture a waterproof, water vapor permeable sock-like liner
which is subsequently inserted and attached to the remainder of the
shoe. The three dimensional sock-like liners are manufactured from
a waterproof, water vapor permeable laminate and require extensive
sewing to create a three dimensional sock-like liner out of a flat
sheet of the laminate. Every seam that is sewn to create the
sock-like liner must be resealed to attempt to the maintain
waterproof, water vapor permeable characteristics of the shoe.
[0007] A waterproof, water vapor permeable laminate may be
manufactured by gluing together at least two layers, for example, a
functional layer and a second layer made from a textile fabric or
other material. The functional layer is typically the waterproof,
water vapor permeable layer. The second or subsequent layers are
generally water vapor permeable and not waterproof. At the areas
where glue is located between the functional layer and second
layer, the glue hinders the water vapor permeability of the
laminate. Therefore, in the manufacture of laminates, efforts have
focused on gluing the functional layer and the second layer
together only at points necessary to maintain the integrity of the
laminate. However, significant areas still remain where glue covers
the functional layer, and at these points, the functionality of
water vapor permeability is reduced or eliminated.
[0008] It is often difficult to guarantee waterproofing and water
vapor permeability in either of these type of shoe designs, even
when the seams have been resealed, because every seam which is sewn
into the laminate can transport water to the inside of the shoe via
capillary action. Furthermore, the use of sealant often detracts
from the waterproof, water vapor permeable design of the shoe
because the sealant, such as tape or glue, is not typically
waterproof, water vapor permeable. Portions of the shoe in which
sealant are applied typically lose their waterproof, water vapor
permeable properties.
[0009] Using either of these above-described methods to manufacture
waterproof, water vapor permeable shoes also requires that
different sized liners be manufactured to obtain different sized
shoes. Requiring a different sized liner for different sized shoes
increases production costs.
[0010] There are illustrated in WO 95/30793 waterproof, breathable,
flexible, seamless shaped articles made from a first layer of a
microporous, elastomeric, thermoplastic polyester polyurethane or
polyether polyurethane that is water vapor permeable and a second
layer of a hydrophilic, continuous non-porous polymer layer that is
waterproof and water vapor permeable.
[0011] There is illustrated in EP 0 665 259 A1 a process for
manufacturing waterproof, water vapor permeable three dimensional
articles made by treating a 3-dimensional mold with an aqueous
dispersion of a copolyether ester at least once in a manner,
analogous to that employed for a latex dispersion in the rubber
industry, followed by heating to obtain a film.
[0012] There is illustrated in U.S. Pat. No. Re. 34,890 a shoe
construction comprising a sole, an upper and a separate sock-like
liner comprised of a laminate of at least three layers. The liner
may be secured by stitching and thereafter covered with tape and a
thermoplastic resin adhesive. Heat and pressure are then applied to
the seam of the liner covered with tape and adhesive. This process
waterproofs the stitching of the seam of the liner. The seams of
this invention may also be formed without stitching instead using
electro-disealing and adhesives.
[0013] As described above, there is still a need for a waterproof,
water vapor permeable shoe design that overcomes the
above-described obstacles.
SUMMARY OF THE INVENTION
[0014] It is an object of the invention to provide for a
waterproof, water vapor permeable shoe design that avoids problems
of laminated layers and reduces the necessity to seal the seams in
the waterproof, water vapor permeable portions of the shoe.
[0015] It is a further object of the invention to provide a more
economical and efficient waterproof, water vapor permeable shoe
design by reducing the necessity for various sized liners and for a
reduction in the time spent in the process of manufacturing the
liner.
[0016] These and other objects of the present invention are
achieved herein. In the invention, a waterproof, water vapor
permeable shoe is manufactured from the incorporation of a
waterproof, water vapor permeable functional layer into the shoe
design. The sock-like functional layer is not attached to the liner
except at the top opening of the shoe, i.e., the upper portion of
the upper. The sock-like functional layer is separate from the
lining and the upper and is not a laminate. The waterproof, water
vapor permeable functional layer may be formed from a solution or a
dispersion of a waterproof, water vapor permeable polymer.
[0017] The shoe construction of the present invention provides a
waterproof, water vapor permeable shoe with no or a reduced risk of
losing its waterproof, water vapor permeability. The shoe
construction of the present invention accomplishes these objectives
by providing for a seamless or virtually seamless functional layer
that obviates or reduces the need for seams or seam-sealing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a cross-sectional view from the side of the
shoe.
[0019] FIG. 2 is a cross-sectional view from the side of the shoe
having an injection molded sole.
[0020] FIG. 3 is a view from the bottom of the sock-like functional
layer showing a cut in the bottom of the functional layer.
[0021] FIG. 4 is a view of the cut ends of the functional layer
being connected.
[0022] FIG. 5 is a view of the cut ends of the functional layer
being connected with glue over tape.
[0023] FIG. 6 is a view from the front of a the sock-like
functional layer in which the bottom of the functional layer has
been removed and replaced with an insole.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] The present invention provides a waterproof, water vapor
permeable shoe design in which a waterproof, water vapor permeable
functional layer is formed from a dispersion or solution of
waterproof, water vapor permeable polymer. The functional layer is
in the shape of a sock and is then is incorporated into the
shoe.
[0025] The present invention provides a waterproof, water vapor
permeable shoe design comprising 1) a waterproof, water vapor
permeable functional layer produced by dipping a foot shaped, solid
form into a dispersion or a solution of waterproof, water vapor
permeable polymer and allowing the form to dry and harden and then
peeling the sock-like functional layer from the form, and 2)
attaching the functional layer to the lining of a shoe wherein the
attachment is at least at the opening of the shoe.
[0026] The sock-like functional layer is inserted into the upper
material, a lining is inserted into the functional layer, and
finally a sole is incorporated onto the bottom portions of the
upper material and/or the functional layer. The functional layer
may only be connected to the lining near the opening of the shoe.
Optionally, the lining may be inserted into the functional layer,
before the functional layer is inserted into the upper.
[0027] In other embodiments, the present invention provides a shoe
construction where, prior to insertion into the upper, an opening
may be cut into the bottom of the functional layer to further
increase the adaptability of the functional layer. Once an opening
has been cut into the functional layer, portions of the functional
layer may be removed from the opening and the edges of the opening
may then be reconnected. By removing portions of the functional
layer, a smaller-sized functional layer is made without using
different sized forms. Additionally, once an opening has been made
in the functional layer, an insole may be inserted into the opening
to increase adaptability of the functional layer.
[0028] The present invention provides a process for manufacturing
waterproof, water vapor permeable shoes by forming a functional
layer from a dispersion of a waterproof, water vapor permeable
polymer, inserting the functional layer into an upper, inserting a
lining into the functional layer, and attaching the functional
layer to the lining at least at the top opening of the shoe.
Optionally, the lining may be inserted into the functional layer
before the functional layer is inserted into the upper.
[0029] FIG. 1 shows a shoe of the present invention having an upper
1, a functional layer 2, a lining 3, and a sole 5. The functional
layer 2 is waterproof and water vapor permeable and is situated
between the upper 1 and the lining 3.
[0030] The functional layer 2 is preferably attached only at the
top portion of the upper 1, i.e., the top opening where a foot of a
wearer is inserted into the shoe. In a preferred embodiment, the
portion of the upper near the opening of the shoe shown in FIG. 1
is folded over the ends of the functional layer 2 and the lining 3
and fixed over a seam 4. This connection between the functional
layer 2 and the lining 3 near the opening of the shoe is preferably
the only connection between the functional layer 2 and the lining
3.
[0031] The functional layer 2 is in the shape of a sock and is not
bonded with the lining with the exception of at the opening of the
shoe. At the bottom of the shoe, the upper 1 is bonded to the sole
5, preferably over a seam and/or over a glue. The part of the
functional layer adjacent to the sole may be bonded, preferably
using glue or a sewing technique, to the sole. If the functional
layer is sewn to the sole, the outer contour of the sole may be
sewn to the functional layer and the holes in the functional layer
may be resealed by another application of waterproof, water vapor
permeable polymer.
[0032] In another embodiment of the present invention, injection
molded shoe designs are possible. See, for example, U.S. Pat. No.
5,930,917, incorporated by reference herein. FIG. 2 shows a
construction of a shoe of the present invention whereby the sole 6
is injection molded. In the case of injection molded soles, the
material that is injected to form the sole may fill and seal any
seams or other breaches (caused by manufacturing) in the
waterproof, water vapor permeable functional layer. Therefore, the
seams caused by a cut in the functional layer, either to increase
size adaptability or to insert an insole, may not require further
glue and tape to maintain waterproofness. In this construction, the
functional layer 2 is bonded to the injection molded material.
[0033] Surprisingly, a separate form is not necessary for every
shoe size or style because of the relative thinness of the
functional layer. When the functional layer is incorporated into a
shoe, the folds and creases the functional layer makes as it
conforms to the interior portions of the shoe are not noticed by
the wearer of the footwear since the material forming the
functional layer is relatively thin, i.e., 10 to 150 microns. One
particular size functional layer may be incorporated into many
different sizes of shoes. This interchangeability of the functional
layer reduces manufacturing costs as a separate sized liner is not
required to be manufactured for each individual shoe size.
[0034] The upper 1, lining 3, and the sole 5 may be selected from
materials well known in the art. See, for example, U.S. Pat. No.
5,678,326, incorporated herein by reference. The upper 1 may be
made from, for example, leather, textiles, woven fabrics, canvas,
fabric, chintz, everglaze, terry, velvet, Manchester velvet,
corduroy, velveteen, Norzon, leatherette, muslin, duvetine, satin,
fur, imitation fur, suede leather, satin finish leather, patent
leather or polished, embossed, shrunk or grained leather.
[0035] The lining 3 may be made from, for example, terry, goat
skin, sheep skin, cowhide, pig skin, velvet, camel hair, fabric,
knitted or woven fleece, woven fabrics, cotton, wool, synthetic
fibers, and/or cellulose materials.
[0036] The sole 5 may be made from waterproof materials such as,
for example, rubber, polyurethane, polyvinyl chloride and their
derivatives, and mixtures of the same.
[0037] The functional layer of a waterproof, water vapor permeable
laminate may be manufactured from polymers which are suitable for
forming a microporous polymeric matrix. See, for example, U.S. Pat.
No. 5,732,479, incorporated by reference herein its entirety.
Suitable polymers include polyolefines, such as
polyethylene-propylene copolymers, polyethylene, terephthalates,
polycaprolactam, polyvinylidenefluoride, polybutyleneterephthalate,
polyester copolymers and polytetrafluoroethylene. A waterproof,
water vapor permeable functional layer may also be a coating or an
impregnation or a membrane of the aforementioned polymers on a
copolyether ester base, or may be made of oriented
polytetrafluoroethylene, preferably with a microporous polyurethane
coating (Gore-tex). Polymers of a copolyether ester base (Sympatex)
have proved to be excellent materials for this purpose due to their
properties of high water vapor permeability, high waterproofness
and wear resistance.
[0038] The waterproof, water vapor permeable functional layer, also
referred to herein as "the functional layer", is preferably formed
by dipping a form into a solution or dispersion of a waterproof,
water vapor permeable polymer and allowing the polymer to harden,
and then peeling the functional layer from the form. The dipping
process may be repeated several times. After dipping and before
removal from the form, the polymer dispersion on the form may be
heated, causing the polymer to melt and form a continuous film. The
form may roughly be in the shape of a human foot or other three
dimensional, solid article that would confer a sock-like shape to
the functional layer. Manufacture of the functional layer may be
accomplished using the methods and materials as described in EP 0
665 259 A1 or in WO 95/30793, both of which are incorporated herein
by reference in their entireties.
[0039] The waterproof, water vapor permeable polymer solution or
dispersion may contain copolyether esters obtained by
copolymerizing an aromatic dicarboxylic acid or ester forming
equivalent thereof with a dioic acid molecular weight of not more
than 300, a diol or ester forming equivalent thereof with a dioic
molecular weight of not more than 250, and a polyalkylene oxide
glycol with a molecular weight in the range of 600 to 4,000 and an
atomic ratio of carbon to oxygen in the range of 2.0 to 4.3 with at
least 20% by weight of the long chain glycol having a carbon to
oxygen ratio in the range of 2.0 to 2.4 and 15% to 50% by weight
being part of the copolyether ester. The aromatic dicarboxylic acid
preferably is terephthalic acid or napthalene dicarboxlyic acid,
while the low-molecular weight diol preferably is ethylene glycol
or butane diol. In addition, preference is given to a polymer
having a melting point of at least 150.degree. C. See for example,
EP 0 665 259.
[0040] The sock-like functional layer may be made by dipping the
form into more than one dispersion or solution of polymers that
each possess different qualities to provide and/or improve the
waterproof, water vapor permeable characteristics of the sock-like
liner. By using different solutions or dispersions, a composite
sock-like functional layer may be formed. The first layer of the
composite may be a microporous, elastomeric, thermoplastic
polyester polyurethane or polyether polyurethane that is water
vapor permeable. The second layer or subsequent layers of the
composite may be a non-porous layer that is hydrophilic,
waterproof, and water vapor permeable. The second layer or
subsequent layer may improve the waterproofness and/or water vapor
permeability of the first layer or impart other desired
characteristics, such as wear resistance. The preferred
polyurethanes for the first layer are elastomeric polyurethanes
based on a linear, hydroxyl terminated polyester (although a
polyester polyol or a polyether/polyester blend may be used) and a
diisocyanate, with a small addition of a difunctional low molecular
weight reactant.
[0041] The second hydrophilic polymer layer of the composite may be
made from hydrophilic elastomers such as, for example, polyesters,
polyamides, cellulose derivatives, polyacrylic acid and its
homologs, natural or synthetic rubber with hydrophilic impurities,
copolyoxamides, polyureas, polyelectrolytes, polyphosphates,
polyvinylamines, polyvinylalcohol, polyether and copolymers
thereof; polythioether, polythioether-polyether,
copolyepichlorohydrinether, polysulphosphates, copolyesterether and
derivatives or mixtures thereof Preferably the hydrophilic polymer
is a copolyether ester, polyurethane or a copolyetheresteramide.
All of these polymers are permeable to water vapor, but are highly
impervious to liquid water. See, for example, WO 95/30793, herein
incorporated by reference in its entirety.
[0042] The sock-like functional layer may have a thickness of, for
example, about 10 to 150 microns. Preferably, the functional layer
has a thickness of, for example, about 40 to 100 microns. The
sock-like functional layer may be formed dipping, spraying or any
other process, well known in the art, of applying a dispersion or
solution to a form or three-dimensional article.
[0043] In another embodiment of the present invention, the
adaptability of the functional layer may be increased by cutting an
opening in the bottom of the functional layer 2. As shown in FIG.
3, by making a cut in the bottom of the functional layer, for
example, along line 7 and thus forming cut ends 13a and 13b as
shown in FIG. 4, it is possible to adapt the shape of the
functional layer 2 to a variety of shoe sizes. As shown in FIG. 4,
the cut ends 13a and 13b of the functional layer 2 may then be
bonded together with glue and/or with a seam 8. As shown in FIG. 5,
the connection between the cut ends 13a and 13b may be made
watertight by tightening the cut ends 13a and 13b over a tape 9 and
over glue 10. If cut ends 13a and 13b are too long after rejoining,
removing a portion of the functional material along the cut or
cutting the excess length of the cut ends may provide for a smaller
sock-like functional layer, further increasing the adaptability of
the sock like liner to an even greater variety of shoe sizes.
[0044] In another embodiment, an insole 11 may be incorporated with
the sock-like functional layer. As shown in FIG. 6, the functional
layer 2 is cut out in the bottom area (i.e., the surface of the
functional layer which would have been adjacent to the sole) and
removed. The ends of the functional layer, made by cutting out the
bottom area, are preferably bonded to the edges of the insole over
seams 12. The connection between the functional layer and the
insole may be made waterproof if the ends of the functional layer
and the insole are connected in a manner analogous to FIG. 5, i.e.,
the functional layer and the insole are connected over glue and
tape. The functional layer, insole and upper may be joined to the
sole by, for example, gluing, sewing, adhesives, injection molding,
or other techniques.
[0045] The functional layer, after having an insole inserted, a cut
made along line 7 to increase the adaptability of the shoe, or
other modification which might have breached the waterproof, water
vapor permeable properties of the shoe, may have the solution or
dispersion of waterproof, water vapor permeable polymer reapplied
to the functional layer to regain or improve the waterproof, water
vapor permeable properties of the functional layer.
[0046] As shown in FIG. 1, the glue used to attach the bottom of
the shoe to the upper and functional layer may provide a sealant
for the any seams between the sole, the upper and the functional
layer. This glued connection may also seal any seams or breaches in
the functional layer created from having an insole inserted., a cut
made along line 7 to increase adaptability or other modification.
It is also possible to first glue the seams between the functional
layer and the upper to make the seams watertight and then to glue
the sole to the bottom of the upper and the functional layer.
* * * * *