U.S. patent application number 10/356361 was filed with the patent office on 2004-02-05 for rubber footwear with neoprene layer.
This patent application is currently assigned to LaCrosse Footwear, Inc.. Invention is credited to Rinehart, Robert G., Thomas, Kent A..
Application Number | 20040020077 10/356361 |
Document ID | / |
Family ID | 30774642 |
Filed Date | 2004-02-05 |
United States Patent
Application |
20040020077 |
Kind Code |
A1 |
Thomas, Kent A. ; et
al. |
February 5, 2004 |
Rubber footwear with neoprene layer
Abstract
A waterproof footwear includes a neoprene sock having a floor
region and a side wall extending upward therefrom terminating in an
upper edge. An outer rubber layer is bonded to and covers the
entire outer surface of the neoprene sock side wall. A rubber floor
portion covers the floor region of the neoprene sock and an outsole
is attached to the rubber layer.
Inventors: |
Thomas, Kent A.; (Camas,
WA) ; Rinehart, Robert G.; (Portland, OR) |
Correspondence
Address: |
FOLEY & LARDNER
777 EAST WISCONSIN AVENUE
SUITE 3800
MILWAUKEE
WI
53202-5308
US
|
Assignee: |
LaCrosse Footwear, Inc.
|
Family ID: |
30774642 |
Appl. No.: |
10/356361 |
Filed: |
January 31, 2003 |
Current U.S.
Class: |
36/4 ;
12/142E |
Current CPC
Class: |
A43B 7/12 20130101; A43B
23/07 20130101; A43B 7/34 20130101 |
Class at
Publication: |
36/4 ;
12/142.00E |
International
Class: |
A43B 001/12 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 25, 2002 |
CN |
022610359 |
Claims
What is claimed is:
1. A footwear comprising: an upper including a neoprene layer
having an inner surface, an outer surface, a lower edge, and an
upper edge; an outer rubber layer bonded to and covering
substantially the entire outer surface of the neoprene layer; and
an outsole attached to the outer rubber layer.
2. The footwear of claim 1, further including a neoprene floor
portion including a neoprene portion attached to the neoprene
layer.
3. The footwear of claim 1, further including a rubber floor
portion covering the neoprene floor portion and bonded to the outer
rubber layer.
4. The footwear of claim 1, wherein the outer rubber layer includes
an upper edge coterminous with the upper edge of the neoprene
sock.
5. The footwear of claim 1, further including a layer of material
attached to the inner surface of the neoprene layer.
6. The footwear of claim 1, wherein the rubber floor portion is
bonded directly to the neoprene floor portion.
7. The footwear of claim 6, further including a midsole formed from
ethyl vinyl acetate.
8. The footwear of claim 6, further including an insole located
between the neoprene floor portion and the rubber floor
portion.
9. The footwear of claim 5, wherein the neoprene floor region is
stitched to the inner layer of neoprene.
10. The footwear of claim 1, wherein the outer rubber layer does
not hold a human scent.
11. A waterproof footwear comprising: an upper including an outer
layer of rubber and an inner layer of neoprene, the rubber covered
neoprene extending to a top edge of the upper; a floor including a
neoprene portion attached to the neoprene layer of the upper, and a
rubber portion bonded to the neoprene portion and the rubber layer
of the upper; a rubber outsole being attached to the upper forming
a waterproof barrier.
12. The waterproof footwear of claim 11, including a layer of
material secured to the neoprene layer distal the rubber layer.
13. The waterproof footwear of claim 12, wherein the layer of
material is fleece.
14. The waterproof footwear of claim 13, including a midsole
located between the outsole and floor and being formed of ethyl
vinyl acetate.
15. The waterproof footwear of claim 14, further including an
insole located between the floor portion and the midsole.
16. A method of manufacturing a waterproof footwear comprising:
covering an upper region of a last with a layer of neoprene having
an outer surface; covering substantially all of the layer of
neoprene with a layer of rubber; and vulcanizing the rubber layer
and neoprene layer.
17. The method of claim 16, further including covering a bottom
portion of the last with a layer of neoprene defining a floor
region.
18. The method of claim 17, further including adhering a rubber
layer of material to the neoprene floor region.
19. The method of claim 17, including forming the neoprene sock by
stitching a floor portion to at least one other neoprene piece of
material.
20. The method of claim 18, further including securing a rubber
outsole to the rubber covered neoprene layer.
21. The method of claim 20, further including securing a midsole
formed from ethyl vinyl acetate to the outsole.
22. The method of claim 18, further including placing an insole
between the floor portion of the neoprene material and floor
portion and the rubber layer prior to the vulcanizing step.
23. The method of claim 22, further including attaching a material
to the inner surface of the neoprene layer.
24. The method of claim 23, wherein the material is fleece.
25. The method of claim 16, wherein the layer of neoprene is
completely covered by the layer of rubber.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the field of
footwear and more particularly to a waterproof rubber footwear.
Waterproof footwear such as boots are used in outdoor recreational
activities as well as in a number of industrial and professional
uses. Specifically waterproof boots are used in hunting and fishing
to ensure that the sportsman feet remain dry during the
recreational activity. Additionally, waterproof boots are used in
the animal husbandry and farming environments as well as by
firefighters.
[0002] One type of waterproof boot includes an outer rubber
waterproof layer. The use of rubber as the waterproof material
provides a number of functional benefits. One such benefit is that
rubber of sufficient thickness is strong and resilient, resistant
to punctures, durable, and in the area of outdoor recreational
sports is scent proof. However, rubber boots are typically
inflexible, heavy, and do not fully fit the foot and/or leg of the
user very well.
[0003] There have been a number of attempts to provide a waterproof
boot to minimize the negative aspects of rubber. One such attempt
has been made by the Muck Boot Company which has replaced the outer
rubber material with a neoprene material covered with an outer
layer of fabric. While the neoprene covered fabric provides a
waterproof boot, the neoprene is not as durable or puncture proof
as rubber. Additionally, the nylon coated neoprene absorbs and
gives off scent which is undesirable for the outdoor sportsman.
[0004] Another attempt to use a neoprene inner sock is disclosed in
U.S. Pat. No. 5,937,543 entitled "Footwear having a Variable Sized
Interior" by the U.S. Navy. The '543 patent discloses a neoprene
inner sock that is smaller than and partially attached to the outer
rubber covering so that users with different feet size may be able
to use the same boot. However, U.S. Pat. No. 6,427,362 entitled
"Boot with Strapping to Restrain Movement of Foot" assigned to
Norcross Safety Products, L.L.C., argues that the boot disclosed in
the '543 patent "cannot be easily manufactured with a predominantly
rubber upper and with a predominantly rubber sole, by conventional
vulcanizing methods, as closed cell neoprene foam takes a set and
loses its elasticity when vulcanized" [See Col. 1 lines 35-46].
[0005] Accordingly, it would be desirable to provide a rubber boot
that is durable, puncture resistant, light weight, flexible, and
scent proof, and fits and conforms to the foot in a comfortable
way. It would further be desirable to combine the thermal
protection of neoprene with the waterproof layer of rubber in order
to provide thermal protection that still allows the boot to be
lightweight and flexible.
SUMMARY OF THE INVENTION
[0006] One feature of the invention is to provide a waterproof boot
that is lightweight and flexible. Another feature of the invention
is to provide a lightweight waterproof boot with thermal
protection. A further feature of the invention is to provide a
rubber coated waterproof boot having a neoprene layer that is scent
proof.
[0007] In one embodiment, a shoe includes a neoprene sock having a
floor region and a side wall extending upward therefrom terminating
in an upper edge. An outer rubber layer is bonded to and covers the
entire outer surface of the neoprene sock side wall. A rubber floor
portion covers the floor region of the neoprene sock and an outsole
is attached to the rubber layer.
[0008] In another embodiment a waterproof boot includes an upper
including an outer layer of rubber and an inner layer of neoprene.
The rubber covered neoprene extends to a top edge of the upper. A
floor includes a neoprene portion attached to the neoprene layer of
the upper, and a rubber portion bonded to the neoprene portion and
the rubber layer of the upper. An outsole is attached to the upper
forming a waterproof barrier.
[0009] In still another embodiment, a method for manufacturing a
waterproof shoe includes first forming a sock from a neoprene
material having an inner surface and an outer surface; a floor
region configured to contact the bottom portion of a user's foot,
and an upper region extending from the floor region and terminating
at an upper edge. The neoprene sock is then placed over a last such
that the outer surface is exposed. A rubber layer of material is
placed over the entire upper region of the outer surface of the
neoprene sock. The rubber covered neoprene sock is then
vulcanized.
[0010] In yet another embodiment, a footwear includes an upper
including a neoprene layer having an inner surface, an outer
surface, a lower edge, and an upper edge. An outer rubber layer is
bonded to and covering substantially the entire outer surface of
the neoprene layer. An outsole is attached to the outer rubber
layer. The outer rubber layer may also be bonded to and completely
cover the entire outer surface of the neoprene layer.
[0011] In a further embodiment, a waterproof footwear includes an
upper including an outer layer of rubber and an inner layer of
neoprene. The rubber covered neoprene extends to a top edge of the
upper. A floor includes a neoprene portion attached to the neoprene
layer of the upper. A rubber portion is bonded to the neoprene
portion and the rubber layer of the upper. A rubber outsole is
attached to the upper forming a waterproof barrier.
[0012] In still another embodiment a method for making footwear
includes covering an upper region of a last with a layer of
neoprene having an outer surface. The layer of neoprene is then
substantially covered with a layer of rubber. The rubber layer and
neoprene layer is then vulcanized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a cross sectional view of one embodiment of the
waterproof footwear.
[0014] FIG. 2 is a metal last used in the manufacture of the
waterproof footwear boot.
[0015] FIG. 3 is a sock sewn out of neoprene material.
[0016] FIG. 4 is a neoprene sock stretched over the last of FIG.
2.
[0017] FIG. 5 is a schematic of the rubber sheets with cement
applied thereto.
[0018] FIG. 6 is a the rubber sheets adhesively attached to the
neoprene sock.
[0019] FIG. 7 is the outsole to be adhered directly to the rubber
covered neoprene.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring to FIG. 1, a boot 10 includes an upper 12, an
outsole 14, a midsole 16, and an insole 18. Upper 12 includes an
outer rubber layer 20 extending around an inner neoprene sock 22
having an outer neoprene layer 24 and a inner fleece layer 26. The
inner layer 26 could be other materials known in the art including
but not limited to THINSULATE, cotton, nylon, cotton, canvas, mesh
or wool. The term fleece is used herein to represent any of these
materials. The neoprene layer 24 extends to a top edge 28 of the
upper 12.
[0021] Neoprene sock 22 is formed from at least two pieces of
neoprene material. One piece of neoprene material defines a floor
region 30 upon which a users foot rests and a second upper region
32 surrounding the sides and top of a user's foot including the
ankle and calf region. The floor region 30 of the neoprene layer
may be connected to the upper region 32 of neoprene by a threaded
stitch 34.
[0022] The neoprene sock 22 forms the foundation upon which the
entire boot 10 is constructed. Referring to FIGS. 2-7, the neoprene
sock 22 is placed upon a metal last 36 that defines the interior
region of boot 10. The neoprene sock 22 is stretched over the metal
last 36 with the fleece layer 26 adjacent last 36 and with the
neoprene layer 24 of sock 22 facing outward. A plurality of
individual rubber sheets or pieces 38 are cut to cover the exposed
layer of neoprene. A bonding cement is applied to one or both of
the rubber sheets and neoprene sock in order to temporarily secure
the rubber pieces 38 to neoprene layer 26. The rubber sheets 38
cover both upper portion 32 of the neoprene sock 22 as well as the
floor portion 30 of neoprene sock 22. In this manner rubber sheets
38 completely cover the neoprene sock 22.
[0023] In the next step of the operation, a sole 40 including a
rubber outsole 14 and a midsole 16 is adhesively applied directly
to the rubber sheet 38 covering the floor portion 30 of neoprene
sock 22. The sole 40 further includes an upwardly extending portion
42 that covers a lower edge 44 of the rubber layer 20 material.
Finally the entire assembly is placed into an autoclave and subject
to heat and pressure to vulcanize the rubber sheets 38 such that
the rubber material bonds directly to the neoprene layer 24 and to
outsole 40.
[0024] In another embodiment an insole 18 is located between the
floor portion 30 of neoprene sock 22 and rubber material 38 that
covers the floor portion 30. Insole 18 is adhesively attached to
the floor portion 30 to provide a smooth planar surface upon which
the rubber material portion 38 is applied to the rubber material 38
forming the upper. Insole 18 may be formed from one or more pieces
of material as is commonly known in the art. The sole 40 is then
applied as discussed above prior to being vulcanized.
[0025] In another embodiment, midsole 16 is formed of an EVA (ethyl
vinyl acetate) material providing a lighter weight material than a
rubber midsole. Sole 40 with an EVA midsole may be attached to the
rubber upper prior to or after vulcanization. However, midsole 16
may also be formed from other materials such as polyurethane,
rubber, phylon or other materials known in the art.
[0026] The neoprene layer 24 and outer rubber sheets 38 once
vulcanized provide a flexible composite which is less rigid than
previously rubber boots since the neoprene material provides and
allows for the outer rubber sheets 38 to retain a certain degree of
resiliency. The rubber material 38 is bonded directly to the
neoprene material 22 around the entire region upon which the rubber
is in contact with the outer surface of a neoprene layer. As
illustrated in FIG. 1 the rubber layer 20 encompasses the entire
outer periphery of the neoprene sock 22 covering the bottom of
floor portion 30 of a neoprene sock 22 to the top 28 edge of the
upper 12 of boot 10.
[0027] In an alternative embodiment, the outer rubber material
forms an outer bond upon which an insole 18 is sandwiched between
the floor portion 30 and the lower rubber material 38. However, the
entire region from the heel and toe upward to the top edge 28 of
boot 10 the rubber is attached to the neoprene liner or sock 22
prior to vulcanization. This continuous bonding allows for the
rubber and neoprene material to provide a flexible and resilient
feel for the user while also allowing for a durable puncture proof
outer surface and further retaining the scent proof characteristic
that is desirable for this product.
[0028] In one preferred embodiment, the rubber layer 20 covering
the neoprene layer 24 is about 0.030 inches. The neoprene sock 22
itself is 4.5 millimeters thick with the neoprene layer 24 being
about 3 millimeters thick and the fleece layer 26 on the inside
surface of the neoprene being 1.5 millimeters. Accordingly, the
total thickness of the outer rubber layer 20, neoprene layer 24 and
fleece 26 layer is approximately 0.250 inches. Of course the layers
may be of other thickness as well.
[0029] In a preferred embodiment, the neoprene layer 24 is a closed
cell foam rubber which may be SBR or CR type. However, other types
of neoprene may also be used and still fall within the scope of the
invention. It should also be noted that the thickness of the
neoprene layer 24 may be less than or greater than 0.030 inches.
The rubber boot 10 as disclosed in the embodiment shown in FIG. 2
includes a midsole 16 formed of a EVA material that is
substantially lighter than a similar rubber boot that does not use
a neoprene layer and having a midsole formed of rubber. In fact,
this type of boot disclosed is 30% lighter than similar boots with
an all rubber sole and a separate THINSULATE layer that is
currently used in the prior art.
[0030] This resulting construction includes both a reduction in
weight by the utilization of neoprene and by changing the way the
outsole is attached to provide for a midsole made of EVA material.
Additionally, there is an improved fit to the user because a
neoprene rubber combination stretches and forms to a users foot.
The boot may be smaller in size and volume for a particular user
since it will be more snug to the foot and its greater resiliency
allows for a more comfortable wear and a smaller size. The
increased resiliency of the rubber coated neoprene allows a user to
roll over the shaft area 46 of upper 12. Additionally, the
resilient nature of the rubber coated neoprene allows the shaft
area 46 to be repeatedly rolled or folded over without out the
danger of cracking or failure of the rubber layer.
[0031] The sloppy fit or loose fit that has been accompanied with
large rubber boots is thereby eliminated. The large fit was
required due to the inflexibility and hardness of the outer rubber
material which results when the outer rubber material is bonded to
the standard nylon material as used in the art. Since neoprene
material provides insulative properties, the amount of fleece that
would otherwise be required in the boot is reduced thereby adding
to the reduction both in bulk and weight of the overall product. As
illustrated in FIG. 1, the neoprene layer 24 extends from the top
edge 28 of upper 12 through the vamp area 48 around the toe region
across the floor of the boot, and around the heel and ankle region
of the boot. In one embodiment, the neoprene layer is secured to a
rubber layer completely around the entire outer periphery of the
neoprene layer. In an alternative embodiment, the outer rubber
layer is bonded to the neoprene layer 24 in all regions except
where an insole 18 is placed between the floor portion 30 and the
rubber floor covering 50. In both of these embodiments, a complete
waterproof rubber layer is formed about the neoprene sock 22
independent of the sole 40. Of course it is contemplated that the
rubber floor portion 50 may be omitted if desired. However, any
leaking that may occur between the sole 40 and upper 12 may result
in water seeping into the inner area of the boot through stitches
34, or any other seam that may be created to attach the neoprene
floor portion 30 with the upper portion of the neoprene sock
22.
[0032] In one embodiment, the upper edge of the neoprene layer in
the upper of the footwear is at least 4 inches from the bottom of
the sole. In another embodiment, the upper edge of the neoprene
layer is at least six inches from the bottom of the sole. In
certain applications such as boots, the upper edge of the neoprene
layer may be at least 18 inches from the bottom of the sole.
Additionally, in footwear used as hip or chest waders, the upper
edge of the neoprene layer may be up to 60 inches or higher from
the bottom of the sole. The neoprene material placed on the last in
the method of manufacture may include a floor portion or only an
upper portion. It may also be possible to construct the neoprene
material while on the last, however in a preferred embodiment the
neoprene material is formed into a sock having at least an upper
tube portion and in another embodiment the sock includes a floor
portion. In one embodiment, the upper edge of the neoprene material
extends to the upper edge of the footwear and is completely covered
with the outer rubber layer. In another embodiment, the upper edge
of the neoprene material may be lower than the upper-edge of the
outer rubber material. It is also possible that a flexible rubber
section such as a folded pleat be built into a portion of the
footwear proximate the upper edge of the footwear and extending
only a portion of the upper periphery of the footwear. Similarly,
an expansion portion maybe located proximate the upper edge of the
footwear and include a piece of material that is flexible to allow
for easier expansion and stretching than the neoprene and rubber
bonded layers. The flexible region may include a section of rubber
60 that is not bonded to an inner layer of neoprene.
[0033] It will be understood that the above description is
exemplary embodiments and that the invention is not limited to the
specific embodiments described. Various substitutions,
modifications, changes, and omissions may be made in the
arrangement of the elements without departing from the scope of the
invention as expressed in the appended claims.
* * * * *