U.S. patent application number 10/346207 was filed with the patent office on 2004-07-22 for waterproof footwear.
Invention is credited to Wiener, Robert J..
Application Number | 20040139629 10/346207 |
Document ID | / |
Family ID | 32712083 |
Filed Date | 2004-07-22 |
United States Patent
Application |
20040139629 |
Kind Code |
A1 |
Wiener, Robert J. |
July 22, 2004 |
Waterproof footwear
Abstract
Waterproof footwear and methods for making the same. The
footwear includes a laminate upper having at least a waterproof,
water vapor permeable functional layer and an outer layer stitched
to a strobel board to form a closed upper. A waterproof gasket
material is adhered to the inner surface of the bottom of the
closed upper.
Inventors: |
Wiener, Robert J.;
(Middletown, DE) |
Correspondence
Address: |
Allan M. Wheatcraft, Esquire
W. L. Gore & Associates, Inc.
551 Paper Mill Road
Newark
DE
19714-9206
US
|
Family ID: |
32712083 |
Appl. No.: |
10/346207 |
Filed: |
January 16, 2003 |
Current U.S.
Class: |
36/12 |
Current CPC
Class: |
A43B 9/02 20130101; A43B
7/125 20130101 |
Class at
Publication: |
036/012 |
International
Class: |
A43B 013/28 |
Claims
What is claimed is:
1. Waterproof footwear comprising: a laminate upper having at least
a waterproof, water vapor permeable functional layer and an outer
layer stitched to a strobel board, forming a closed upper having an
inner surface, an outer surface, an open top, and a closed bottom;
and a waterproof gasket material adhered to the inner surface of
the closed bottom of the closed upper.
2. The waterproof footwear of claim 1, wherein an outer sole is
attached to the outer surface of the closed bottom of the closed
upper.
3. The waterproof footwear of claim 1, wherein the waterproof
gasket material is adhered to the closed bottom of the closed upper
utilizing an adhesive material selected from the group consisting
of polyurethane, natural latex rubber, nitrile rubber, silicone
rubber, butyl rubber, fluorinated rubber, copolyether polyester,
polyester, ethylene vinyl acetate, and polyamide.
4. The waterproof footwear of claim 1, wherein the inner surface of
the closed upper is further provided with an inner liner
material.
5. The waterproof footwear of claim 4, wherein the inner liner
material comprises at least a textile material selected from the
group consisting of woven, knit, mesh, non-woven, and felt
constructions.
6. The waterproof footwear of claim 5, wherein the textile fabric
comprises at least a material selected from the group consisting of
cotton, polyesters, polyamides, polypropylenes, polyolefins, and
blends thereof.
7. The waterproof footwear of claim 1, wherein the waterproof,
water vapor permeable functional layer of the laminate upper
comprises at least a polymeric membrane.
8. The waterproof footwear of claim 7, wherein the polymeric
membrane is selected from the group consisting of fluoropolymers,
polyurethanes, polyesters, polyethers, polyamides, polyacrylates,
copolyether esters, and copolyether amides.
9. The waterproof footwear of claim 8, wherein the fluoropolymer is
expanded polytetrafluoroethylene.
10. The waterproof footwear of claim 1, wherein the outer layer of
the laminate upper comprises leather.
11. The waterproof footwear of claim 1, wherein the outer layer of
the laminate upper comprises a textile fabric selected from the
group consisting of woven, knit, mesh, non-woven, and felt
constructions.
12. The waterproof footwear of claim 11, wherein the textile fabric
comprises a material selected from the group consisting of cotton,
polyesters, polyamides, polypropylenes, polyolefins, and blends
thereof.
13. The waterproof footwear of claim 1, wherein the waterproof
gasket material is a material selected from the group consisting of
polymeric containing material, waterproof fabric, and textile
material treated to make it waterproof.
14. Method for making waterproof footwear comprising: stitching to
a strobel board a laminate upper having at least a waterproof,
water vapor permeable functional layer and an outer layer to form a
closed upper having an inner surface, an outer surface, an open
top, and a closed bottom; and adhereing a waterproof gasket
material to the inner surface of the closed bottom of the closed
upper.
15. The method of claim 14, wherein an outer sole is attached to
the outer surface of the closed bottom of the closed upper.
16. The method of claim 14, wherein the waterproof gasket material
is adhered to the closed bottom of the closed upper utilizing an
adhesive material selected from the group consisting of
polyurethane, natural latex rubber, nitrile rubber, silicone
rubber, butyl rubber, fluorinated rubber, copolyether polyester,
polyester, ethylene vinyl acetate, and polyamide.
17. The method of claim 14, wherein an inner liner material is is
attached to the inner surface of the closed upper.
18. The method of claim 17, wherein the inner liner material
comprises at least a textile material selected from the group
consisting of woven, knit, mesh, non-woven, and felt
constructions.
19. The method of claim 18, wherein the textile fabric comprises at
least a material selected from the group consisting of cotton,
polyesters, polyamides, polypropylenes, polyolefins, and blends
thereof.
20. The method of claim 14, wherein the waterproof, water vapor
permeable functional layer of the laminate upper comprises at least
a polymeric membrane.
21. The method of claim 20, wherein the polymeric membrane is
selected from the group consisting of fluoropolymers,
polyurethanes, polyesters, polyethers, polyamides, polyacrylates,
copolyether esters, and copolyether amides.
22. The method of claim 21, wherein the fluoropolymer is expanded
polytetrafluoroethylene.
23. The method of claim 14, wherein the outer layer of the laminate
upper comprises leather.
24. The method of claim 14, wherein the outer layer of the laminate
upper comprises a textile fabric selected from the group consisting
of woven, knit, mesh, non-woven, and felt constructions.
25. The method of claim 24, wherein the textile fabric comprises a
material selected from the group consisting of cotton, polyesters,
polyamides, polypropylenes, polyolefins, and blends thereof.
26. The method of claim 14, wherein the waterproof gasket material
is a material selected from the group consisting of polymeric
containing material, waterproof fabric, and textile material
treated to make it waterproof.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to waterproof footwear and
methods for making the same.
DESCRIPTION OF RELATED ART
[0002] Common footwear constructions, such as those used in boots
or shoes, employ waterproof constructions comprising a liquid
waterproof but water vapor permeable (i.e., breathable) layer as
part of a lining between the wearer's foot and the exterior parts
of the footwear. The waterproof, water vapor permeable material is
referred to in the art as the "functional layer". The functional
layer is incorporated in a mult-layered lining fabric referred to
as a waterproof, breathable fabric. Waterproof, breathable fabric
panels are usually sewn together and sealed at the seams to form a
waterproof liner within the footwear. One prior art embodiment of
such a waterproof liner is called a bootie wherein the waterproof,
breathable fabric essentially surrounds the foot completely. There
also exists non-bootie waterproof, breathable fabric liner
constructions other than a bootie wherein the lining fabric is
sealed to other waterproof materials in the sole area, rather than
having the fabric extend completely underfoot as in the bootie. In
either case, the fabric panels which form the waterproof breathable
liner are normally an interior part of the footwear with an outer
textile layer of the fabric panel in contact with the inner
surfaces of the footwear upper. The footwear upper is usually
composed of leather, fabrics, etc. and additionally includes
components such as eyelets, heel counters, steel safety toes, toe
caps, etc.
[0003] The waterproof, breathable fabric panels of the liner are
composed of multiple layers wherein the different layers may
provide different functions, e.g., durability, waterproofness,
fashion appeal, etc. In making the material for the panels of the
liners, a thin functional layer is commonly laminated to at least
one fabric layer, and often times laminated between fabric layers.
Sometimes thin coatings on fabric are used as the functional layer
instead of a membrane. The waterproof layer is typically thin and
fragile. Thus, it is normally provided with at least an outermost
protective fabric layer which is designed to provide durability and
abrasion resistance between the thin functional layer and the
footwear upper.
[0004] The above mentioned footwear constructions lead to several
fabrication problems. For example, at least the outermost fabric of
the laminate must be attached to (e.g., by stitching, gluing, etc.)
the inner surfaces of the shoe upper. This, of course, introduces
an additional manufacturing step to the already labor intensive
process of producing footwear. Moreover, the attachment of the
upper to the outermost fabric of the laminate also provides another
area for the footwear to fail. For example, attachment of the
laminate to the upper may fail over a course of use of the
footwear. Moreover, the inclusion of the waterproof, breathable
fabric panels in the footwear may cause sizing problems (i.e.,
depending on the method used to construct the footwear, utilization
of waterproof, breathable fabric panels may cause the shoe to be
somewhat smaller than originally sized). Thus, it can be
appreciated that problems exist in making durable, waterproof
footwear.
[0005] The current invention provides footwear and methods for
making the same which provide durable, waterproof footwear which is
simply made in a minimal number of steps. Moreover, since the
footwear of the invention is of the "stitched" construction type,
there is no need for the expensive, time consuming lasting
equipment that is currently used in efforts to produce waterproof
footwear.
SUMMARY OF THE INVENTION
[0006] The invention relates to novel waterproof footwear
constructions of the stitched type (e.g., of the strobel stitched
type) and methods for making the same.
[0007] The footwear comprises a laminate upper including at least a
waterproof, water vapor permeable functional layer and an outer
layer laminated thereto. The upper is stitched to a strobel board
to form a closed upper having an inner surface, an outer surface,
an open top, and a closed bottom. A waterproof gasket material is
adhered to the inner surface of the closed bottom of the closed
upper, covering the strobel board, the stitching and at least a
perimeter edge of the upper.
[0008] A method for forming the novel footwear includes forming
into the shape of an upper a laminate having at least a waterproof,
water vapor permeable functional layer and an outer layer.
Stitching the upper to a strobel board to form a closed upper
having an inner surface, an outer surface, an open top, and a
closed bottom. And adhereing a waterproof gasket material to the
inner surface of the closed bottom of the closed upper, such that
the waterproof gasket material covers the strobel board, the
stitching and at least a perimeter edge of the upper.
DESCRIPTION OF THE DRAWINGS
[0009] The operation of the present invention should become
apparent from the following description when considered in
conjunction with the accompanying drawings, in which:
[0010] FIG. 1 is a cross-sectional view of a closed upper according
to the invention.
[0011] FIG. 2 is a cross-sectional view of a waterproof footwear
article according to the invention.
[0012] FIG. 3 is a top view of the inner surface of the bottom
portion of a closed upper according to the invention.
[0013] FIG. 4 is a top view of the inner surface of the bottom
portion of a waterproof footwear article according to the
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The novel footwear of the invention includes a laminate
upper including at least a waterproof, water vapor permeable
functional layer and an outer layer laminated thereto. The upper is
stitched to a strobel board to form a closed upper having an inner
surface, an outer surface, an open top, and a closed bottom.
[0015] The invention can best be described with reference to the
non-limiting figures wherein FIG. 1 shows, in cross-section, a
closed upper according to the invention. Footwear 1 includes
laminate upper 2 stitched to strobel board 3 by stitching 4.
Referring to FIG. 3, it can be seen that laminate upper 2 extends
somewhat under to the bottom of the closed upper forming a
perimeter edge.
[0016] Referring to FIG. 2, waterproof gasket material 6 is shown
adhered to the inner surface of the closed bottom of the closed
upper, covering the inner surface of the strobel board 3, the
stitching 4, and at least a portion of the perimeter edge of the
upper 2. FIG. 4 is a top view of the footwear wherein it can be
seen that waterproof gasket material 6 covers the strobel board 3,
the stitching 4, and the perimeter edge of the upper 2.
[0017] The laminate upper comprises at least two layers. One layer
is a waterproof, water vapor permeable functional layer, such as a
breathable polymeric membrane. As used herein "water vapor
permeable" and "breathable" are used interchangeably and mean that
the functional layer has a water vapor permeability coefficient Ret
of less than 200 m.sup.2 Pa W.sup.-1. The water vapor permeability
is tested by the Hohenstein skin model. This test method is
described in DIN EN 31092 (02/94) or ISO 11092 (19/33). Breathable
polymeric membranes may be breathable by virtue of pores in the
breathable polymeric membrane or through a solution diffusion
mechanism. Breathable polymeric membranes may be selected from, for
example, the group consisting of fluoropolymers, polyurethanes,
polyesters, polyethers, polyamides, polyacrylates, coplyether
esters and copolyether amides. In an aspect of the invention, a
water-impermeable, breathable polymeric membrane is a membrane of
microporous polytetrafluoroethylene (PTFE), such as expanded PTFE
as taught in, for example, U.S. Pat. Nos. 3,953,566 and 4,187,390
to Gore. The subject matter of these patents is hereby incorporated
by reference.
[0018] The second layer of the laminate upper is laminated to the
functional layer to serve as the outer layer of the footwear.
Lamination is generally carried out with the use of a discontinuous
pattern of suitable adhesive. Thus, water vapor permeability is not
significantly effected. The outer layer can be a textile fabric or
leather. Textile fabrics can be woven, knit, mesh, nonwoven, felt
constructions, etc. Textiles can be produced from natural fibers
such as cotton, or from synthetic fibers such as polyesters,
polyamides, polypropylenes, polyolefins, or blends thereof. The
outer layer is relatively durable, abrasion resistant and provides
an aesthetically pleasing appearance.
[0019] To form the laminate into the shape of an upper, panels of
the laminate material can be cut and assembled to the desired form.
Pieces of laminate can be joined together by sewing, welding,
gluing, etc. When pieces of laminate are sewn together the seams
can be made waterproof by applying known seam sealing tape
materials, such as GORE-SEAM.RTM. tape (available from W.L. Gore
and Associates, Inc.), to the seam area. Moreover, other sealants
may be applied to the seams to render them waterproof if they are
not inherently waterproof due to welding or gluing.
[0020] Once formed into the desired shape of a footwear upper, the
laminate upper can be stitched to a strobel board using, for
example, the well known Strobel stitching machine to form a closed
upper, illustrated in FIG. 1. Suitable materials which can be used
as a strobel board are well known to the skilled artisan.
[0021] The waterproof gasket material can be any suitable
waterproof material, which is generally formed into the shape of
the bottom of a wearer's foot (or to the footwear bottom). Suitable
waterproof gasket materials include, for example, polymeric
materials, a polymeric containing material, waterproof fabrics
(either woven or nonwoven), a textile material treated to make it
waterproof, etc. In an aspect of the invention the gasket can be
more than one layer. For example, the gasket can be a backer
material (such as a nonwoven, knit, etc.) laminated or otherwise
attached to a thin polyurethane film. On the opposite side of the
polyurethane film could be provided a flowable adhesive which is
capable of melting and flowing to form a bond and waterproof seal
with the laminate upper. In any case, the waterproof gasket
material is adhered to the inner surface of the bottom of the
closed upper. The adhesive may be any suitable adhesive material.
Non-limiting adhesives include, for example, polyurethane, natural
latex rubber, nitrile rubber, silicone rubber, butyl rubber,
fluorinated rubber, copolyether polyester, polyester, ethylene
vinyl acetate or polyamide. In an aspect of the invention, the
adhesive is a thermoplastic material. The adhesive can be applied
to the surface of the strobel board and the perimeter edge of the
upper, to the bottom surface of the waterproof gasket, or to the
surface of the strobel board, the perimeter edge of the upper and
to the bottom surface of the waterproof gasket. In an aspect of the
invention, the waterproof gasket may be previously supplied with
adhesive material (such as in the layered gasket material discussed
above), which can be activated at the point of footwear assembly by
application of heat, or heat and pressure. The adhesive need only
be applied in such an amount and at selected locations to provide a
waterproof seal between the gasket and the laminate upper. It is
generally desirable, however, to provide adhesive such that the
entire surface of the gasket which is in contact with the bottom of
the closed upper is covered with adhesive.
[0022] To adhere the waterproof gasket material to the inner
surface of the bottom of the closed upper the closed upper can be
turned inside out and the gasket adhered to the bottom surface of
the upper and then the upper returned to outside out configuration.
In an alternative embodiment, the gasket can be slipped into the
closed upper and adhered to the bottom of the closed upper. If
pressure is used to accomplish adhesion, then a shoe last could be
inserted into the closed upper to apply pressure to the gasket.
[0023] It may be desirable to provide the inner surface of the
laminate upper with an inner liner material, either for aesthetics,
for increased wearer comfort, or for increased durability. Such an
inner liner material can be adhered or otherwise attached to the
functional layer of the laminate upper. Suitable inner liner
materials include, for example, the textile fabrics mentioned
above.
[0024] Moreover, after the waterproof gasket is adhered to the
inner surface of the closed bottom of the closed upper, any
suitable foot bed can be inserted into the footwear to provide for
improved wearer comfort, if desired. Suitable foot bed materials
are well known to the skilled artisan and include, for example,
ethylene vinyl acetate, felt, etc. Foot beds are usually easily
inserted and/or removed from the footwear article and are, thus,
replaceable. Moreover, foot beds can also be glued in place. In an
aspect of the invention the waterproof gasket material can serve as
a foot bed. For example, the waterproof gasket material may
comprise a material which provides the necessary waterproofness as
well as the desired comfort to the wearer. Ethylene vinyl acetate
is particularly well suited for this aspect of the invention.
[0025] Of course, any suitable outer sole material can be attached
to the bottom, outer portion of the closed upper.
[0026] In a further aspect of the invention it may be desirable to
provide the outer layer material with selectively located
decorative or functional materials to complete the footwear
article. For example, in the case of sports shoes it may be
desirable to add heel counters (made from, for example,
thermoplastic polyurethane) to reduce over pronation. Further, a
rubber toe cap can be provided to provide the toe area with extra
protection. Moreover, simply decorative materials can be
selectively located on the outer layer material to improve the
visual appearance of the footwear. Such selectively located
decorative or functional materials can be attached to the outer
layer material in any suitable manner (e.g., adhesive, sewn, etc.).
If the material is sewn to the outer layer material care should be
taken to insure that waterproofness is not compromised (i.e.,
waterproof tape material or other sealant should be applied to
cover any holes created by the stitching).
[0027] What is meant by "Waterproof footwear" is determined as
follows. The footwear is placed on top of a piece of blotter paper.
The inside of the footwear is filled with room temperature water to
a height of about 30 mm (measured from the insole at the heel area
of the footwear). The water is allowed to stand in the footwear for
two hours. At the end of the two hour period the blotter paper and
footwear upper are examined to determine if water has reached the
blotter paper or the outer layer of the upper. If no water has
reached the blotter paper or the the outer layer of the upper, then
the footwear is waterproof.
[0028] As used herein the "waterproof, water vapor permeable
functional layer" and the "waterproof gasket material" are
"waterproof" if, when combined to form the footwear according to
the invention, they result in the footwear being "waterproof" as
defined above.
[0029] While particular embodiments of the present invention have
been illustrated and described herein, the present invention should
not be limited to such illustrations and descriptions. It should be
apparent that changes and modifications may be incorporated and
embodied as part of the present invention within the scope of the
following claims.
* * * * *