U.S. patent application number 10/987162 was filed with the patent office on 2005-05-19 for waterproof/breathable moisture transfer liner for snowboards, alpine boots, hiking boots and the like.
Invention is credited to Baychar.
Application Number | 20050102862 10/987162 |
Document ID | / |
Family ID | 27114727 |
Filed Date | 2005-05-19 |
United States Patent
Application |
20050102862 |
Kind Code |
A1 |
Baychar |
May 19, 2005 |
Waterproof/breathable moisture transfer liner for snowboards,
alpine boots, hiking boots and the like
Abstract
The waterproof/breathable moisture transfer liner for a
snowboard boot includes an inner liner selected from technically
advanced fabrics which are carefully selected. A series of layers
are provided outside the inner liner including foam material
layers, breathable membranes, a supportive mesh or a moldable foam,
and an outer shell fabric. The applicability of the liner to
alpine, cross country and hiking boots, along with appropriate
variations for each application.
Inventors: |
Baychar; (Carrbasactt,
ME) |
Correspondence
Address: |
MATTINGLY, STANGER, MALUR & BRUNDIDGE, P.C.
1800 DIAGONAL ROAD
SUITE 370
ALEXANDRIA
VA
22314
US
|
Family ID: |
27114727 |
Appl. No.: |
10/987162 |
Filed: |
November 15, 2004 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10987162 |
Nov 15, 2004 |
|
|
|
09500535 |
Feb 9, 2000 |
|
|
|
09500535 |
Feb 9, 2000 |
|
|
|
08910116 |
Aug 13, 1997 |
|
|
|
6048810 |
|
|
|
|
08910116 |
Aug 13, 1997 |
|
|
|
08832800 |
Apr 4, 1997 |
|
|
|
08832800 |
Apr 4, 1997 |
|
|
|
08747340 |
Nov 12, 1996 |
|
|
|
5738937 |
|
|
|
|
Current U.S.
Class: |
36/55 ;
36/10 |
Current CPC
Class: |
B32B 2307/304 20130101;
B32B 2262/0253 20130101; Y10T 442/3854 20150401; B32B 2260/046
20130101; Y10T 442/15 20150401; D04H 1/58 20130101; Y10T 442/651
20150401; A41D 27/02 20130101; Y10T 442/682 20150401; B32B 2307/724
20130101; B32B 2307/7145 20130101; Y10T 428/249986 20150401; Y10T
442/335 20150401; B32B 5/022 20130101; B32B 5/18 20130101; Y10T
442/697 20150401; Y10T 428/249981 20150401; Y10T 428/1369 20150115;
Y10T 428/1366 20150115; Y10T 442/469 20150401; Y10T 442/695
20150401; Y10T 442/3358 20150401; Y10T 442/3341 20150401; B32B
2262/14 20130101; A43B 5/0405 20130101; Y10T 442/3472 20150401;
Y10T 428/24998 20150401; Y10T 442/649 20150401; Y10T 442/3325
20150401; Y10T 442/674 20150401; B32B 2260/021 20130101; B32B
2262/08 20130101; B32B 27/12 20130101; Y10T 442/102 20150401; Y10T
428/1362 20150115; D04H 1/4374 20130101; B32B 2262/0276 20130101;
Y10T 442/10 20150401; Y10T 428/249975 20150401; A43B 7/125
20130101; A43B 5/0401 20130101; Y10T 442/647 20150401; Y10T 442/195
20150401; B32B 2266/06 20130101; A43B 23/07 20130101; B32B
2266/0278 20130101; B32B 5/026 20130101; D04H 1/42 20130101; Y10T
428/24496 20150115; B32B 2437/02 20130101; B32B 2307/7265 20130101;
D04H 1/46 20130101; Y10T 442/136 20150401; B32B 5/26 20130101; B32B
5/024 20130101; B32B 2307/728 20130101; Y10T 428/249953 20150401;
A43B 1/0045 20130101; B32B 5/245 20130101; Y10T 442/3041 20150401;
A43B 19/00 20130101; B32B 5/24 20130101; B32B 5/32 20130101; Y10T
428/24273 20150115; Y10T 428/24996 20150401 |
Class at
Publication: |
036/055 ;
036/010 |
International
Class: |
A43B 003/10 |
Claims
1-8. (canceled)
9. A Composite for footwear and apparel comprising: an inner
moisture transfer material; a second layer of a breathable,
moisture vapor transferring, cellular elastomeric composite
comprised of at least two layers and utilizing a foam and a
nonwoven as a component, the cellular elastomeric composite being
attached to the inner moisture transfer material;
10. A composite according to claim 9, wherein the cellular
elastomeric nonwoven and foam composite is attached to a
breathable, moisture transferring, open cell foam.
11. A composite according to claim 9, wherein the cellular
elastomeric nonwoven and foam composite is backed by an apertured,
moisture transferring and breathable nonwoven.
12. A composite according to claim 9, wherein the cellular
elastomeric nonwoven and foam composite is backed by a moisture
transfer, breathable thermal nonwoven.
13. A composite according to claim 9, wherein the cellular
elastomeric nonwoven and foam composite is backed by a moisture
vapor transferring, waterproof, breathable membrane.
14. A composite according to claim 9, wherein the cellular
elastomeric nonwoven and foam composite is backed by a breathable,
moisture transferring knitted fabric.
15. A composite according to claim 14, wherein the breathable,
moisture transfer knitted fabric is waterproofed.
16. A composite according to claim 9, wherein the breathable,
cellular elastomeric nonwoven and foam composite is backed by a
breathable, moisture transferring woven fabric.
17. A composite according to claim 16, wherein the breathable,
moisture transferring woven fabric is waterproofed.
18. A composite according to claim 9, wherein the cellular
elastomeric nonwoven and foam composite is attached to a nonwoven
treated to have reversible enhanced thermal properties.
19. A composite according to claim 9, wherein the cellular
elastomeric nonwoven and foam composite is attached to breathable,
moisture vapor transferring foam treated with reversible enhanced
thermal properties.
20. A composite according to claim 19, wherein the breathable,
moisture vapor transferring foam is backed by a moisture vapor
transferring, breathable, waterproof membrane.
21. A composite according to claim 20, wherein the breathable,
moisture vapor transferring foam and waterproof breathable membrane
are attached to an outer shell material.
22. A composite according to claim 19, wherein the breathable,
moisture vapor transferring foam is backed by a moisture vapor
transferring, breathable, waterproof material.
23. A composite according to claim 9, wherein a least one portion
of the composite has reversible enhanced thermal properties.
24. The composite for a liner according to claim 9, wherein the
non-woven top sheet includes at least one material selected from a
group consisting of spandex, wood pulp, cotton, polypropylene,
polyester and rayon.
25. A composite for footwear and apparel comprising: an inner
moisture vapor transfer material; and a layer of breathable open
cell foam attached to the inner moisture vapor transfer material,
the layer of foam being capable of transferring moisture, wherein
the layer of foam is treated to have reversible enhanced thermal
properties.
26. A composite for footwear or apparel comprising: a non-woven
material being capable of absorbing and transferring moisture vapor
mechanically bonded to an open cell foam to form a breathable,
moisture transfer, nonwoven and foam composite.
27. A composite for footwear or apparel according to claim 26,
wherein the open cell foam is treated to have reversible enhanced
thermal properties and is backed by a knitted fabric.
28. The composite according to claim 26, wherein the non-woven
material includes at least one material selected from a group
consisting of spandex, wood pulp, cotton, polypropylene, polyester
and rayon.
29. A composite according to claim 26, wherein a least one material
in the composite has reversible enhanced properties.
30. A composite for footwear and apparel comprising: a layer of
breathable, moisture transfer foam having reversible enhanced
thermal properties; and a breathable non-woven material positioned
in contact with the layer of foam, the non-woven material being
capable of absorbing and transferring moisture vapor.
31. A composite according to claim 30, wherein the breathable foam
is attached to a knitted material and a waterproof breathable outer
layer.
32. A composite according to claim 30, wherein the breathable foam
is attached to a nonwoven material and a waterproof breathable
outer layer.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to liners used in a variety of
applications. For example, the liner of the present invention may
be employed in a variety of applications including snowboard boots,
alpine boots, cross-country boots, downhill boots and even apparel
such as shirts. The liner is breathable and waterproof to increase
comfort for the rider.
BACKGROUND OF THE INVENTION
[0002] Various types of liners are known in the prior art. However,
these liners do not provide the advantages realized by the present
invention. The present inventor has recognized the problems faced
by snowboard riders developed liners to overcome such problems.
[0003] There is an ongoing need for comfort, breathability and
support for snowboard boot liners. In prior liner designs, a rigid,
non-breathable outer material, such as vinyls, foams and nylons is
often used. The inner liners have been leather, synthetic leather,
nylon or polyester blends which extremely limited the ability to
breathe or wick moisture away from a rider's body. These materials
have prevented the foot from breathing adequately.
SUMMARY OF THE INVENTION
[0004] An object of the present invention is to provide lining
system employing a warmer and more breathable liner that meets the
needs of each individual snowboard rider. Accordingly, the liner of
the present invention can be accommodated to the needs of snowboard
riders of various skill categories by permitting the inner liner
material, which is against the foot, to vary in fiber content and
construction.
[0005] This object of the present invention is realized by
providing a lining system having lining materials which act as a
moisture transfer system. Moisture vapors are transferred through
the liner from one side to the other side. The various lining
materials can be attached to each other by lamination, mechanical
bonding (or stitch bonding as done by Tietex, Inc. or Xymid group
of Dupont) or a combination of the two. Specific examples are
proved below in the description of the preferred embodiments of the
present invention.
[0006] Other objects, features and advantages of the present
invention will become readily apparent in view of the following
detailed description of the preferred embodiments in conjunction
with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates a first portion of the liner according to
a first embodiment of the present invention.
[0008] FIG. 2 illustrates a second portion of the liner according
to a first embodiment of the present invention.
[0009] FIG. 3 illustrates an example of the liner according to the
first embodiment of the present invention.
[0010] FIG. 4 illustrates the liner shown in FIG. 3 which will form
a part of a snowboard boot.
[0011] FIGS. 5(a) and 5(b) illustrate a sole portion of a boot
constructed according to a preferred embodiment of the present
invention.
[0012] FIGS. 6 and 7 illustrate a tongue portion of a boot
constructed according to a first embodiment of the present
invention.
[0013] FIG. 8 illustrates a more detailed view of the liner portion
used for the tongue of FIGS. 6 and 7.
[0014] FIG. 9 illustrates a portion of the liner used in the upper
cuff area.
[0015] FIG. 10 illustrates the travel of moisture through a
reticulated foam then a flexible mesh and into and through a
breathable membrane according to the first embodiment of the
present invention.
[0016] FIG. 11 illustrates the toe portion of a boot according to a
preferred embodiment of the present invention.
[0017] FIG. 12 illustrates an overall drawing of a snowboard boot
which will incorporate the liner of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The following detailed description of the preferred
embodiments of the present invention is undertaken in connection
with the drawings. This description, while undertaken with respect
to the disclosed embodiments, is intended to enable a variety of
different applications and slight modifications which form a part
of the present invention as claimed. More specifically, many of the
materials used in this lining system have been developed relatively
recently, and in many cases are still being modified and improved.
Where possible, tradenames of specific products have been used to
assist in the understanding of the invention. The lining system
according to the present invention can be easily adapted to
accommodate further developments in these materials. For example,
while the preferred embodiments are illustratively presented below
as a specific sequence of layers, it should be understood that one
or more of these layers may be omitted depending upon the specific
needs of any application. In other words, it is not strictly
necessary to have a certain number of foam layers just as that
disclosed in the currently preferred embodiment. This also applies
for other elements that are described. For the sake of conciseness,
every possible combination contemplated by the inventor are not
specifically enumerated. With this in mind, the preferred
embodiments currently. envisioned are set forth below.
[0019] FIG. 1 illustrates a portion of the liner, or lining system,
according to a first embodiment of the present invention. This
embodiment is directed to a liner for a snowboard boot which is
generally non-removable. The various layers of materials discussed
below can be attached to one another is a number of ways,
particularly by lamination, mechanical bonding (or stitch bonding
such as that done by Tietex, Inc. or Xymed Group by Dupont) or a
combination of lamination and mechanical bonding. Mechanical
bonding can be performed using nylon or LYCRA.RTM. thread, or the
like. As shown in FIG. 1, a first foam material 20 is provided
between an inner liner 10 and a second foam material 30. The inner
liner 10 can be attached to the first foam material 20 by
lamination or the like. The second foam material 30 is a germicidal
and reticulated foam and has a thickness of approximately 1/4 inch.
The first foam material is also preferably germicidal and
reticulated and has a thickness of approximately 1/8 inch. All of
the foam materials used in the present invention are assumed to be
breathable and their thicknesses can be varied depending upon
specific needs. Alternatively, some of the foam materials can be
replaced with a germicidal, hydrofilic open-cell foam. For example,
a foam called AQUAZONE (made by Foamex) may be used. Preferably,
the AQUAZONE is attached to a non-woven top sheet made of wood
pulp, polyester, cotton, rayon, polypropylene, LYCRA.RTM. or a
combination of these, etc.
[0020] The inner liner 10 is preferably constructed using specific
fabrics possessing certain desired characteristics. A list of
fabrics which can be employed depending upon the individual needs
of their application as well as the individual needs of each rider
are provided below. These fabrics may either be used individually
or in combination and can be double sided with one fiber on one
side and another on the other side. Variations for use in a
snowboard boot are specifically recited.
[0021] The first fabric is an antimicrobial, antifungal
polypropylene (also referred to as polyolefin) LYCRA.RTM. blend
(2%) with INNOVA fiber, or the like. INNOVA is a continuous
filament fiber (manufactured by Deercreek Fabrics, Inc. or Menra
Mills).
[0022] The second fabric is an antimicrobial, antifungal
polypropylene having a polyester or cotton backing, or the like
(such as that manufactured by Coville, Inc.). For uses such as for
alpine boots, the polyester or cotton backing can be replaced with
wool or silk.
[0023] The third fabric is an antimicrobial, antifungal
polypropylene/cotton blend with ALPHA fiber (such as that
manufactured by Intex Fabric, Inc.).
[0024] The fourth fabric is a field sensor polyester with waffle
weave construction (such as that manufactured by Toray and
distributed by Yagi & Co., Inc.). Alternatively, a polyester
material known as AQUA-DRY, manufactured by Teijin Shojin can be
employed.
[0025] The fifth fabric is a hydrofilic antimicrobial DRI-LEX
DRI-LEX BABY KID or perforated material (such as that manufactured
by Faytex Corp.).
[0026] The sixth fabric is a polyester looped terry (such as that
manufactured by Kronfli Spundale Mills, Inc.).
[0027] The seventh fabric is a sueded/sanded polyester microfiber
material (distributed by Yagi & Co., Inc. and Teijin Shojin,
Inc.).
[0028] The eighth fabric is POLAR TEC Series 2000, which is a
wickable, moisture transfer fiber, containing LYCRA.RTM. and
polypropylene. This fabric is also antimicrobial.
[0029] The ninth fabric is a moisture transfer fabric by Tietex,
Inc.
[0030] The tenth fabric is a wool blend with a cotton, polyester or
the like backing.
[0031] Finally, spacer fabrics, polyester or polyester blends
manufactured by Malden Mills and others can be used. These are
composite fabrics having layers of fabrics.
[0032] All of these fabrics have good moisture transfer
characteristics which prevent damage to a rider's foot by
preventing excessive moisture built-up.
[0033] The moisture transfer characteristics of the inner liner 10
causes moisture vapors to be passed from a rider's body through the
inner liner 10 where it then comes into contact with the first foam
material 20. The moisture vapors travel through the first foam
material 20 and come into contact with the abutting second foam
material 30.
[0034] First foam material 20 may be a cellular elastomeric
composite, or the like, having a layer of 1/8" germicidal,
reticulated foam (or germicidal, hydrophilic open-cell foam such as
AQUAZONE, or the like) backed with a nonwoven top sheet comprised
of wood pulp, rayon, cotton, polypropylene, polyester, LYCRA.RTM.,
or a combination thereof. The cellular elastormeric composite is
formed in one process. Alternatively, foam material 20 can be a
foam that is separate from the nonwoven top sheet and is attached
to the nonwoven top sheet by lamination, stitched or ultrasonically
bonded. The nonwoven top sheet (when used) abuts the next layer of
1/4" reticulated/hydroflic open cell foam, or second foam material
30, The second foam material 30 may also be a germicidal,
hydrophilic, open-cell 1/4" foam, such as AQUAZONE, or the like.
The second foam material is preferably backed with a nonwoven top
sheet as mentioned above. In fact, any of the foam materials
discussed herein can be backed by such a nonwoven top sheet. Also,
many of the foam materials are interchangeable depending upon
specific needs. Alternatively, the foam materials can be flame
laminated to a non woven apertured top sheet of cotton,
polypropylene or polyester, or a blend thereof, for example.
[0035] For example, the first foam layer 20 may also be substituted
with a germicidal, hydrofilic open-cell, 1/8" foam, such as
AQUAZONE. The foam can also be backed by non-woven top sheet. Also,
a temperature regulating membrane called OUTLAST, by Gateway
Technologies can be inserted between inner layer 10 and the first
foam material 20 or applied to the fibers of layer 10.
[0036] Alternatively, Frisby Technologies can be embedded in the
first open cell, hydrofilic foam layer 20 or placed in the second
foam mateiral 30. The hydrofilic foam is preferably AQUAZONE, but
may be a Frisby product called COMFORTEMP.
[0037] The OUTLAST membrane can be placed on the other side foam,
outside the nonwoven top sheet, if present. In fact, OUTLAST or
Frisby may be combined with any foam or insulative layer and can be
on either side.
[0038] A number of patents have been issued to Triangle Research
& Development Corp. disclosing details related to the processes
now being employed by Gateway Technologies and Frisby. For example,
U.S. Pat. Nos. 4,756,958 and 5,366,801 are directed to fibers and
fabrics with reversible enhanced thermal properties, respectively.
The disclosures of these two patents are hereby incorporated by
reference. Other patents assigned to Triangle Research &
Development Corp., that are related by subject matter and have
overlapping inventorship, include U.S. Pat. Nos. 5,415,22,
5,290,904, and 5,244,356. These patents are also hereby
incorporated by reference.
[0039] Another patent, U.S. Pat. No. 5,499,460, which has
overlapping inventorship with the above-mentioned patents, is
directed to a moldable foam insole with reversible enhanced thermal
storage properties. The disclosure of this patent is hereby
incorporated by reference, and is illustrative of one type of
moldable foam that can be used as mentioned herein.
[0040] As shown in FIG. 2, a third foam material 50, which provides
support and has similar characteristics to the second foam material
30, allows the moisture vapors to continue their movement toward
the outside. This third foam material 50 is formed in certain areas
to take necessary shapes such as the shape of an ankle, heel cup
and foot bones and is positioned so as to allow the moisture to
pass through into subsequent elements, such as
waterproof/breathable membrane 60 and the outer layer 70 of the
overall lining system. The third foam material 50 may alternatively
be a spacer fabric by Muller or the like. The spacer fabric or the
third reticulated/open cell foam material 50 can be designed to
provide a well defined heel lift, and heel pocket. This invention
develops the components necessary to increase technical performance
with the increased support around the heel, toe and ankle. The toe
box is from top to bottom, wider and more flexible than in previous
boot liners. The laminated foams under the heel support the riders
lower back and allows for a comfortable stride. With this added
comfort, the aggressive or recreational snowboard rider can achieve
a higher level of continued performance.
[0041] As shown in FIG. 3, between the supporting second foam
material 30 and the third foam material 50 is a structural mesh 40
which can be a flex guard, for example such as one manufactured by
NALTEX or Conwed or the like, that adds structural integrity to the
lining system. A spacer fabric, moldable foam, or the like, may
also be used in place of this flex guard or mesh. Also, neither may
be used is some circumstances. The moldable foam, if not very
breathable, can be made breathable by puncturing. Alternatively,
the moldable foam can be a reticulated or hydrofilic, open-cell
structure, or the like. A non-woven top-sheet (with or without
apertures) can be attached to the moldable foam. If a moldable foam
is used, then the second foam material may be omitted. Also, the
moldable foam can be AQUAZONE. Preferably, for snowboard
applications the moldable foam or spacer fabrics are used instead
of the flexible mesh as layer 40.
[0042] As mentioned earlier, the third foam material 50 is
preferably similar in construction to the second foam material,
namely being either germicidal, reticulated and approximately 1/4
inch thick or being germicidal, hydrofilic, open-cell (for example,
AQUAZONE). This material is preferably laminated to a non-woven top
sheet (which may or may not be apertured) comprised of wood pulp,
rayon, or cotton. The top sheet abuts the waterproof/breathable
membrane 60.
[0043] For snowboard boots, due to the cold weather conditions, a
combination of thermolite (or thermoloft) and foam or thermolite by
itself is preferably used for third foam material 50. Thermolite,
manufactured by Dupont, is a thin insulation having a hollow
polyester fiber laid in random layers with an acrylic binder (loose
felted) needle punched through the cross section to attach layers
and tie them down. Various types of thermolite can be used, such as
thermolite extreme, thermoloft, microloft, TFI 2000 G/M2 or TFI
4000 G/M2, etc. If encapsulation is used in outer layer 70, as
discussed herein, then it is important to use thermolite as layer
50. Again, the OUTLAST membrane or Frisby can be used in
combination with third foam material 50, especially in combination
with thermolite.
[0044] The moisture vapor continues from the second foam material
30 through the mesh or spacer material 40 and on through the third
exterior foam or Thermolite material 50. The moisture vapors are
then passed through waterproof/breathable membrane 60. The moisture
vapors are absorbed into the waterproof/breathable membrane and
passed through to an outer layer of fabric 70, as shown in FIG. 4.
The waterproof/breathable membrane 60 can be selected from a
variety presently available on the market. Those under the
tradenames VAPEX 2000/PLUS/STANDARD/1300, SECO-TEC, THINTEC,
LAY-TEK and Witcoflex Super Dry film by Baxenden Chemicals (a
hydrofilic membrane) are currently being considered. However, the
membranes currently considered to be the preferred ones are called
TX-1540 (application by Shawmut Mills). TX-1540 is intended to be
an ultra-thin, skin friendly, moisture barrier that allows moisture
vapors to escape while preventing outside water from penetrating.
The OUTLAST membrane or the Frisby Technologies can be used in
combination with other membranes, with encapsulation techniques, or
with structurally knitted fabrics and can adjust to temperature
changes. Of the various encapsulation techniques, the one practiced
by Nextec is particularly advantageous.
[0045] Also shown in FIG. 4 is an optional protective rim or cuff
80, preferably made of a slow recovery foam (by Foamex, for
example) or neoprene covered by LYCRA.RTM.. Cuff 80 could also be
made of a reticulated foam. A pull tab 90, preferably made of
nylon, is connected to the protective rim 80. A abrasive protective
material 100 is provided adjacent to a tongue 300. Another abrasive
protective material 110 is provided around the heel portion of the
boot. Abrasive protective material 110 is supplied by Schoeller or
Dupont, or the like.
[0046] The outer layer of fabric 70 of the lining system has 200 to
6000 denier strength and is made waterproof by a membrane,
encapsulation technology or by using structurally knitted, water
repelling fabrics. Encapsulation technology is being utilized by a
company called Nextec, Inc. or Toray, Inc. (a Japanese Company or
the like). Nextec Technology can be combined with the OUTLAST
membrane or Frisby Technology. The OUTLAST membrane may be coated
or laminated to the outer fabric. If the outer fabric is
encapsulated then the OUTLAST technology must be applied to the
fiber or fabric prior to encapsulation. The Frisby temperature
regulating molecules can be incorporated into the spaces between
the encapsulated fibers and may be inserted at the time of
encapsulation. The breathable membranes preserve the outer layer of
fabric 70 and perform as a waterproof barrier for the boot liners.
If the encapsulation technology is applied to the outer layer of
fabric 70, then the breathable laminate membranes need not be
used.
[0047] The outer layer 70 may be any of the following materials,
either individually or in combination. These materials include
synthetic breathable leathers, or the like, by Daowoo, Kevlar and
Cordura fabrics, by Schoeller, Kelvar and technical fabrics by
Dupont and Toray, Cordura treated by Encapsulation by Dupont,
Travis and the like, 4 ply supplex, Cordura waterproofed by the
breathable membrane, F.L. fabric by Malden Mills, DERMIZAX by
Toray, ENTRANT GIL and WAXEY by Toray, GYMSTAR PLUS and TUFLEX-HR
both by Unitika. The Corduras can be those made by others as well.
There are primarily three ways of protecting outer layer 70,
encapsulation, using a membrane, structurally knitting the fabric
to repell water or coating the fabrics with a waterproof film.
Preferably, the outer layer 70 is a combination of one of the
above-mentioned materials with one of the following: the OUTLAST or
Frisby Technologies and encapsulation by Nextec or the like, or the
OUTLAST membrane or Frisby Technologies and the
waterproof/breathable fabrics such as ENTRANT GIL, DERMIZAX, TUFLEX
or GYMSTAR. The OUTLAST membrane is laminated or coated to the
outer fabric's fibers, or the Frisby Technology embedded in the
outer fabric and then laminated to the waterproof/breathable
membrane, the Frisby or OUTLAST Technologies in combination with
structurally-knitted or woven waterproofed fabrics, or finally the
Frisby or OUTLAST Technologies in combination with ENTRANT GIL,
Dermaizax, Turflex or GYMSTAR or the like. The outer fabrics in
several performance catagories may not apply either Frisby or
OUTLAST Technologies.
[0048] Selecting the proper materials depends upon the needs of
each individual snowboard rider. The non-abrasive fabrics used in
the moisture transfer inner liner of the present invention greatly
reduces the possibility of trapped moisture, thereby protecting the
foot from fungus growth and any damage. The antifungal,
antimicrobial polypropylene (polyolefin) fabrics quickly remove
moisture away from the foot. Skin damage in minimized because the
polypropylene fabric has a smooth, continuous surface. This fabric
also prevents bacterial build-up which can cause foot odor and
fungus.
[0049] The polyester looped terry blend is an excellent wicking
fabric and can remove moisture rapidly when treated with a wetting
agent.
[0050] The antifungal, antimicrobial, DRI-LEX nylon fabrics, like
the polypropylene, is sanded and soft. The material not only
removes moisture from the foot, but also is extremely comfortable
and cool to the touch.
[0051] The polyester field sensor fabric works well with those
individuals who prefer riding free-style. This liner absorbs
moisture immediately.
[0052] A polyester microfiber fabric is smooth to touch and
wickable. A wetting agent may be added to assist in moisture
transfer.
[0053] Finally, a wool blend backed with polyester or cotton or the
like.
[0054] As a result of using this lining system, the rider continues
to have a cooler, drier foot. The lightweight kevlar, starlite,
Cordura and DERMIZAX outer liner materials are twice as durable as
the former heavyweight nylons and synthetic leathers often used on
the outer shell, but function as a softer, stronger feeling
breathable outer surface and aid in the moisture transfer.
[0055] FIGS. 5(a) and 5(b) illustrate a sole portion 200 of a foot
foam pad covered with cambrelle DRI-LEX nylon. Preferably, however,
the foot pad is designed using Sontara Technology nonwoven, by
Dupont, and called ComforMaxSPORT, or the like. ComforMaxSPORT is
backed by hydrophilic foam and helps protect the foot bed from
damage due to friction. The inserted hydrophilic foam foot pad adds
support and transfers moisture downward. The bottom portion of the
foam is preferably provided with a nonwoven top sheet as described
earlier. The heel pocket foam protects the back of the heel with a
double layered reticulated support foam. This cushion protector
allows circulation in the heel. ComforMaxSPORT or an antimicrobial
cambrelle DRI-LEX nylon 210, or the like, covers a molded
hydrophilic foam or a slow recovery foam 220 that supports the arch
and insures additional comfort for a rider.
[0056] FIGS. 6, 7 and 8 illustrate the tongue 300 of the boot in
more detail. The tongue is designed to add further comfort and
support. As shown in FIG. 8, an inner liner fabric 310 of the
tongue 300 is preferably one of the other inner liner materials
mentioned above, especially the polypropylene LYCRA.RTM. blend with
INNOVA fiber, the polyester microfiber, the polyester looped terry
or the fabrics by Malden Mills, Miliken or the like. This inner
liner fabric 310 is preferably laminated to a structural support
foam 320, which is preferably a 1/4 inch germicidal, reticulated
foam. A hydrophilic perforated foam 330 (also could be a
reticulated foam, or PORON which is a slow recovery foam by Rogers,
Inc., or the like) abuts a structural support foam 320. The
hydrophilic perforated foam 330 can take the shape of the foot
bones and protect the upper foot from damage. The structural
support 320 can also be shaped to accommodate the foot and protect
the ankle bones. Optionally, a moldable spacer fabric by Muller, or
the like, may also be used as portion 330. A moisture transfer
material 340 lies over the hydrophilic perforated foam 330. This
moisture transfer material 340 is preferably made from a material
known as aero-spacer DRI-LEXDRI-LEX, which is manufactured by
Faytex Corp, or an aero-spacer fabric manufactured by Apex Mills,
or the like. Optionally, a nonwoven material such as Sontara
Technology manufactured by Dupont can be used. In one embodiment,
neither the aero-spacer or the nonwoven by Sontara Technology is
used.
[0057] The nonwoven material, Sontara Technology, can be a spun
lace moisture management product called Typar, for example. It can
have a sanded surface treatment or it can look like steel wool and
would wrap around the edges of the tongue. It should be understood
that these nonwoven materials can always be substituted for the
aero-spacer DRI-LEX, even if not specifically mentioned in other
parts of this disclosure. This material 340, is wrapped around the
outer edge of the tongue to allow moisture vapors traveling from
the upper foot area to escape through moisture transfer material
340 to the outer surface of the tongue 300. Material 340 also aids
in providing a softer edged tongue. Finally, an outer layer 350 is
provided over a central portion of the material 340. Another
hydrophilic, molded foam (not shown), or slow recovery form or
hydrofilic foam, is shaped to fit between the outer layer 350 and
material 340.
[0058] As shown in FIG. 6, outer layer 350, which can be a
breathable synthetic leather (by Daewoo Corp. for example) or a
kevlar, or the like is surrounded by aero-spacer DRI-LEX 340, a
substitute as mentioned above or a combination thereof. At the top
of the tongue 300 is an abrasive reflective grip fabric 100 (such
as that manufactured by Schoeller and identified by the number
6500, or the like), also shown in FIG. 4. Stitching is identified
by numeral 370. FIG. 7 illustrates a top portion of the tongue 300,
and shows stitching 370 and the inner liner fabric 310.
[0059] The liners are preferably provided with a pull tab 90 as
illustrated in FIGS. 4, 9 and 10 on the back of a cuff 80
constructed of a slow recovery foam (by Rogers, or the like) or
neoprene covered by LYCRA.RTM.. Optionally, cuff 80 can be omitted
altogether. FIG. 9 shows an opened up version of the liner looking
from the back of the boot. Located just beneath the LYCRA.RTM.
covered neoprene cuff 80 is a abrasive grip fabric material 410,
such as that manufactured by Schoeller, Inc. and referred to by the
number 6500. Below material 410 is a reflective grip composite
material 420. Below the reflective grip composite material 420 is a
highly abrasive fabric 110, as shown in FIG. 4. Fabric 110 is
preferable a Kevlar or Starlite or a cordura, or the like. Finally,
outer shell fabric 70 is the same as that shown in FIG. 4, and can
be any of the fabrics listed previously in connection with outer
shell fabric 70. The nylon pull tab 90 allows the rider to easily
slip into the liner.
[0060] FIG. 10 shows the other side of the liner of FIG. 9. In FIG.
10, 510 can be a 1/4 inch moldable foam which has been punctured or
a moldable spacer fabric or the like. 520 represents the
combination of the flexible mesh and foam (in the case the moldable
foam is not used as depicted), the breathable membrane and the
outer shell fabric. As in all of the Figures, the arrows depict the
flow of moisture.
[0061] FIG. 11 illustrates the toe portion 400 of the boot.
Preferably, the toe portion 400 is constructed with an inner liner
10, followed by a foam material 30, followed by a breathable
membrane 60 and finally followed by the outer fabric 70. Foam
material 30 can either be a single foam, two foams, a thermolite, a
thermolite and foam combination, or any of these in combination
with a non-woven top sheet (or a cellular elastomeric composite).
Abrasive grip fabric 100 is also shown.
[0062] The 6500 high abrasive fabrics manufactured by Schoeller,
Inc. or the like are optionally located on the back of the cuff and
the top of the toe box and heel. The Kevlar and cordura, starlite
fabrics provide comfort and durability to the liners and are
extremely strong and resistant to abrasion and allow for
breathability and performance.
[0063] FIG. 12 illustrates a snowboard boot incorporating the
lining system discussed above. The following elements of the
snowboard boot are shown: numeral 610 represents a waterproof
breathable synthetic leather, a Kevlar fabric (made by Shoeller, or
a similar material), Schoeller, Dupont & Toray or the like,
Cordura or DERMIZAX by Toray; numeral 615 represents materials
similar to that of numeral 610; numeral 620 is also similar to the
materials of numeral 610, but can have different colors for
aesthetic purposes; numeral 630 represents a Kevlar or a material
made by Schoeller, or the like, with the heel portion being
synthetic rubber or the like, manufactured by Daewoo; numeral 635
represents an inner moisture transfer material covering a molded
breathable foam; numeral 640 represents a Kevlar or cordura
material; numeral 645 is preferably a Kevlar material; numeral 650
represents some decorative piping made of synthetic leather or the
like; numeral 655 represents a pull tab made of nylon or synthetic
leather; numeral 660 represents the base of the boot which can be
made of a synthetic polyurethane; numeral 670 represents a
reflective Kevlar back; and finally, numeral 675 represents an
optional sock that can be inserted into the boot if desired.
[0064] The sock 675 is made up of three layers. The first layer can
be any of the inner liner materials discussed above. The second
layer is a layer of foam or thermolite or a combination thereof.
The third layer is a fabric such as moisture transfer LYCRA.RTM.
blend manufactured by Deercreek Fabrics, Memra Mills or the like.
Encapsulation technology can also be applied to the third layer.
Sock 675 can be used for additional warmth and is removable, unlike
the boot liner. The three layers can be attached to one another by
lamination, although mechanical bonding, or stitching, or
ultrasonically bonded, can also be used.
[0065] The microfiber technology disclosed above is rapidly
developing and changing and has greatly increased the potential for
improved performance of such products such as snowboard boots,
provided that they are properly utilized as in the present
invention. These new products are part of rapidly developing fabric
technology. The present invention employs a combination of fabric,
foam, moldable spacer materials and thermolite layers with
breathable membranes, structurally woven or knitted waterproof
fabrics, coated fabrics or encapsulated outer fabrics in such
combinations that increase the performance of the products in which
they are used as well as increase breathability. The breathable
membranes have also only recently developed and are believed to be
less that ten years old.
[0066] While the discussion above has focused upon snowboard boots,
similar applications can be made with alpine or cross country
boots, or in-line skates, with slight modifications. For example,
in the case of a cross country ski boot, the liner would preferably
have a waterproofed outer fabric attached to a synthetic rubber
base. Encapsulation technology and membranes such as TX1540,
WILCOFLEX DRY combined with the OUTLAST made by Gateway
Technologies can be employed. It is preferable to use OUTLAST or
Frisby close to the individuals foot in alpine, alpine
cross-country, and hiking boots. OUTLAST or Frisby Technologies may
also be added to any of the inner lining material listed.
Otherwise, the liner could be very similar, although the use of the
supportive mesh could be limited to certain areas. Adjustments in
the breathable membrane would be made to accommodate winter
conditions and cosmetic changes could be applied to the surface
areas.
[0067] The following is a brief discussion of the variations that
are preferably employed for a removable shell liner for alpine
boots, alpine cross country boots and hiking boots. Similar names
correspond to similar products discussed above and are not
described in further detail.
[0068] Alpine Boots
[0069] First, a liner for alpine boots is similar to in-line skate
boots except that Naltex and the like are not necessary although
they can be used for high performance boots. This liner would have
the following layers of materials (additional drawings for these
applications are omitted in order to be concise). The liner will be
described in a sequence of layers beginning with the innermost
layer. The first layer is selected from a group including
antimicrobial, anti-fungal, polypropylene INNOVA or ALPHA; DRI-LEX
cambrelle or DRI-LEX Doe skin manufactured by Faytex Corp.; looped
poly terry by Kronfli; DRI-LEX/Polyterry by Faytex, polypropylene
or wool blends backed by another fiber for example cotton or wool
or the like by Coville, Cordora; Polyester sueded or fleeced;
Spacer fabrics by Malden Mills; COOL MAX by Dupont; Tietex moisture
transfer materials; or Malden Mills polyester and blends thereof,
or the like. A combination of these materials may also be employed
depending upon the needs of any individual rider.
[0070] Just as in the case of the snowboard boot, the various
layers can be combined by lamination, mechanical bonding stitch
bonding, ultrasonic bonding or a or a combination of these two. The
second and third layers would include a foam that contacts the
first layer and is a germicidal, reticulated foam or a hydrofilic,
open-cell foam, such as AQUAZONE Foamex or COMFORTEMP by Frisby or
the like. Alternatively, these layers can be a cellular elastomeric
composite which is one of the above-mentioned foams backed by a
non-woven apertured top sheet composed of wood pulp, polyester,
rayon, cotton, or polypropylene, in a single process. Adjacent to
the inner liner composite foam is a 1/4" reticulated layer of
AQUAZONE.
[0071] The fourth layer is a molded hydrofilic AQUAZONE, slow
recovery foam (by Foamex) or flex-guard or a polyester spacer
material (by Muller) or the like for support. In this case,
AQUAZONE is laminated to a flat non-woven top sheet composed of
woodpulp, rayon, cotton, polyester, polypropylene which abuts a
waterproof/breathable membrane (fifth layer). If the flex-guard is
used it is followed by another layer of AQUAZONE with a top sheet
abutting the waterproof/breathable membrane.
[0072] If the spacer material is used it may or may not be molded
to accomodate the foot. The non-woven top sheet will be elminated.
The spacer material will be followed by either a waterproof
membrane, an encapsulated or coated fabric. The spacer material may
alternatively be used in a number of the boot layers.
[0073] The fifth layer is a waterproof/breathable membrane which
may be any one of the following: OUTLAST membrane by Gateway
Technologies in combination with Seco-Tex, No. TX-1540 (laminated
by Shawmut Mills), THINTEC, VAPEX 2000/1300 standard, LAYTEX and
ENTRANT GIL by Toray or the like. The OUTLAST membrane by Gateway
Technologies is in conjuncation with one of the suggested
breathable membrane or the like. The laminated or coated OUTLAST
membrane may also be combined with some encapsulated fibers and
fabrics. The Frisby Technology may be embedded in the proceed foam
or Thermolite or Microloft by Dupont, but is not in combination
with a breathable membrane. Frisby Technology can be used in
conjunction with structurally knitted waterproof fabrics, or with
the encapsulation technology by Nectex, Toray or the like.
Encapsulation by Nextec combined with the OUTLAST technologies is
preferred. If encapsulation is employed, than the fourth layer
preferably includes thermolite. If a non-removable liner is
employed instead of a removable liner, a waterproof-breathable thin
film can be used instead of encapsulation or a
waterproof/breathable membrane.
[0074] The sixth and final layer in this removable shell liner may
be cordura, starlite, tudor, 3/4/ply supplex, Kevlar fabrics,
DERMIZAX or encapsulated fabric or any combination of them. Also, a
waterproof breathable thin film coated fabric could be used.
[0075] Alpine Cross Country Boots
[0076] A liner for the alpine cross country boots is similar to the
snowboard boot liner except the cross country boot does not having
a sock liner and the foams (or thermolite and foam) are thinner.
This liner would include the following. A first layer selected from
a group including polypropylene, LYCRA.RTM. or wool backed by
cotton, wool, or a rayon blend or an anti-microbial, anti-fungal
INNOVA or ALPHA; sueded polyester; polyester field sensor; looped
polyester terry; DRI-LEX doeskin or baby kid by Faytex Corp.;
polyester DRI-LEX Terry by Faytex; polyester spacer fabric by
Malden; and polypropylene backed by cotton by Coville.
[0077] The second layer is a germicidal open cell hydrofilic foam
it may be COMFORTEMP by Frisby or AQUAZONE with Frisby
Technologies. This foam can be provided with or without a nonwoven
top sheet. The nonwoven top sheet can be selected from any of the
materials previously specified.
[0078] The third layer is a structural support foam or a moldable
spacer material surrounding the ankle and heel. The foam may be a
moldable hydrofilic AQUAZONE. The heel and arch may also have a
slow recovery foam added for comfort. The thickness of the layer of
foam or spacer fabric and Thermolite may vary for performance.
[0079] The fourth layer is a thin layer of Thermolite, or AQUAZONE
or the like with a non-woven top sheet made of wood, pulp, rayon,
cotton, polyester or polypropylene. The fourth layer may be
optional in some performance catagories.
[0080] The fifth layer is a waterproof/breathable membrane which
may be any one of the following: Seco at Shawmut Mills, THINTEC,
VAPEX 2000/1300 standard, LAYTEX, or ENTRANT GIL by Toray. The
OUTLAST membrane by Gateway Technologies is employed for this
layer. The OUTLAST membrane can be used by itself, with another
membrane or with encapsulation technology, such as by Nextec, Toray
or the like. Alternatively, instead of the membrane, just
encapsulation of the sixth layer can be performed to achieve
similar results. A combination of OUTLAST or Frisby and
encapsulation fibers or fabrics by Nextec or the like is preferred.
If encapsulation is employed, then the fourth layer preferably
includes thermolite.
[0081] The sixth layer is one of the following fabrics. Note that
if these fabrics are encasulated, the waterproof/breathable
membrane in the fifth layer may not be needed in combination. These
fabrics include the following: cordura; LYCRA.RTM. blends; starlite
by Faytex Corp.; Kevlar fabric by Schoellar
(14705,6500,13207,13632,65563, etc.); Dupont and Toray or the like,
Cordura 2000 by Dupont, DERMIZAX and ENTRANT GIL By Toray, 3 or 4
ply supplex; mojave and tudor nylon and polyester blends by Travis;
6 ply maxus nylon blends or the like; and synthetic leathers by
Daowoo, Inc. or the like. These fabrics may be used individually or
in combination.
[0082] The seventh layer is a LYCRA.RTM. covered neoprene, moldable
slow recovery foam or reticulated open cell foam ankle cuff.
[0083] The tongue for the alpine boot is similar to the tongue of
in-line skate. The tongue of the cross country boot is similar to
the snowboard boot. They can be constructed of AQUAZONE molded
foams with a top sheet or moldable spacer fabrics. A slow recovery
foam can also be used as specified with the snowboard boot. The
inner fabric is one or more of DRI-LEX Areo-spacer, polyester
spacer by Malden, polypropylene, polar fleece INNOVA or ALPHA or
DRI-LEX doeskin, polyester sueded or fleeced or the like. The outer
tongue fabrics are high abrasive fabrics Kevlar, starlite or
Schollars corduras, 6500, DRI-LEX Aero-Spacer (or other Aero-spacer
materials) by Faytex, or the like, and breathable synthetic
leathers by Daewoo, or the like.
[0084] Hiking Boots
[0085] A liner for the hiking boot would include the following. The
first layer is selected from a group including: polyester field
sensor; looped poly terry; DRI-LEX by Faytex by Faytex, Doeskin,
baby kid, Cambrelle by Faytex; anti-fungal, anti-microbial
polypropylene fabrics; INNOVA or ALPHA, sueded polyester blends and
COOL MAX, or the like. Any combination of these can also be
used.
[0086] The second layer is a cellular elastomeric composite or
hydrofilic open cell AQUAZONE foam or COMFORTEMP by Frisby. This
layer can be combined with the OUTLAST membrane. If a foam is used,
a nonwoven top sheet selected from previously mentioned materials
can be attached as a backing.
[0087] The third layer is a molded hydrofilic AQUAZONE backed by an
aperture top sheet composed of cotton, polyester, polypropylene,
rayon or woodpulp. A moldable heel and ankle spacer fabric by
Muller or the like may also be used in place of the third layer of
hydrofilic foam is preferably also used. A moldable slow recovery
foam may be added around the toe box and back cuff. A molded
heel/ankle insert by Foss is preferably also used.
[0088] The fourth layer is a waterproof/breathable membrane which
may be any one of the following: OUTLAST membrane by Gateway
Technologies combined with Seco-Tex, TX1540 (distributed by Shawmut
Mills), THINTEC, VAPEX 2000/1300 standard, LAYTEX, WILCOFLEX DRY or
the like. The OUTLAST membrane may also be used independently of
the breathable membrane and may also be coated to the outer fabric.
Also, this membrane layer may be eliminated in some models
depending upon the hiker's needs. Alternatively, instead of the
membrane, encapsulation of the fifth layer can be performed to
achieve similar results. If encapsulation is employed, than the
third layer is preferably AQUAZONE or a moldable spacer fabric or
thermolite. The OUTLAST membrane can be used either with another
membrane or in combination with encapsulation, such as by Nextec,
or the like.
[0089] The fifth and last layer is a combination of one or more of
the following: corduras; supplex nylon; starlite; tudor; kevlar;
polyester nylon blends; and breathable synthetic leathers.
Preferably, this layer is waterproofed by using encapsulation,
waterproof films or coatings or breathable membranes, with or
without the OUTLAST or Frisby technologies.
[0090] Furthermore, the breathable liner according to the present
invention could also be added to clothing, such as shirts, pants,
etc., by omitting elements such as the structural mesh and by
adjusting the number of foam material layers and their thickness.
For example, clothing preferably has a wickable inner liner,
followed by an {fraction (1/16)} to 1/8 inch AQUAZONE foam which
may be embedded with Frisby Technologies, a nonwoven may or may not
be laminated to the foam. A breathable membrane abuts the foam or
nonwoven and is laminated to the outer fabric. The outer fabric may
be encapsulated, laminated to a breathable waterproof membrane,
coated with a waterproof film or structurally woven or knitted to
repell water. Indeed the amount of foam used can be reduced due to
cost consideration etc. Thermolite or Microft by Dupont may also be
added for colder conditions. Also, the breathable membrane may vary
depending upon whether the liner will be used in the summer or
winter etc. Presently, this liner system is investigating the use
of polyester spun bonded filter products by Tangerding
Vlitesstoffe, Vitafiber or the like to be used as an alternative to
hydrofilic foam layers.
[0091] While the present invention has been described above in
connection with the preferred embodiments, one of ordinary skill in
the art would be enabled by this disclosure to make various
modifications to the disclosed embodiments and still be within the
scope and spirit of the present invention as recited in the
appended claims.
* * * * *