Coated footwear and methods for making and using the same

Abstract

Coated footwear and methods for making and using the same. An outer surface of a fabric layer conforming closely to the top, sides, bottom and individual toes of a foot is coated with a material in the areas where the fabric layer conforms closely to the sides, bottom and individual toes of the foot. The fabric layer can be elastic, breathable, ultraviolet light inhibiting, and/or chosen from the class of materials including supplex, spandex, nylon, and nylon/cotton blend. The coating can be textured, chosen from one or more of the class of materials including latex, nitrile, and polyurethane and/or including a chemical agent to insure adhesion of the coating to the outer surface of the fabric layer. The footwear can be made by immersing the fabric layer in a container filled with the coating material. Also, if desired, a second coating can be adhered over the first coating.

Description

TECHNICAL FIELD

[0001] The present invention relates to footwear and methods for making and using the same, and more particularly, to footwear and methods for making and using the same.

BACKGROUND OF THE INVENTION

[0002] Many types of footwear are known and have been employed since time immemorial. However, people who work or recreate out-of-doors have not had footwear available which would protect their feet from the heat and roughness of the supporting ground or pavement while providing tactile feel and allowing the components of the foot freedom of movement.

[0003] Footwear intended for use in a casual or recreational environment exists in many forms. Of course, socks of woven or knitted construction are an important form of footwear. Conventional woven or knitted socks offer little or no protection against the elements.

[0004] It is therefore an object of the present invention to provide an improved work or recreation shoe that provides protection of a foot from the heat of the ground or pavement.

[0005] It is a further object of the present invention to provide an improved work or recreation footwear that provides protection of a foot from rough surfaces including ground and pavement, swimming pool bottoms, beach shores and workout areas.

[0006] It is another object of the present invention to provide an improved work or recreation footwear capable of improved tactile feel for heightened physical performance, including but not limited to a textured coating that helps retain traction on wet or slick surfaces.

[0007] It is yet another object of the invention to provide improved work and recreation footwear that insulates the skin from direct contact with unsanitary surface, thus limiting risk of Athlete's Foot and other contagious conditions.

[0008] An advantage of the present invention is that it can provide foot protection for a user in various environments while the user is wearing it.

SUMMARY OF THE INVENTION

[0009] According to one aspect, the invention is a footwear for a foot on a human leg having an ankle. The footwear includes a fabric layer and a coating. The fabric layer has an inner surface and a corresponding outer surface. The inner surface conforms closely to the top, sides, bottom and individual toes of the foot. The coating is adhered to sections of the outer surface of the fabric layer. The sections correspond to the portions of the inner surface of the fabric layer that conform closely to the sides, bottom and individual toes of the foot.

[0010] According to a second aspect, the invention is a method for making a footwear for a foot on a human leg having an ankle. The method includes the step of a) forming a fabric layer having an inner surface and a corresponding outer surface, where the inner surface conforms closely to the top, sides, bottom and individual toes of the foot. The method further includes the step of b) adhering a first coating to sections of the outer surface of the fabric layer that correspond to the portions of the inner surface of the fabric layer that conform closely to the sides, bottom and individual toes of the foot.

[0011] According to a third aspect, the invention is an apparatus for making a footwear for a foot on a human leg having an ankle. The apparatus includes means for forming a fabric layer having an inner surface and a corresponding outer surface, the inner surface conforming closely to the top, sides, bottom and individual toes of the foot. The apparatus also includes means for adhering a first coating to sections of the outer surface of the fabric layer that correspond to the portions of the inner surface of the fabric layer that conform closely to the sides, bottom and individual toes of the foot.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a schematic drawing of a fabric layer of a first embodiment of the invention.

[0013] FIG. 2 is a schematic drawing of the first embodiment of the invention, showing the coated fabric layer.

[0014] FIG. 3 is a schematic drawing of a fabric layer of a second embodiment of the invention.

[0015] FIG. 4 is a schematic drawing of the second embodiment of the invention, showing the coated fabric layer.

[0016] FIG. 5 is a schematic drawing of a fabric layer of a third embodiment of the invention.

[0017] FIG. 6 is a schematic drawing of the third embodiment of the invention, showing the coated fabric layer.

[0018] FIG. 7 is a block diagram of a method for making the various embodiment of the invention.

[0019] FIG. 8 is a schematic drawing of an apparatus for making the second embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

[0020] FIG. 1 is a schematic drawing of a fabric layer of a first embodiment of the invention and FIG. 2 is a schematic drawing of the first embodiment of the invention, showing the coated fabric layer. The footwear 50 is intended to be worn on the foot 51 (shown in phantom lines) of a human leg having an ankle. The footwear 50 includes a fabric layer 52 having an inner surface 54. An outer surface 56 of the fabric layer 52 corresponds to the inner surface 54. The fabric layer 52 may be elastic and/or breathable. Preferably, the fabric layer 52 is woven from one or more materials chosen from the class of materials including supplex, spandex, nylon, and nylon/cotton blend. Further, the fabric layer 52 can include an ultraviolet light inhibitor for protection of the fabric layer 52 against sun exposure. Also, if desired, the fabric layer 52 can be made from a sheer material that doesn't break down in water and dries quickly once wet.

[0021] The fabric layer 52 has an upper opening 53 into which the foot 51 is inserted when the footwear 50 is worn. If desired, the fabric layer 52 can be high enough so that the upper opening 53 extends above the ankle 55 of the human leg.

[0022] The foot 51 has a top 60, sides 62 (such as left side 62.sub.L and heel side 62.sub.H, as well as the right side (not shown)), a bottom 64 and individual toes 66 (big toe 66.sub.B, little toe 66.sub.P, middle toe 66.sub.M, and second and fourth toes 66.sub.S and 66.sub.F, respectively. The inner surface 54 conforms closely to the top 60, sides 62, bottom 64 and individual toes 66 of the foot 51.

[0023] The footwear 50 also includes a first coating 68 which is adhered to portions of the outer surface of the fabric layer corresponding to the portions of the inner surface 54 that conform closely to the sides, bottom and individual toes of the foot 51. The first coating 68 can be made from one or more of the form-fitting materials chosen from the class of materials including latex, nitrile, and polyurethane.

[0024] FIG. 3 is a schematic drawing of a fabric layer of a second embodiment of the invention and FIG. 4 is a schematic drawing of the second embodiment of the invention, showing the coated fabric layer. The same reference numerals are used in FIGS. 3 and 4 to describe features already described in FIGS. 1 and 2. The footwear 50 is intended to be worn on the foot 51 (shown in phantom lines) of a human leg having an ankle. The footwear 50 includes a fabric layer 52 having an inner surface 54. An outer surface 56 corresponds to the inner surface 54. The fabric layer 52 may be elastic and/or breathable. Preferably, the fabric layer 52 is made from one or more materials chosen from the class of materials including supplex, spandex, nylon, and nylon/cotton blend. Further, the fabric layer 52 can include an ultraviolet light inhibitor for protection of the fabric layer 52 against sun exposure. Also, if desired, the fabric layer 52 can be made from a sheer material that doesn't break down in water and dries quickly once wet.

[0025] The fabric layer 52 has an upper opening 53 into which the foot 51 is inserted when the footwear 50 is worn. If desired, the fabric layer 52 can be high enough so that the upper opening 53 extends above the ankle 55 of the human leg.

[0026] The foot 51 has a top 60, sides 62 (such as left side 62.sub.L and heel side 62.sub.H, as well as a right side), a bottom 64 and a single toe box 166 for the big toe 66.sub.B and a group toe box 167 for all of the remaining toes (little toe 66.sub.P, middle toe 66.sub.M, and second and fourth toes 66.sub.S and 66.sub.F, respectively). The inner surface 54 conforms closely to the top 60, sides 62, bottom 64 and the toe box 166 of the foot 51.

[0027] The footwear 50 also includes a first coating 68 which is adhered to portions of the outer surface of the fabric layer corresponding to the portions of the inner surface 56 that conform closely to the sides, bottom and toe boxes 166 and 167 of the foot 51. The first coating 68 can be made from one or more of the form-fitting materials chosen from the class of materials including latex, nitrile, and polyurethane.

[0028] FIG. 5 is a schematic drawing of a fabric layer of a third embodiment of the invention, and FIG. 6 is a schematic drawing of the third embodiment of the invention, showing the coated fabric layer. The same reference numerals are used in FIGS. 5 and 6 to describe features already described in FIGS. 1-4. The footwear 50 is intended to be worn on the foot 51 (shown in phantom lines) of a human leg having an ankle. The footwear 50 includes a fabric layer 52 having an inner surface 54. An outer surface 56 corresponds to the inner surface 54. The fabric layer 52 may be elastic and/or breathable. Preferably, the fabric layer 52 is made from one or more materials chosen from the class of materials including supplex, spandex, nylon, and nylon/cotton blend. Further, the fabric layer 52 can include an ultraviolet light inhibitor for protection of the fabric layer 52 against sun exposure. Also, if desired, the fabric layer 52 can be made from a sheer material that doesn't break down in water and dries quickly once wet.

[0029] The fabric layer 52 has an upper opening 53 into which the foot 51 is inserted when the footwear 50 is worn. If desired, the fabric layer 52 can be high enough that the upper opening 53 just extends above the ankle 55 of the human leg. If desired, the upper opening 53 of the fabric layer 52 can have a cuff 57 to help to prevent sand and the like from entering the footwear 50.

[0030] The foot 51 has a top 60, sides 62 (such as left side 62.sub.L and heel side 62.sub.H, as well as a right side 62.sub.R (not shown)), a bottom 64 and a single toe box 166 for the big toe 66.sub.B, and a group toe box 167 for all of the remaining toes (little toe 66.sub.P, middle toe 66.sub.M, and second and fourth toes 66.sub.S and 66.sub.F, respectively). The inner surface 54 conforms closely to the top 60, sides 62, bottom 64 and the toe box 166 of the foot 51.

[0031] The footwear 50 also includes a first coating 68 which is adhered to lower portions of the outer surface of the fabric layer corresponding to the lower portions of the inner surface 56 that conform closely to the bottom 64, and the lower halves of the sides 62 and toe boxes 166 and 167 of the foot 51. The first coating 68 can be made from one or more of the form-fitting materials chosen from the class of materials including latex, nitrile, and polyurethane.

[0032] FIG. 7 is a block diagram of a method 100 for making the various embodiment of the invention. In the method, the first step is to form a fabric layer (block 102). Preferably, the fabric layer is made from one or more materials chosen from the class of materials including supplex, spandex, nylon, and nylon/cotton blend. Further, the fabric layer can include an ultraviolet light inhibitor for protection of the fabric layer against sun exposure. Also, if desired, the fabric layer can be made from a sheer material that doesn't break down in water and dries quickly once wet.

[0033] The next step in the method (block 104) is to adhere a first coating to a portion of the outer surface of the fabric layer. This step can also include immersing the fabric layer in a container of coating material to suffuse the material through the fabric layer. If desired, the coating material may possibly have an additive to improve adhesion between the coating material and the fabric layer. The first coating is then dried, either by exposing the first coating to an ambient condition, or by exposing the first coating to an elevated temperature or other condition to cause the first coating to dry. The first coating can be made from one or more of the form-fitting materials chosen from the class of materials including latex, nitrile, and polyurethane.

[0034] The next step in the method (block 106) is to adhere a second coating to portions of the outer surface of the fabric layer in the same way that the first coating is adhered.

[0035] FIG. 8 is a schematic drawing of an apparatus for making the second embodiment of the invention. The apparatus 200 includes an arm 202 that supports a foot-shaped form 204. The fabric layer 206 is placed over the foot-shaped form 204 so that the big toe 208.sub.B of the form 204 is contained in a toe box 210.sub.B. and the other toes are contained in a single toe box 212 or in individual toe boxes. This is signified by position A in FIG. 8.

[0036] The apparatus 200 then lowers the arm 202 and the foot-shaped form 204 into a container 214 of the coating material until the desired portions of the outer surface of the fabric layer are immersed in the coating material. This is signified by position B in FIG. 8.

[0037] Next, the apparatus 200 raises the arm 202 and foot-shaped form 204 until the foot-shaped form 204 is clear of the coating material in the container 214. The apparatus 200 then allows the coating material to dry or set so that the coated fabric layer is ready for use. This is signified by position B in FIG. 8. The coated fabric layer is then removed from the foot-shaped form 204. Alternatively, the apparatus 200 lowers the foot-shaped form 204 into the container 214 (or another container containing another coating material) so that the coating process is repeated. If desired, the second coating can be caused to have a textured surface, as will be known by those skilled in the relevant arts.

[0038] While the foregoing is a detailed description of the preferred embodiments of the invention, there are many alternative embodiments of the invention that would occur to those skilled in the art and which are within) the scope of the present invention. Accordingly, the present invention is to be determined by the following claims.

Claims

1. Footwear for a foot on a human leg having an ankle, comprising: a fabric layer having an inner surface and a corresponding outer surface, the inner surface conforming closely to the top, sides, bottom and individual toes of the foot; and a coating adhered to portions of the outer surface of the fabric layer corresponding to the portions of the inner surface of the fabric layer that conform closely to the sides, bottom and individual toes of the foot.

2. The footwear of claim 1 wherein the fabric layer is elastic.

3. The footwear of claim 1 wherein the fabric layer is breathable.

4. The footwear of claim 1 wherein the fabric layer is made from one or more materials chosen from the class of materials including supplex, spandex, nylon, and nylon/cotton blend.

5. The footwear of claim 1 wherein the fabric layer extends above the ankle.

6. The footwear of claim 1 wherein the fabric layer includes an ultraviolet light inhibitor for protection against sun exposure.

7. The footwear of claim 1 wherein the coating is made from one or more of the form-fitting materials chosen from the class of materials including latex, nitrile, and polyurethane.

8. The footwear of claim 1 wherein the coating has a textured surface.

9. A method for making a footwear for a foot on a human leg having an ankle, comprising the steps of: a) forming a fabric layer having an inner surface and a corresponding outer surface, the inner surface conforming closely to the top, sides, bottom and individual toes of the foot; and b) adhering a first coating to portions of the outer surface of the fabric layer corresponding to the portions of the inner surface of the fabric layer that conform closely to the sides, bottom and individual toes of the foot.

10. The method of claim 9, wherein step b) includes immersing the portions of the outer surface of the fabric layer corresponding to the portions of the inner surface of the fabric layer that conform closely to the sides, bottom and individual toes of the foot in a container filled with the material composing the first coating.

11. The method of claim 10, wherein step b) further includes adding a chemical agent to the material composing the first coating to insure adhesion of the first coating to the outer surface of the fabric layer corresponding to the portions of the inner surface of the fabric layer that conform closely to the sides, bottom and individual toes of the foot in a container filled with the material composing the first coating.

12. The method of claim 9, further including the step of: c) adhering a second coating over the first coating.

14. The method of claim 9, wherein step c) includes causing the second coating to have a textured surface.

15. The method of claim 9, wherein step b) includes suffusing the first coating through the fabric layer.

16. The method of claim 9, wherein step b) includes drying the first coating.

17. An apparatus for making a footwear for a foot on a human leg having an ankle, comprising: means for forming a fabric layer having an inner surface and a corresponding outer surface, the inner surface conforming closely to the top, sides, bottom and individual toes of the foot; and means for adhering a first coating to portions of the outer surface of the fabric layer corresponding to the portions of the inner surface of the fabric layer that conform closely to the sides, bottom and individual toes of the foot.

18. The apparatus of claim 17, wherein the means for adhering includes means for immersing the portions of the outer surface of the fabric layer corresponding to the portions of the inner surface of the fabric layer that conform closely to the sides, bottom and individual toes of the foot in a container filled with the material composing the first coating.

19. The apparatus of claim 18, wherein the means for adhering further includes means for adding a chemical agent to the material composing the coating to insure adhesion of the first coating to the outer surface of the fabric layer corresponding to the portions of the inner surface of the fabric layer that conform closely to the sides, bottom and individual toes of the foot in a container filled with the material composing the first coating.

20. The apparatus of claim 17, further including means for adhering a second coating over the first coating.

21. The apparatus of claim 17, wherein the means for adhering includes means for suffusing the first coating through the fabric layer.

22. The apparatus of claim 17, wherein the means for adhering includes means for drying the first coating.