U.S. patent application number 11/583881 was filed with the patent office on 2007-12-27 for soft shell boots and waterproof /breathable moisture transfer composites and liner for in-line skates, ice-skates, hockey skates, snowboard boots, alpine boots, hiking boots and the like.
Invention is credited to Baychar.
Application Number | 20070294920 11/583881 |
Document ID | / |
Family ID | 38872267 |
Filed Date | 2007-12-27 |
United States Patent
Application |
20070294920 |
Kind Code |
A1 |
Baychar; |
December 27, 2007 |
Soft shell boots and waterproof /breathable moisture transfer
composites and liner for in-line skates, ice-skates, hockey skates,
snowboard boots, alpine boots, hiking boots and the like
Abstract
The soft boot and liner include a moisture transfer system that
includes an inner fabric layer carefully selected from technically
advanced fabrics. A series of layers are provided outside the inner
liner including foam material layers, spacer fabrics and breathable
membranes, in various orders. Encapsulation technology and
waterproofing are used as well. The outer fabric layer is also
capable of working with the other layers to promote the transfer of
moisture. Frothed foams and flocking with fibers are further
characteristics of the present invention. The moisture transfer
system is incorporated into a soft boot or skate or as a removable
liner for a shell boot. Numerous other modifications and
applications are disclosed.
Inventors: |
Baychar;; (Kingfield,
ME) |
Correspondence
Address: |
MATTINGLY, STANGER, MALUR & BRUNDIDGE, P.C.
1800 DIAGONAL ROAD
SUITE 370
ALEXANDRIA
VA
22314
US
|
Family ID: |
38872267 |
Appl. No.: |
11/583881 |
Filed: |
October 20, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60730941 |
Oct 28, 2005 |
|
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Current U.S.
Class: |
36/113 ;
428/36.1 |
Current CPC
Class: |
A43B 3/0084 20130101;
A43B 7/145 20130101; B29L 2031/501 20130101; B32B 5/26 20130101;
B29K 2995/0069 20130101; A43B 7/1475 20130101; A43B 7/20 20130101;
B29L 2031/30 20130101; A43B 7/144 20130101; A43B 5/049 20130101;
A43B 19/00 20130101; A43B 23/07 20130101; A43B 5/002 20130101; B29C
63/0073 20130101; Y10T 428/1362 20150115; A43B 7/125 20130101; B29L
2031/52 20130101; A43B 5/0405 20130101 |
Class at
Publication: |
036/113 ;
428/036.1 |
International
Class: |
A43B 3/00 20060101
A43B003/00; B29D 23/00 20060101 B29D023/00 |
Claims
1. A soft shell alpine or climbing boot comprised of a series of
composite layers: an absorbent, breathable, moisture transferring
inner lining fabric; a breathable, moisture transfer, and absorbent
open-cell, anti-microbial foam material mechanically bonded to an
absorbent, breathable, moisture transferring nonwoven composite
layer comprised of synthetic shaped, grooved fibers, stretchable
fibers and silver fibers; a water resistant, breathable, exterior
soft shell synthetic fabric or material.
2. The soft boot according to claim 1, wherein the inner lining
fabric is treated with nano-technology.
3. The soft boot according to claim 1, wherein the moisture
transfer nonwoven and foam composite contains stretchable
fibers.
4. The soft boot according to claim 1, wherein the moisture
transfer nonwoven and foam composite contains thermal regulated
materials.
5. A technical, moisture transfer, soft shell composite for product
is comprised of a series of breathable layers: a wicking, moisture
transferring, lining nonwoven material; a foam coated dotted matrix
or pattern containing thermal regulating material applied to the
back of the inner moisture transfer, absorbent, breathable nonwoven
material; a waterproof and breathable, exterior soft-shell fabric
with stretchable characteristics.
6. A technical, moisture transfer, soft shell composite according
to claim 5, wherein at least one layer contains anti-microbial
properties.
7. A technical, moisture transfer, soft shell composite according
to claim 5, wherein the exterior shell fabric contains
nano-technology to resist stains.
8. A technical, moisture transfer, soft-shell composite according
to claim 5, wherein the exterior shell fabric contains
nano-technology to waterproof.
9. A technical, moisture transfer, soft shell composite according
to claim 5, wherein the inner lining fabric is treated with
nano-technology to increase the moisture transfer properties.
10. A technical, moisture transfer, soft shell composite according
to claim 5, wherein the inner moisture transfer nonwoven is
replaced with a breathable moisture transfer, absorbent fabric.
11. A technical, moisture transfer, soft-shell composite according
to claim 5, wherein the absorbent nonwoven has shaped, hollow,
grooved and/or split fibers.
12. An absorbent nonwoven composite according to claim 11, wherein
the shaped, grooved, hollow and/or split fibers are combined with
anti-microbial fibers or treatments.
13. An absorbent nonwoven composite according to claim 11, wherein
the shaped, grooved, hollow and/or split fibers are combined with
stretchable, elastomeric fibers.
14. An absorbent nonwoven composite according to claim 11, wherein
the shaped, grooved, hollow and/or split fibers are combined with
stretchable, elastomeric fibers and reversible enhanced thermal
properties.
15. An absorbent nonwoven composite according to claim 11, wherein
the shaped, grooved, hollow and/or split fibers are combined with
stretchable, elastomeric fibers and a foam coating.
16. An absorbent nonwoven composite according to claim 11, wherein
the shaped, grooved, hollow and/or split fibers are combined with
stretchable, elastomeric fibers and a foam coating containing
nano-technology
17. A absorbent nonwoven composite according to claim 11 wherein
the shaped, grooved, hollow and/or split fibers are combined with
stretchable, elastomeric and cotton fibers.
18. A absorbent nonwoven composite according to claim 17, wherein
absorbent nonwoven layer contains lyocel.
19. An absorbent nonwoven composite according to claim 11, wherein
nonwoven layer is waterproofed with encapsulation.
20. A composite according to claim 1, wherein the exterior shell
material is waterproofed with nano-technology.
Description
CROSS-REFERENCES
[0001] This application claims priority from U.S. Provisional
Application 60/730,941, filed Oct. 28, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates to composite materials,
removable insert liners and completed product constructions with a
non-removable liner used in a variety of applications. For example,
the liner of the present invention may be employed in a variety of
applications including in-line, ice or hockey skates (shell and
soft boot) and the like. This liner system composite may be
utilized for all weather boots and alpine and hiking applications.
The liner is breathable, transfers moisture and waterproof to
increase comfort for the skater. The liner may contain thermal
fibers, thermal PCM encapsulated molecules or fibers and/or a
silica, acrylic, polyester fiber based polymers micro-spheres or
the like containing air, polymers or liquid fibers that aid in
cooling or thermal regulating temperatures during performance and
are capable of absorbing an electrical charge. The micro-sphere
encapsulating the air, polymer or electrically sensitive to thermal
absorbing material may be constructed of an inherently conductive
polymer such as those created by the Polymer Research Institute in
New South Wales, Australia.
BACKGROUND OF THE INVENTION
[0003] Various types of liners are known in prior art. These liners
are designed to provide certain levels of comfort and durability.
Furthermore, in-line skates are also well-known in the art as
evidenced by U.S. Pat. Nos. 5,340,132; 5,397,141; and 5,437,466. Of
these patents, only U.S. Pat. No. 5,437,466 discloses what is
commonly referred to as a "soft-boot". In other words, the shoe
body is made of a soft, pliable material. General statements are
provided about the materials used for the shoe body, but not in
great detail. All of the patents listed above are hereby
incorporated by reference.
[0004] However, the liners in ice hockey and in-line skates, as
well as snowboard boots, etc., known in the art do not provide the
advantages realized by the present invention. With the art of
hockey and in-line skating becoming increasingly recreational,
numerous categories of skaters are developing in large numbers. The
present inventor has recognized the problems faced by the
aggressive and the recreational categories of skaters and has
developed a liner to overcome such problems.
[0005] There is an ongoing need for comfort, moisture transfer,
breathability, and support for both removable liners as well as
non-removable hockey, ice and soft boot liners. In prior removable
liner design, the conventional liner is often constructed with
rigid, non-breathable outer materials such as vinyls, foams, and
nylons. The inner liners have been leather, nylon, or polyester
blends which extremely limited the ability to breathe or wick
moisture away from a skater's body. These materials have prevented
the foot from breathing adequately. In the case of "shell boot"
skates, the plastic material that forms the outer shell boot
structure holds the heat and moisture inside the boot. As a result,
the lining becomes saturated with sweat which adversely affects the
skater's comfort and performance level. This problem is even worse
with the aggressive hockey skaters whose needs for proper
ventilation are even greater.
SUMMARY OF THE INVENTION
[0006] An object of the present invention is to provide a lining
system employing a cooler, warmer, drier and more breathable liner
that meets the needs of each individual skater. Accordingly, the
liner of the present invention can be accommodated to the needs of
skaters of various skill categories by permitting the inner liner
material, which is against the foot, to vary in fiber content and
construction.
[0007] This object of the present invention is realized by
providing a lining system having lining materials which acts as a
moisture transfer system and poses inherent moisture transfer
polymers fibers and absorbent natural and synthetic fibers. The
fibers may be combined in knits, wovens, nonwovens or in a combined
construction of two or more constructions. An example of a combined
construction is a warp-knit fabric such as such as the SENSITIVE
Fabrics. Moisture vapors are transferred through the liner from one
side to the other side by a multi-layered technically engineered
fiber and foam system. In several composite systems the technically
nonwoven fibers replace the foam. This is accomplished by utilizing
certain materials in a manner determined by the inventor after
considerable experimentation and effort. The details of the
specific materials as used in the combination are disclosed in the
Detailed Description of the Preferred Embodiments.
[0008] The moisture transferring lining system of the present
invention overcomes the problems in the prior art lining systems
and liners and meets the needs of even the most aggressive
skaters.
[0009] Various 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
[0010] FIG. 1 illustrates a first portion of the liner according to
a first embodiment of the present invention.
[0011] FIG. 2 illustrates a second portion of the liner according
to a first embodiment of the present invention.
[0012] FIG. 3 illustrates an example of the liner according to the
first embodiment of the present invention.
[0013] FIG. 4 illustrates the liner shown in FIG. 3 as applied to
an inline skate.
[0014] FIGS. 5(a) and 5(b) illustrate a sole portion of a shoe
constructed according to a preferred embodiment of the present
invention.
[0015] FIGS. 6 and 7 illustrate a tongue portion of a shoe
constructed according to the first embodiment of the present
invention.
[0016] FIG. 8 illustrates a more detailed view of the liner portion
used for the tongue of FIGS. 6 and 7.
[0017] FIG. 9 illustrates a portion of the liner used in the upper
cuff area.
[0018] FIG. 10 illustrates the travel of moisture through a
breathable, reticulated foam then a flexible mesh and into and
through a breathable membrane according to the first embodiment of
the present invention.
[0019] FIG. 11 illustrates the toe portion of a shoe according to a
preferred embodiment of the present invention.
[0020] FIG. 12 illustrates an overall drawing of a snowboard boot,
soft alpine boot, alpine or hiking boot which will incorporate the
lining material of the present invention.
[0021] FIGS. 13 and 13A illustrate an insert for an in-line skate
or hockey skate with a first portion enlarged.
[0022] FIGS. 14 and 14A illustrate another embodiment of an insert
for an in-line skate or hockey skate with a second portion
enlarged.
[0023] FIGS. 15 and 15A illustrate another embodiment of an insert
for an in-line skate or hockey skate with a third portion
enlarged.
[0024] FIGS. 16, 16A and 16B illustrate an insert for a soft-shell
alpine boot with first and second portions enlarged.
[0025] FIGS. 17, 17A and 17B illustrate an insert for a soft-shell
alpine boot with first, second and third portions enlarged.
[0026] FIGS. 18 and 18A illustrates a soft-shell alpine boot
exterior shell composite with a first portion enlarged.
[0027] FIGS. 19A and 19B illustrates a soft-shell alpine boot
exterior shell composite with a first portion enlarged.
[0028] FIG. 20 is a polymer shell for a hockey skate including a
moisture transfer liner.
[0029] FIG. 21 illustrates soft-shell in-line skate or the like
exterior shell composite.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] 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. 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.
[0031] Where possible, trade names 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 currently envisioned are set forth
below.
[0032] FIG. 1 illustrates a portion of the liner, or lining system,
according to a first embodiment of the present invention. As shown
in FIG. 1, a first foam (20) is provided between an inner liner
(10) and a second foam or nonwoven material (30). The inner liner
(10) can be attached to the first foam material (20) by lamination,
stitch, needled or ultrasonically bonded, or the like. The second
foam (30) is a germicidal anti-microbial reticulated and/or
hydrophilic open-cell foam and has a thickness of approximately
1/16 to 1/4 inch. Optionally, the first and second foam layers 20
and 30 may be a nonwoven and foam composite, a foam included in a
nonwoven fiber or a foam with selected fibers flocked or needled
fabric into either side. The first foam material is also preferably
germicidal reticulated or open-cell hydrophilic and has a thickness
of approximately 1/16-1/8 inch. Alternatively, the first and second
foam maybe replaced by a technically engineered, nonwoven fiber
blend with or without open-cell foam inclusive or an moisture
transfer, breathable, elastomeric composite or a foam and nonwoven
fiber composite. A technically engineered nonwoven spacer fabric
with natural and/or synthetic fibers can be substituted in some
performance categories and be utilized in layers 20 and 30. The
moisture transferring nonwoven or nonwoven and foam layers are
combined by needling, lamination, ultrasonic bonding, flocking or
the like to the back of the inner lining fabric. The spacer fabric
may also be combined with the nonwoven composite with or with out
foam in the same manner as mentioned above.
[0033] The elastomeric patent and process patent listed below are
hereby incorporated by reference: U.S. Pat. No. 6,074,966, entitled
"Nonwoven Fabric Composite Having Multi-directional Stretch
Properties Utilizing a Cellular or Foam Layer", and U.S. Pat. No.
6,479,009 B1, entitled "Method For Producing Nonwoven Fabric
Composite Having Multi-directional Stretch Properties Utilizing a
Cellular or Foam Layer".
[0034] The elastomeric cellular process is further developed in
this application with a combined wet lay and/or dry lay process.
The polymer base and aqueous phase are sprayed from the jets and
combined during the water jet or air pressurization with the fiber
mesh. The selected fiber blend is distributed on a screen bed is
fused in one process as the polymer and aqueous phase combine with
the fiber surface, react and solidifies. The polymer base reacts
and solidifies as the aqueous phase is combined during the
pressurization. All three elements, the polymer base, the aqueous
phase and the fibers, are fused together with pressure on the
screen surface creating an elastomeric, cellular nonwoven
product.
[0035] This water or air jet combines the polymer base and aqueous
solution during the active spray and pressurization and can
regulate the amount of polymer or aqueous phase needed for selected
performance categories in this invention.
[0036] All the nonwovens in this invention are selected for the
inherent ability to transfer and/or absorb moisture and may have
anti-microbial silver fibers by Foss, Static or the like added to
the blend. In a number of options, the fibers included in the inner
lining material, or nonwoven top sheet are embedded in the foam and
possess anti-microbial, thermal and conductive properties. All of
the foam materials used in the present invention are assumed to be
breathable, hydrophilic, open-cell and their thickness is variable.
Depending on the application, some of the foam materials may not be
used and the thickness of any foam material or spacer fabrics that
is used can be changed as needed. All the foams in this application
may include Microsphere Technology. For example, a foam called
Aquazone, Premium, VPF by Foamex, Comfortemp by Frisby or the like,
Netsorb by Vita Olympic, CoFoam Hydrophilix, or Dri-Z by Dicon,
hydrophilic foam with nonwoven fibers or the like can be used.
Preferably, the germicidal, anti-microbial hydrophilic, flocked
fiber open-cell hydrophilic foam or a reticulated foam is treated
with a surfactant to increase the moisture transfer rate. These
chemical friendly additives can be combined directly into the foam
polymer or may be applied after the foam is created. A hydrophilic
coating such as that created by CIBA Specialty Chemicals
(ULTRAPHIL), Wisconsin Global Technology or the like may be added
to the foam matrix or nonwoven abutting the foam. The foam can be
attached to a non-woven top sheet of synthetic or natural fibers.
The fibers may be flocked into the foam or added to the liquid
polymer. The preferably, nonwoven fiber selection includes wood
pulp and cotton, corn, kapok, lyocel, acrylic, chlorofibre,
acetate, wool, hemp, polypropylene, polyester, rayon, LYCRA.RTM.,
elastine, SPANDEX.RTM., elastine or SPANDEX.RTM. or a combination
thereof. This top sheet is designed to absorb and move moisture.
The addition of LYCRA.RTM., elastine, SPANDEX.RTM. or elastine or
SPANDEX.RTM. to achieve stretchable properties are optional.
Evolon.RTM., a product by Freudenberg with or without stretchable
properties, may be used as a top sheet option in any layer in this
invention. Nonwovens by Freudenberg with elastomeric or stretchable
properties are preferred in this invention in some performance
categories. However, any nonwoven that is comprised of absorbent
and moisture transferring properties with or without stretchable
characteristics can be applied. In some options tubular knits can
be used for protective gear or skate liner uppers, tongues, heels
cups or toe boxes. The nonwoven or nonwoven knitted layer can be
ionized to increase the moisture transfer and enhance
performance.
[0037] The nonwoven may contain one or more combinations of split
fibers, hollow fibers, grooved fibers, shaped fibers,
anti-microbial fibers or treatments. In some options the nonwoven
layer is the inner lining material or outer shell material
selection. The moisture transfer nonwoven antimicrobial composite
comprised of a moisture transfer nonwoven, open-cell foam layer
abutting another moisture transfer nonwoven may comprise the entire
liner in a skate, hockey or helmet. The breathable moisture
transfer composite system may be enhanced with phase change
technologies or additional fiber technology benefits.
[0038] The select nature and synthetic fibers and shaped, hollow
and split fibers in the nonwoven group have inherent moisture
transfer and absorption properties and can be treated with a number
of MVT surfactants or wicking solution to increase performance.
Intera Technology, Ultraphil, nano-technology or the like are
treatments that enhance moisture transfer performance.
Nano-technology may be applied to the nonwoven fibers to enhance
moisture transfer or waterproof the nonwoven layer. Nano-Technology
by Burlington Technologies or Toray Industries is preferable.
Cofoam, a hydrophilic foam treatment by Hydrophilix may be applied
to the foam or nonwovens to increase the rate of transfer. Coolfix
which is developed by Trend Technology, Wisconsin Global Technology
or Feran Ice Process may be included in this nonwoven layer fiber,
fabric foam layers or combinations in this application. The
nonwoven top sheet construction may optionally be replaced by a
knitted fiber construction. The nonwoven top sheet or knitted fiber
construction may be utilized for a scrum on either side of a foam
or thermal nonwoven. The selected nonwoven fiber or blend of fibers
may be inclusive in the thermal nonwoven blend, the foam or
nonwoven wet-laid, spun bond or needle punch product may be
inclusive in the foam. The nonwoven fibers in this application are
extremely important and they are selected for the abilities, as
stated previously, to transfer moisture, absorb, increase or
decrease temperature and provide stability. They are both active
and passive in their performance. The polyester fiber inclusive in
the nonwoven top sheet, knitted layer or layers of the thermal
composites is preferably a shaped fiber such as the 4-8 deep groove
polyester fiber or a variation of the shaped polyester fiber
preferably, manufactured by the F.I.T Group or the like. A shaped
(CCF) fiber by Clemson University or a Technofine polyester fiber
by Gelanots may be an option in this layer. These technically
engineered polyester shaped fibers provide channels for the
moisture to travel along and transfer quickly to the exterior
surface. The shaped fabrics may be combined with an active carbon
compound such as that by Craghoppers or silica gel which increases
the absorbent factor. Response Technology by Craghoppers is an
option in this application for the inner lining polyester fibers
and nonwoven and/or foam composites. A selection of shaped natural
and synthetic fibers as well as polyester such as corn, acrylic,
acetate and the like may be included in any layer in the moisture
transfer system. The elastomeric cellular composite referenced in
the U.S. Pat. No. 6,074,966 may include the selected nonwoven and
shaped fibers discussed previously. Optionally, the moisture
transfer, breathable, elastomeric composite may be used in place of
the nonwoven top sheet on either side of the foam or thermal
nonwoven or in place of the selected foam. In some performance
categories the moisture transfer, breathable, elastomeric composite
may be mechanically or ultrasonically bonded to the inner lining
material abutting the foam, nonwoven or thermal nonwoven. The
moisture transfer, breathable, elastomeric composite contains
synthetic and natural fibers and foam. These fibers may be treated
with wetting solutions and/or hydrophilic foam such Cofoam as well
as that by Hydrophilix Inc. (U.S. patent application Ser. No.
09/823,129) The moisture transfer, breathable, elastomeric
composite may be applied to the thermal nonwoven on either side or
be mechanically or ultrasonically bonded to the thermal nonwoven.
The moisture transfer, breathable, elastomeric composite may be
attached or included in any layer in the moisture transfer system
or may be in any layer in the moisture transfer system excluding
the exterior shell fabric.
[0039] The Cofoam, breathable foam or the like may be used as the
selected foam in the moisture transfer, breathable, elastomeric
composite or be applied to any layer in the moisture transfer
system. Cofoam may be used in place of the selected open-cell foam
or in combination with any layer in the moisture transfer system.
The Cofoam may be combined with the thermal blend by Foss
Manufacturing, INVISTA.RTM. thermal nonwovens such as THERMOLITE,
Ultrathin or with 3M thermal nonwovens such as THINSULITE, nonwoven
by Millennium or the like.
[0040] The nonwoven top sheet may be a dry-laid, wet laid, melt
blown, spun bond or a needle punch product or a knitted scrum. The
selected fibers, fiber construction and treatment of the nonwoven
top sheet are a key element in the moisture absorption and transfer
properties in the system. The nonwoven may or may not require a
wicking solution or treatment. The product category and performance
level determines the selection of treatment and the fiber or
combination of is a wet laid apertured nonwoven top sheet.
[0041] The selected nonwoven top sheets are manufactured by
INVISTA.RTM. (Sonatra Technology nonwoven), Alhstrom Nonwovens,
Dexter Synthetics, Freudenberg nonwovens, Veritex, Nordlys, or the
like. All nonwoven fibers in this application possess either active
or passive moisture transfer abilities or both. The nonwoven blends
may have elastic properties, polymer or silica microspheres or
encapsulated PCM technology added with various fibers or fiber
blends.
[0042] The preferable construction contains cooling and/or heating
properties and elastine or SPANDEX.RTM. fibers. The Outlast melt
spun fiber may be an option in this layer or in the thermal
nonwoven layer. In some options the nonwoven fibers in the top
sheet may be wrapped by another fiber or coated with hydrophilic
foam spray. The foam and fiber composite, nonwoven fabric or the
moisture transfer, breathable, elastomeric composite may be coated
with a hydrophilic foam such by Hydrophilix or treated with
Ultraphil, Coolfix or the like to increase the MVT function and the
cooling or thermal application. Optionally, layer 20 may be
eliminated when the hydrophilic foam, Cofoam by Hydrophilix or the
like is applied or sprayed to the back of the inner lining fabric
or material or to the abutting nonwoven. In fact, Cofoam,
breathable foam or the like may be substituted for any foam layer
in this application creating an extremely thin lining or outer
lining moisture transfer composite. The inner lining fabric coated
with Cofoam abutting the nonwoven or the nonwoven coated with
Cofoam abutting the inner lining material may abut a spacer fabric,
a cellulose material by Fox Run, a foam and polymer mesh composite
or the outer shell fabric for use in several of the defined
categories discussed in this application.
[0043] However, in a number of categories the nonwoven abutting the
inner lining fabric or material in layer 10 or foam in layer 20 is
a thermal spun bond, melt-blown or needle punch product. The
preferable thermal nonwoven is a needle punch product by Foss
Manufacturing containing a blend of deep groove polyester fibers,
silver fibers and natural or synthetic fibers. The nonwoven
composite developed by Baychar Technologies and manufactured by
Foss Manufacturing referred to as the Foss composites is
constructed of a number of layers and contains fibers such as
elastine or SPANDEX.RTM., lyocel, PVA, silver fibers, shaped,
hollow and/or grooved polyester or like or a blend needled together
with or without foam. Alternatively, the nonwoven composite
developed at Foss Manufacturing may be constructed with a nonwoven
thermal by INVISTA.RTM. such as Ultralite, THERMOLITE or the like
or the Foss composite may have a 3M nonwoven included such as
THINSULITE 100, 200, 300 or the like. These composites transfer
moisture and thermally regulate the product by increasing or
decreasing the fiber content or treated fibers. Of course, Invista,
INVISTA.RTM., 3M and Foss nonwovens may be used in place of the
moisture transfer nonwoven composite developed at Foss
Manufacturing LLC. in any layer between the inner material and
outer shell fabric.
[0044] The selected nonwoven thermal, shaped, hollowed or grooved
fibers optionally may be flocked to the back side of the inner
lining material, the exterior shell fabric or to any foam, foam
composite such as the moisture transfer, breathable, elastomeric
composite, breathable membrane, thermal or thermal composite
containing shaped and hollow fibers with or without a foam layer or
polymer layer treatment. Fibers may be flocked as well to the foam
inclusive of the nonwoven fibers, nonwoven sheet or polymer mesh.
The flocked fiber or blended fibers optionally may be flocked to
both sides of the nonwoven, breathable membrane, breathable
adhesive or open-cell foam. The thermal nonwoven, THERMOLITE
INVISTA.RTM. or THINSULITE by 3M optionally may be attached to the
foam inclusive of the fibers or polymer mesh or both or may
included a foam layer.
[0045] The previously mentioned, aperture nonwoven alternatively
may be mechanically bonded to the foam layer in 20, 30, 50 on one
side or both sides. Optionally, the apertured nonwoven and
breathable foam composite combination may be combined with the
thermal nonwoven, nonwoven composite with or without a foam
material or a flocked composite blend applied to the wet, dry
polymer laid nonwoven or foam surface. In some options the
nonwoven, foam and polymer mesh layer may be needled or
ultrasonically bonded to the thermal nonwoven. The preferred
hydrophilic foams are developed by Dicon Foams, Vita Olympic,
Hydrophilix, Rubberlite, Lendall, Dynamic, Alpin foams or Foamex
foams distributed by Rogers Corporation or the like.
[0046] The breathable, foam or foam and nonwoven laminated or
welded combinations in layer 20 or 30 as previously suggested may
be optionally replaced by a needle punched nonwoven with or without
foam, preferably the Foss composite or by the moisture transfer,
breathable, elastomeric composite having a foam fused with nonwoven
fibers formed in a single process.
[0047] The inner liner fabric is a moisture transfer fabric capable
of wicking moisture. The inner liner 10 is preferably constructed
using specific fabrics possessing certain desired characteristics,
but with varying fiber compositions. A list of fabrics which can be
employed depending upon the individual needs of their application
as well as the individual needs of each skater are provided below.
These fabrics may be used either individually or in combination.
The following inner moisture transfer liner 10 materials may also
be replaced by new moisture transfer fabrics with similar
characteristics as the technology on the market develops for this
invention. The technical engineering of several fiber constructions
and combinations is employed in this application. A flocked fiber
blends may be added to the back of the inner lining or shell fabric
material.
[0048] The multi-faceted shaped polymer based synthetic and natural
fiber blends lend endless possibilities in construction to the
first layer. These new shaped fibers increase moisture transfer,
cooling and heating applications and increase performance levels.
Moisture transfer rates and thermal properties vary with the
performance criteria.
[0049] The first fabric or nonwoven is a moisture transfer material
capable of wicking moisture. These fabrics and materials may be
treated with wicking solutions to increase the moisture transfer
rates. The inner liner 10 is preferably constructed using specific
fabrics possessing certain desired characteristics. The fiber
blends and construction may vary with the products and performance
needs.
[0050] A list of fabrics which can be employed depending upon the
individual needs of each skater are provided below. These fabrics
or nonwovens may be used individually or in combination. All
fabrics or nonwovens in the first layer may be treated with a
wicking solution such as Coolfix, Ultraphil or the like and must
provide active as well as passive moisture transfer capabilities.
Fabric or nonwoven construction, fiber selection and MVT
surfactants and/or coating may be employed in multiple combinations
in this first layer 10 to increase the transfer rate. Optionally
the first layer is a multi-tiered construction containing flocked
fibers on the back of an elastomeric or needle punch nonwoven. The
first layer alternatively may have fibers flocked to the back side
of the inner moisture transfer fabric or nonwoven lining material
abutting the foam layer, foam and nonwoven blend or a nonwoven
layer. This multi-tiered construction absorbs and transfer moisture
and may be treated with a cooling microsphere coating or spray or
chemical option. The inner lining material may further include an
active carbon compound to increase the moisture transfer as well as
shaped and silver fibers.
[0051] The following inner moisture transfer liner materials may
also be replaced by new moisture transfer fabrics with similar
characteristics as the technical textiles technology on the market
develops for this invention.
[0052] The first fabric is an anti-microbial, anti-fungal
polypropylene (also referred to as polyolefin) containing
LYCRA.RTM., blend (2%) with INNOVA fiber, elastine or SPANDEX.RTM.
fibers or the like. INNOVA is a continuous filament fiber
(manufactured by Coville, Deercreek fabrics).
[0053] The second fabric is an anti-microbial, anti-fungal
polypropylene, polyester or polyester blend having a polyester or
cotton, corn or lyocel backing or the like (such as that
manufactured by Coville, Inc. This fabric has the face of one fiber
and the backing of another and may vary in composition depending on
the performance level of the skater.
[0054] The third fabric is an anti-microbial, antifungal
polypropylene/cotton blend with ALPHA fiber, or the like (such as
that manufactured by Intex Fabric, Inc.)
[0055] The fourth fabric is a Field Sensor.RTM. polyester with
waffle-weave construction (such as that distributed by Yagi &
Co., Inc. and manufactured by Toray). This fabric is constructed to
transfer moisture immediately away from the foot and performs best
as the liner for the soft-boot in-line skate. Alternatively, a
polyester material known as Aqua-Dry.RTM., distributed by Teijin
Shojin can be employed or the like.
[0056] The fifth fabric is a Technofine polyester shaped fiber by
Gelanots.
[0057] The sixth fabric is 3.times.Dry process fabrics or by
Schoeller.
[0058] The seventh fabric is a two-layered fabric by Feron Ice
process on a synthetic or natural fiber or a blend of natural and
synthetic fibers.
[0059] The eighth fabric or nonwoven is made from corn fibers or a
blend of corn fibers with one or more of the following fibers,
elastine or SPANDEX.RTM., lyocel, acretate, PVA and polyester.
[0060] The ninth fabric is polyester fabric with an active carbon
compound bonded to the polyester by a fabric Craghoppers.
[0061] The tenth fabric group are fabrics by Burlington
Technologies contain Nano-Technology called Nano-Dry Fabrics.
[0062] The eleventh fabric materials is a synthetic leather
preferably by Nextec of Italy, SISA or Clarino.
[0063] The twelfth fabric Technofine polyesters by Gelanots.
[0064] The thirteenth fabric is a Dri-release fabrics by Optimer
Performance fibers.
[0065] The fourteenth fabric is Dri-line and Sphere Technology
fabrics by NIKE.
[0066] The fifteenth fabric is Polyguard guard by KOSA.
[0067] The sixteenth fabric group is Dry-tech Comfort System
fabrics by Westcot.
[0068] The seventeenth fabric group are Thermal Pro Fabrics by
Maiden.
[0069] The eighteenth fabric group is the Gore Windstopper N2S.
[0070] The nineteenth group is Polartec Powerdry.
[0071] The twentieth fabric is a fabric called Aquafil Dryarn by
Rhovyl in France and Italy.
[0072] The twenty-first fabrics Sterling Performance fabric.
[0073] The twenty-second fabric is Dryline by Milliken.
[0074] The twenty-third fabrics are corn fibers and fabrics by
Draper Knitting.
[0075] The twenty-fourth fabric is Acrillian or Duraspun by
Monsanto.
[0076] The twenty-fifth fabric is a hydrophilic, anti-microbial
Dri-Lex Baby Kid or perforated material (such as that manufactured
by Faytex Corp.).
[0077] The twenty-sixth fabric is a polyester looped terry (such as
that manufactured by Fronfli Spundale Mills, Inc.).
[0078] The twenty-seventh fabric is a suede/sanded polyester
micro-fiber material (such as that distributed by Yagi & Co.,
Inc. and Teijin Shojin, Inc., Millken or Malden Mills).
[0079] The twenty-eighth fabric is an anti-microbial, antifungal
PolarTec Series 2000, which is a wickable, moisture transfer fiber,
containing LYCRA.RTM., elastine, SPANDEX.RTM., polypropylene, or
the like.
[0080] The thirtieth fabric group are Sensitive Fabrics.
[0081] The thirty-first fabric are polyester fabrics by
Coville.
[0082] The thirty-second nonwoven fabric is Evolon.RTM. nonwoven by
Freudenberg.
[0083] The thirty-third fabric is nonwoven moisture transfer wool
composite blend by Foss Manufacturing.
[0084] The thirty-fourth nonwoven inner lining selection is
Evolon.RTM. a split fiber technology and process and Novolon.RTM.
technology, a product by Freudenberg with or without stretchable
properties. The Evolon.RTM. and Novolon.RTM. may have a suede or
brushed surface. The invention further includes all up-grades to
the split fiber technology and process for Evolon.RTM. and
Novolon.RTM. products by Freudenberg, the Nonwoven Cooperative at
NCSU or the like.
[0085] Nano-technology may be applied to any selected shell fibers,
nonwoven or fabric to enhance moisture transfer or to waterproof
the exterior shell material. Nano-technology by Burlington
Technologies or Toray Industries is preferable. The selected
exterior material is breathable, moisture transfer and waterproof.
The selected rates of functionality are determined by the product
and the performance level of the product. The breathable and
moisture transfer rates are not ambiguous or underdetermined. The
selected nonwovens and fabrics have determined rates that can be
increased or decreased with the applied technologies and selected
performance needs of the product line. Fabric or nonwoven vender
supplies product rates at the request of the product company.
Enhancing and additional technology varies the rate of
functionality per product group.
[0086] Any of these fabrics and nonwoven top sheets may have the
selected nonwoven fibers flocked to the back surface or may be
laminated to a foam that has the nonwoven fibers flocked into the
back of the foam. The additional flocked surface of moisture
transfer fibers and optional anti-microbial properties allows
increased functionality in the single layer material. All of these
fabrics have good moisture transfer characteristics which prevent
damage to a skater's or snowboarder's foot by preventing excessive
moisture build-up. The moisture transfer inner fabrics may vary in
composition and structure in this liner system as fiber technology
advances.
[0087] This application constructs the following inner lining
composite constructions. As stated previously, all inner lining
materials and fabrics are laminated, needled, stitched,
ultrasonically bonded, adhesively bonded or mechanically bonded to
the abutting nonwoven or foam material. The inner lining materials
or fabrics may be selected from the previous list.
[0088] The first is an inner lining fabric or material abutting an
open-cell, hydrophilic foam laminated or needled to a nonwoven
material.
[0089] The second is an inner lining fabric or material abutting an
open-cell, hydrophilic foam where the nonwoven fibers have been
flocked into the back of the foam, inner lining fabric or
breathable membrane between the inner lining material and foam.
[0090] The third is an inner lining material or fabric with an
elastomeric cellular composite such as that referenced in U.S. Pat.
No. 6,074,966 which is mechanically or ultrasonically bonded to the
inner lining material.
[0091] The fourth is an inner lining material or fabric abutting a
open-cell, hydrophilic foam with the elastomeric cellular composite
mechanically or ultrasonically bonded to the foam layer on either
side or on both sides.
[0092] The fifth inner lining composite construction is an inner
lining material or fabric abutting a Foss nonwoven composite
constructed of one or more of the following fibers, polyester
(preferably 4 Deep Groove by F.I.T. or a variation by Foss
Manufacturing), lyocel or acetate, corn, wood pulp cellulose and
silver fibers.
[0093] The sixth is an inner lining fabric or material with the
foam and nonwoven fibers flocked into the back surface.
[0094] The seventh is an inner lining fabric or material abutting a
foam layer. The foam is inclusive of a nonwoven layer or
fibers.
[0095] The eighth is an inner lining fabric or material abutting a
moisture transfer, nonwoven spacer material. Variations of the
inner lining composite are on going and are suggested in multiple
combinations. The intent of the moisture transfer system is to
provide a complete technical solution in an extremely thin
increment to accommodate the comfort needs of the user.
[0096] All of the above composite options are presumed breathable
and transfer moisture. The inner lining composite abuts second
open-cell hydrophilic foam, nonwoven composite of foam and nonwoven
and/or a thermal nonwoven, a spacer fabric or polymer mesh and the
exterior shell fabric and/or material, skeletal polymer shell or a
combination of one or more. A breathable membrane may be inserted
between the exterior shell fabric and the nonwoven, spacer product,
cellulose material, polymer mesh or foam layer.
[0097] In one option, a combination of breathable, foam and
nonwoven, a foam and a thermal nonwoven or a foam and spacer fabric
or polymer mesh are positioned in layer 30 abutting a spacer
fabric, cellulose material or exterior shell material. The above
combinations are suggested for use in ice and hockey skates,
protective gear, helmets and accessories such as gloves.
[0098] The moisture transfer characteristics of the inner liner
composite allow moisture vapors to be passed from a skater's or
snowboarder'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 nonwoven, foam, spacer or cellulose material 30.
In some performance categories the aperture nonwoven may be
eliminated between layer 20 and 30 or the foam in layer 30 may be a
spacer fabric or thermal nonwoven product or composite is applied.
The spacer fabric and thermal nonwoven are optional as well in
layer 30 and are used to provide comfort and warmth. In the thinner
applications such as in the hockey and ice skate, the inner lining
composite abuts the outer shell fabric and polymer shell. The
performance category determines the materials and combination of
materials in layer 30.
[0099] In another liner option consists of an exterior shell
fabric, a frothed, breathable, open-cell foam or free rise foam
abutting a nonwoven or nonwoven thermal layer preferably by Foss
Manufacturing, Invista, INVISTA.RTM., 3M or the like and the inner
lining material. The breathable foam layer may contain fiber and/or
a polymer mesh. Phase Change Technology may be added to the
selected nonwoven, flocked fibers or composite or a nonwoven by
Outlast, Freudenberg, Alhstrom, Kimberley Clark or the like
Wisconsin Global may be used abutting the exterior shell fabric
material
[0100] As discussed above, first foam material 20 may be a moisture
transfer, breathable, elastomeric cellular composite comprised of a
layer of germicidal, anti-microbial, open-cell hydrophilic,
polyurethane foam such as Foamex foams (VPF, Aquazone.RTM.), Dicon
foams or the like and a non-woven top sheet. Alternatively, a
frothed polymer and fiber combination made in one process can be
used in this layer or others All of the foam materials discussed
herein are preferably breathable, open-cell, free rise foam, slap
foams, frothed foams or foamed coatings made of polyurethane,
although not specifically mentioned each time. The inclusive top
sheet is preferably composed of wood pulp, rayon, elastine or
SPANDEX.RTM., corn, cotton, lyocel, PVA, silver fiber,
polypropylene, polyester, or a combination thereof.
[0101] Alternatively, foam material 20 can be a foam layer that is
separate from the non-woven top sheet and is attached to the
non-woven top sheet by lamination, stitch bonding, adhesive or the
like. The non-woven top sheet (when used) with or without elastine
or SPANDEX.RTM. fibers abuts the next layer of 1/16-1/4''
reticulated and/or open-cell hydrophilic foam, or second foam
material 30. The second foam material 30 (when used) may also be a
breathable, germicidal, anti-microbial, reticulated and/or
open-cell hydrophilic 1/16/1/4'' foam such as Aquazone with or
without surfactants, wicking solutions and/or PCM Technologies,
Sphere Technology applied or Comfortemp. The first layer 20 or the
second foam material in layer 30 may contain a moldable mesh such
as that developed by Naltex or Conwed in some embodiments. The
polymer mesh inclusive in the open-cell foam or laminated to the
open-cell foam can be in applied to any foam layer in this moisture
transfer system. The foam may also include a fiber or a group of
fibers as well as the polymer mesh. The second foam material is
preferably intergraded or backed with a non-woven top sheet as
mentioned above. In fact, any of the foam materials discussed
herein can be intergraded or backed by such a non-woven top sheet
or an elastomeric nonwoven may be applied. The non-woven top sheet
is not necessary and can be removed in a number of options. Also,
many of the foam materials are interchangeable depending upon
specific needs of the skater. The nonwoven apertured top sheet is
comprised of cotton, wood pulp, lyocel, silver fiber, PVA,
polypropylene or polyester or a combination thereof.
[0102] The previous fibers may be flocked into the back of the foam
layer 20, 30, or 50 or additional layers. A nonwoven layer,
moisture transfer, breathable, elastomeric composite or thermal
nonwoven composite may be combined with the foam layer and flocked
fibers and foam layer or flocked fibers and inner lining
material.
[0103] One preferable embodiment for a hockey skate moisture
transfer liner combines the inner lining material laminated to a
foam layer with flocked fiber backing the inner lining or foam and
a spacer fabric or polymer mesh and the exterior shell fabric.
[0104] As shown in FIG. 2, a third foam material 50 provides
support and has similar characteristics to the second foam material
30 Layer. Layer 30 allows the moisture vapors to continue their
movement to the outer layers of the composite or shell layer if the
shell has a breathable exterior layer. Optionally, the foam may
contain a polymer mesh. The layer 50 is a slow recovery moldable
foam (by Poron or Foamex), or a polyurethane reticulated and/or
open-cell hydrophilic, anti-microbial foam or a spacer material
that functions like a moldable foam and is composed of
polypropylene and polyester or a breathable foam high density foam
by Rubberlite. The spacer fabric is formed in certain areas to take
the shape of an ankle, heel pocket, and foot bones. Layer 50 is
optional and is based on the needs of the product and performance
level. The spacer fabrics are engineered with fibers that increase
moisture transfer movement. Layer 50 may abut layer 20 in some
performance categories. An air bladder may also be added in the
area around the ankle in place of the third foam or spacer fabric
material. Layer 50 may be a combination of a moldable foam and
spacer fabric shaped to aid in performance and support. The air
bladder may be inflated by pumping the reflective grip 410 just
under the pull tab. An air bladder may be added in the tongue or
toe area or in the cuff. Furthermore, spacer fabrics may also be
used in place of the foam or bladder 50 in the tongue. The moldable
polyester, polyamide, polypropylene spacer materials may be such as
those manufactured by Muller, Schiebler, Peltzer or Fugafil or the
like in varying combinations. The environmental acceptability of
many foam materials is an important factor to consider when
selecting the proper materials. Material 50 is positioned so as to
allow the moisture to pass through into subsequent elements, such
as waterproof/breathable membrane 60 and the outer shell 70, or an
encapsulated outer fabric of the overall lining system. The outer
fabric may also be treated with a waterproof film and may be
combined encapsulated technology. The third foam, cellulose
material, foam composite or spacer material 50 can be designed to
provide a well defined heel lift and heel pocket. The pocket may
also contain a silicon gel, moldable foam, frothed foam, air or an
open foam, nonwoven, or cellulose material with or without PCMs.
The pocket is optional and may be removable in some applications.
This invention enables improved 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 liners,
specifically those described in U.S. Pat. Nos. 5,092,614, and
5,397,141. The laminated foams under the heel support the skater's
lower back and allow for a comfortable stride. With this added
comfort, the aggressive or recreational skier can achieve a higher
level of continued performance.
[0105] 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 Plastics, or the like, that adds structural
integrity to the lining system. This polymer mesh, as discussed
above, may be included on or in any foam layer. A suggested
combination for the ice and hockey skates would combine the polymer
mesh in the foam abutting a thermal nonwoven or abutting the
nonwoven composite by Foss Manufacturing or the like. The multiple
layers of foam and nonwoven increase rebound and comfort levels.
The nonwoven and nonwoven anti-microbial silver fibers or the like
fibers or anti-microbial treatment may be added in some performance
categories to the foam and mesh composite.
[0106] A nonwoven thermal may be a THINSULITE by 3M thermal
nonwoven, THERMOLITE by INVISTA.RTM. thermal nonwoven, Ssoftherm by
Foss manufacturing, or a nonwoven composite with or without foam. A
shaped and/or grooved polyester or synthetic fiber nonwoven blend
may be combined with one of the selected thermal nonwoven with or
without an additional foam layer. Alternatively, the nonwoven
composite suggested previously may be a nonwoven fibers and foam
layer combined under water or air pressure. The foam layer may be
optionally contain elastine, silver or moisture transfer and/or
absorbent fibers, a polymer mesh or a combination in a number of
performance categories. Alternatively, in one option the foam layer
is combined with the fiber or a polymer mesh may have moisture
transferring fiber blend flocked to the face side of the foam
composite layer or the foam composite may have both sides flocked
in some performance categories. The flock blend additional may
include nano-technology for soil resistance and anti-microbial
properties. This option is recommended for technical climbing
footwear, protective gear or apparel.
[0107] A moldable foam layer, spacer material or gel or the like
may also be used in place of this Flex-guard polymer mesh by
Naltrex or the like and the foam composite combination or an air
bladder around the heel, toe, cuff or ankle areas. The moldable
foam may or may not be a high density, slow recovery foam by
Rogers, Rubberlite or the like. If it is not very breathable, it
can be made breathable by puncturing. Alternatively, the moldable
foam is preferably similar in construction to the second foam
material and can be a polyurethane reticulated and/or open-cell
hydrophilic, anti-microbial germicidal foam approximately 1/4 inch
thick (for example Aquazone, Netsorb, Dri-z by Dicon, Hypr-cell by
Rubberlite, Comfortemp nonwoven combined with a foam layer, or the
like). A non-woven top sheet (with or without apertures) can be
attached to the moldable foam. If a moldable foam or spacer fabric
is used, then the second foam material may be omitted. Also, the
moldable foam can be Aquazone.
[0108] 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
1/16'', 1/8'', or 1/4'' thick or being germicidal, hydrophilic, and
open-cell (for example, Aquazone). This material is preferably
laminated to a nonwoven top sheet (which may or may not be
apertured) comprised of wood pulp, rayon, cotton, corn, silver
fibers, lyocel, polyester, polypropylene, or a combination thereof.
The nonwoven or knitted top sheet maybe applied to either side of
the foam, spacer fabric or thermal nonwoven to increase moisture
transfer. The fibers selected for the nonwoven top sheet may be
also used for the flocked fiber blend and be flocked to the any
fabric, nonwoven, foam, breathable membrane or spacer material in
this liner system. The nonwoven top sheet, when used, abuts the
waterproof/breathable membrane 60 and the polymer shell or a
combination of fabrics and/or materials and polymer. The nonwoven
top sheet may abut an encapsulated outer shell fabric combined with
a polymer shell or a combination. An example of a combined fabric
and polymer shell composite is the soft shell boot and polymer
shell is the Rossignol soft alpine boot or the K2 in-line skate.
The exterior shell material is waterproofed with nano-technology,
encapsulation, DWR finishes or films, coatings or breathable
membranes or ionized treatments.
[0109] The suggested nonwoven top sheet fibers maybe flocked on to
the foam layer, inner lining material, moisture transfer,
breathable, elastomeric composite, breathable membrane or spacer
fabric to increase moisture transfer, waterproof and anti-microbial
properties.
[0110] The anti-microbial flocked fiber composite may be applied to
any layer in the composite system.
[0111] The nonwoven apertured, top sheet may be optionally
mechanically bonded to the thermal nonwoven, foam or to the thermal
nonwoven and foam composite to increase the rate of moisture
transfer.
[0112] The outer shell fabrics may also be treated with waterproof
film and finishes or encapsulated fibers or fabrics in some
performance categories. The waterproof encapsulated outer shell
fabrics eliminate the need for a waterproof/breathable membrane in
most categories. However, the breathable membranes such as Gore,
Event or the like maybe combined in this application with
encapsulation, finishes, films, or coating in some performance
categories. In fact, composites of flocked foams fibers or fabrics
or nonwoven moisture transfer thermals may be abutting a breathable
membrane like Gore, Event, Aquador or membranes by Brookwood or the
like. The outer fabrics may also be constructed to repel water with
breathable membranes, encapsulated fibers or fabrics, a breathable
film or coating. The selected coating and films are breathable and
may be used independently or combined with a breathable membrane in
some performance categories. The waterproof encapsulation is
preferably by Nextec. Nextec is the owner of the Canadian patent CA
1338232 and 593680 application the U.S. Pat. Nos. 4,666,765,
5,004,643, 5,418,015, 5,209,965. The patent documents are hereby
incorporated by reference. Encapsulation by Nextec, Toray, ASF and
others may be developed in any layer in this moisture transfer
system. Preferably the encapsulation is applied to the outer shell
fabric listed in this application. Encapsulation by Toray, ASF and
others wraps the individual fiber or thread in a polymer base
coating. Encapsulation by Nextec coats an internal layer creating a
silicon-coated woven fabric substrate (U.S. Pat. No. 5,418,051 or
U.S. Pat. No. 5,209,965). Encapsulation allows the moisture vapor
to travel around and through the woven, knitted, nonwoven shell
fabric, material or elastomeric or combination.
[0113] The moisture vapor continues from the second breathable foam
material 30 when applied through the mesh or spacer if applied 30,
and on through the third exterior foam material 50, nonwoven layer
or outer shell material. In some performance categories the spacer
fabrics or thermal nonwovens can replace the layer of foam material
50. The moisture vapors are then passed through to the
waterproof/breathable membrane 60 or shell material constructed of
encapsulated other fabrics, or the like. If the outer fabric is
encapsulated, then the moisture vapors pass around the encapsulated
fibers and onto the surface fabric. If the liner employs a
waterproof/breathable membrane, then the moisture vapors are
absorbed into the 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.
[0114] Those under the tradenames, Aquador, Entrant Dermizax,
Witcoflex, Harrison Technologies membranes, Event, Super Dry Film,
Windstopper membrane, Dry comfort, Outdry, Active comfort, Sympatex
Windler, Sympatex Elastic, Drytrail, Eclipse, Endurance, Vapex,
2000/Plus/Standard1300, Seco-Tec, Dermizax, Thintech, Lay-tek,
Witcoflex Ecodry (by Baxenden Chemical), TX-1540, Outdry, Gore
membranes, and PTFE by Tetratec are currently being considered.
However, the membranes currently being considered are Aquador,
Event and Harrison Technologies. A breathable membrane may be
combined with a thermal nonwoven such as THERMOLITE, THINSULITE,
Ssoftherm or the moisture transfer nonwoven and foam thermal
composite disclosed in this application. Outlast fibers which
regulate temperature may be combined in some options with the
nonwoven Outlast/Invista.RTM. products or other nonwoven blends or
foam in this application. If the preceding foam layers are have PCM
Technology applied or included in the foam, the Outlast (PCM's)
fiber or membrane may be eliminated. These waterproof/breathable
membranes are ultra-thin, skin friendly, moisture barriers that
allow moisture vapors to escape while preventing outside water from
penetrating. Outlast Technology is a Phase Change Technology coated
to a membrane, a spun melt fiber or a coating applied to a fabric,
foam or nonwoven surface and is manufactured by Gateway
Technologies, Freudenberg or Schoeller Textil. Phase Change,
micro-encapsulation technology, can adjust to temperature changes
and is added to foam. The Phase Change Technology can be combined
with nano-technology to cool and transfer moisture in a number of
options. Phase Change Materials can be added to a foam layer or
adhesive or foamed dot matrix which is applied to a fabric or foam
surface or the Phase Change materials may be added to a coated
binder and applied foam layer. PCM materials may be further added
to foamed adhesive or binder be sprayed to any material surface or
fiber. PCM Technology can be added to any fiber, fabric, foam, foam
and nonwoven composite, thermal, breathable membrane or flocked
fiber blend in this application. Freudenberg Comfortemp nonwovens
may be applied to any layer in this composite system or be combined
with other nonwovens or foams in this moisture transfer system. The
Freudenberg nonwovens or Freudenberg Comfortemp products (W)
02/12607) may be mechanically bonded into the foam or nonwoven
layer in this composite system to increase the thermal
applications.
[0115] A number of patents have been issued to Triangle Research
& Development Corp. disclosing the details related to the
processes now being employed by Gateway Technologies and Schoeller.
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.
5,415,222; 5,290,904; and 5,224,356. These patents are also hereby
incorporated by reference.
[0116] 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.
[0117] Also shown in FIG. 4 is a protective rim or cuff 80,
preferably made of neoprene covered by LYCRA.RTM. or elastine or
SPANDEX.RTM. materials. Also, a germicidal hydrophilic, open-cell
and/or reticulated foam by Foamex or Vita Olympic, for example, can
be used. A pull tab 90, preferably made of nylon, is connected to
the protective rim 80. An abrasive protective material 100 is
provided adjacent to a tongue 300. Another abrasive protective
material 110 is provided around the heel portion of the shoe.
Abrasive protective material 110 is supplied by Schoeller or
INVISTA.RTM., Invista, for example.
[0118] 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 a waterproof film. If the waterproof
film is applied to the outer fabric, then the membrane or
encapsulation technology may be omitted. Encapsulation technology
is being utilized by a company called Nectex, Inc. (U.S. Pat. Nos.
5,004,643 and 4,666,765) or Toray, Inc., (a Japanese company or the
like). The breathable membranes preserve the outer layer of fabric
70 and perform as a waterproof barrier for the liners. If the
encapsulation technology is applied to the outer layer of fabric
70, then the breathable laminate membranes need not be used. The
encapsulation technology regulates the degree of waterproofing and
breathability of the outer fabric shell by encapsulating an
internal layer of fibers within the outer fabric. When the
encapsulated fiber layer is close to the fabric surface, the fabric
is very waterproof and less breathable. If the layers of
encapsulated fibers are in the middle of the outer shell fabric,
then the fabric is equally waterproofed and breathable.
[0119] The outer layer of fabric 70 is a combination of extremely
durable, lightweight materials, Kevlar.RTM./Keprotec products
13207, 13624, 6500, 14705, 65563, 13602, 13408 (manufactured by
Schoeller, Inc.), the Schoeller Spirit Line 14138, 14118, 14140,
14120, 14124, 14126, 14128, 14134, 14642, 14643, 14641, 14645,
14636, 14637, 14122, 14132, 14640, Kelvar.RTM. and nylon fabrics by
Nam Liong, nylon supplex (such as that manufactured by Travis
Textiles, Inc. or Blank Textiles, Inc.), nylon Cordora.RTM.
(manufactured by Schoeller, Inc.), other Cordoras (manufactured by
Schoeller or INVISTA.RTM.), Maxus 6-ply (manufactured by Blank
Textiles, Inc.) or Starlite Dri-lex nylon fabric (manufactured by
Faytex Corp.), Mojave or Tudor (both manufactured by Travis
Textiles, Inc.), Microft (manufactured by Teijin), Entrant Gil and
Dermizax (both manufactured by Toray), Gymstar Plus (manufactured
by Unitika), Ultrex High Performance Fabrics (manufactured by
Burlington, INVISTA.RTM., Invista, Schoeller, or the like), Nextec
synthetic leathers and nonwovens or the like or the like, or other
fabrics having similar characteristics as these new products.
Nonwovens by Sontara Technologies or the like can be used in
combination with outer fabrics and are not to be confused with the
nonwoven top sheets attached to the inner foam materials. Instead,
this is a high abrasion, moisture transfer, absorbent material that
is a spun lace (polypropylene) moisture management product, such as
Sontara Technology nonwoven manufactured by INVISTA.RTM., Invista,
or nonwoven by Freudenberg for example.
[0120] Selecting the proper materials depends upon the needs of
each individual skater. The non-abrasive cool fabrics used in the
inner liner of the present invention greatly reduce the possibility
of trapped moisture, thereby protecting the foot from fungus growth
and any damage. The more aggressive skaters or snowboarders need a
moisture transfer liner that can remove large amounts of moisture
continuously from the foot. These skaters or boarders often do not
wear socks, and as a result, calluses, abrasions and blisters
become commonplace. A wetting agent may be applied to any of the
inner lining materials 20 to enhance the moisture transfer away
from the foot. The anti-microbial, anti-fungal polypropylene
(polyolefin) fabrics quickly remove moisture away from the foot.
Skin damage is minimized because the polypropylene fabric has a
smooth, continuous surface. This fabric also prevents bacterial
build-up which can cause foot odor and fungus.
[0121] The looped polyester terry blend or the like is an excellent
wicking fabric and can remove moisture rapidly. A wetting agent by
Witco, or the like, may be applied to enhance wickability.
[0122] The anti-microbial, anti-fungal Dri-lex nylon and nonwoven
fabrics blends are sanded and soft. The material not only removes
moisture away from the foot, but is also extremely comfortable and
cool to the touch.
[0123] The polyester Field Sensor fabric or Intera treated
polyesters, polyester blends or the like works well with those
individuals who prefer sport or recreational skating. This liner
absorbs moisture immediately and is recommended for the soft boot
inner liner.
[0124] Finally, polyester microfiber fabric is advantageous in that
it is cool to the touch, smooth and wickable. A wetting agent
treatment enhances wickability.
[0125] As a result of using this lining system, the skater
continues to have a cooler, drier foot. The lightweight
Kevlar.RTM., Starlite, and Cordura.RTM., or the like, outer liner
materials are twice as durable as the former heavyweight nylons
often used on the outer shell, but function as a softer feeling,
breathable outer surface and aid in the moisture transfer.
[0126] FIGS. 5(a) and 5(b) illustrate a sole portion 200 of a
footpad covered with one of the selected fabrics such as
CAMBRELLE.RTM. Dri-Lex nylon, Evolon.RTM. or Novolon.RTM.
technology by Freudenberg, polyester blends or the like.
Preferably, however, the foot pad is designed using a nonwoven,
flocked fibers or Coville fabric. The top sheet is backed by
flocked fibers, a Foss nonwoven composite, a hydrophilic moldable
nonwoven or foam. The footbed insert protects the foot from
abrasion and friction burns. The inserted hydrophilic
anti-microbial foam (an open-cell moisture vapor transfer foam) or
slow recovery punctured foam foot pad adds support and transfers
moisture downward. The bottom portion of the foam is preferably
provided with a nonwoven to sheet or flocked fibers as described
earlier, a material called SaranClimate Insoles by Fugafil or
Sumuntez 1, 2 by Textel may also be used in place of the foam
composite foot bed. The heel pocket foam or gel protects the back
of the heel with a double layered, breathable, reticulated and/or
slow recovery moldable foam or a breathable cellulose material.
This cushion protector allows circulation in the heel. The
anti-microbial silver fibers, shaped or grooved polyesters, nylon
fabric blends or nonwovens or the like, covers a molded hydrophilic
open-cell foam free rise or frothed foam or Foss composite 20 that
supports the arch and insures the skater of a comfortable
stride.
[0127] 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 materials mentioned
above, especially the Evolon.RTM. nonwoven, polypropylene,
polyester or LYCRA.RTM., elastine, SPANDEX.RTM. blend, polyester
microfiber by Coville or the like DriLine or the polyester looped
terry or the like. This inner liner fabric 310 is preferably
laminated to a structural support moldable foam layer 320, which is
preferably a 1/8-1/4 inch anti-microbial, breathable, reticulated
and/or slow recovery punctured foam. A breathable, hydrophilic,
open-cell breathable or reticulated perforated foam 330 abuts a
structural support foam 320. The breathable, hydrophilic open-cell
or the slow recovery perforated foam 330 can take the shape of the
foot bones and protect the upper foot from damage. A moldable
spacer material may also be used in combination with the foam 330
or in some cases in place of the foam 330. The structural support
320 can also be shaped to accommodate the foot and protect the
ankle bones. A moisture transfer material 340 lies over the outer
edges of the hydrophilic perforated foam or combination foam and
spacer material 330 and is connected to the inner liner 310 and
underlies the outer protective polyurethane layer 350. This
moisture transfer material 340 is preferably made from a material
known as aero-spacer Dri-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.RTM. or Invista can be used.
[0128] The nonwoven material such as Cambrelle Dri-Lex, Nextec
synthetic leathers, nonwovens or fabrics, Evolon.RTM. a spun lace,
elastine or SPANDEX.RTM., moisture management products by
Freudenberg or the like can produce strength and moisture transfer
properties to the tongue. It should be understood that these
nonwoven materials can always be substituted for the knitted,
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 protective
polyurethane layer 350, or the like, is provided over a central
portion of the material 340. Another hydrophilic open-cell foam or
slow recovery punctured foam (not shown) is shaped to fit between
the outer protective polyurethane layer, Cordura.RTM. nylons,
Kevlar.RTM., or synthetic breathable leathers (by Daowoo
Corporation, for example) 350 or the like are surrounded by
aero-spacer Dri-lex 340, or a substitute as mentioned above, or the
like. The protective polyurethane layer may be optional in both the
shell liner and the soft boot. If the protective polyurethane layer
is omitted, then the slow recovery foam (not shown) or open-cell
foam may also be omitted.
[0129] As shown in FIG. 6, polyurethane, Kevlar.RTM. fabrics, or
synthetic breathable leather layer (by Daewoo Corp. for example)
350 is surrounded by aero-spacer Dri-lex 340, or a substitute as
mentioned above. At the top of the tongue 300 is an abrasive grip
fabric 100 (such as that manufactured by Schoeller and identified
by the number 6500), also shown in FIG. 4. Stitching is identified
by numeral 370. FIG. 7 illustrates a top portion of the tongue 300
and shows stitching and the inner liner fabric 310. It is
recommended that waterproof LYCRA.RTM., SPANDEX.RTM. or elastine
threads or and nylon thread such as those used by the Dupont, Xymid
Group or Tietex, Kasbar National be used for these stitched areas
or adhesive bonding by Applied Extrusion Technologies, or the like.
In fact, adhesive bonding may be utilized in place of or in
combination with several stitched areas on the outer liner fabrics
or inner lining fabrics or composite layers.
[0130] In-line, ice and hockey skate tongues have in the past been
synthetic hard-edged forms. The shape of these tongues often did
not fit the skater's foot. Furthermore, vinyl may damage the upper
foot where it meets the inner lining edge during active use of the
in-line skate. As a result, the skater may develop blisters,
calluses, or bruises on this upper-foot area. MVT brushed
microfibers, fabrics and nonwovens blends in this liner system
increase performance and prevent foot damage. Additionally, the
inner fabrics of the tongue liner have often been non-breathable
nylon, nonwovens and vinyl, thereby increasing the possibility of
foot bacteria and fungus development. The optional anti-microbial
fiber blends and ionized fibers and fabric discourage bacteria and
fungus growth.
[0131] 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 neoprene or reticulated foam covered by LYCRA.RTM.,
elastine, SPANDEX.RTM., or the like. FIG. 9 shows an opened-up
version of the liner looking from the back of the shoe. The outer
upper cuff that is exposed above the shell of the in-line, ice or
hockey skate removable or non-removable liner is provided to
protect a skater's leg from abrasion. Located just beneath the cuff
80 is an abrasive grip fabric material 410, such as that
manufactured by Schoeller, Inc., Nam Liong or the like. Below
material 410 is a reflective grip material 420. Below the
reflective grip material 420 is a highly abrasive fabric 110, as
shown in FIG. 4. The reflective material 14309 by Schoeller or
Texon may also be used as fabric 110. Fabric 110 is preferably a
Kevlar.RTM. by Toray, INVISTA.RTM., or Schoeller (Keprotec or
Schoeller Spirit) or Texon, Starlite, Cordura.RTM., or the like.
Finally, outer shell fabric 70 is the same as that shown in FIG. 4
and can be any of the fabrics previously listed in connection with
outer shell fabric 70. The nylon pull tab 90 allows the skater to
easily slip into the liner.
[0132] FIG. 10 shows the other side of the liner of FIG. 9. In FIG.
10, 510 can be a 1/4 inch punctured moldable foam, spacer fabric,
or an air bladder of a similar shape. The foam and air bladder may
also be used in combination. Alternatively, the moldable foam or
breathable cellulose material can be replaced by a reticulated or
hydrophilic open-cell foam, silicon gel or Dicon foam or the like.
A nonwoven top sheet (with or without apertures) can be attached to
the moldable-foam or selected fibers may be included in the foam
during formation. Also, a spacer material, such as that made by
Muller or the like, or a cellulose material or elastomeric by
FoxRun or Baychar Technologies can be used as material 510. The 520
application represents the combination of the flexible mesh (in the
case that the moldable foam is not used, as depicted), the
breathable membrane and the outer shell fabric or encapsulated
outer shell fabric. As in all of the figures, the arrows depict the
flow of moisture.
[0133] FIG. 11 illustrates the toe portion 400 of the shoe.
Preferably, the toe portion 400 is constructed with an inner liner
10, followed by a foam material 30 or foam and mesh with or without
fibers, followed by a breathable membrane 60 and the outer fabric
70 or encapsulated outer shell fabrics. The optional foam and
nonwoven fiber composite blend may be used abutting the mesh or
spacer material in the toe box and heel. Abrasive grip fabric 100
is also shown. Texon Aquiline, Nam Liong nylon, Kelvar products,
synthetic leather, nonwoven may be used. The 6500 high abrasive
fabrics manufactured by Schoeller, Inc., Nam Liong, Kelvar.RTM. and
nylon fabrics or the like, are located on the back of the cuff and
the top of the toe box, heel, and tongue grip area. The Kevlar.RTM.
and Cordura Starlite.RTM. fabrics provide comfort and durability to
the liners and are extremely strong and resistant to abrasion and
allow for breathability and performance.
[0134] The microfiber technology disclosed above is rapidly
developing and changing and has greatly increased the potential for
improved performance of such products as in-line skates, 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 technical fabrics,
open-cell, breathable foam layers, moisture transfer and absorbent
nonwovens, breathable spacer fabrics, waterproof/breathable
membranes, polymer mesh and cellulose materials, flocked fibers and
foams technology, encapsulated technology, nano-technology,
structural woven water repellent fabrics, or waterproof film
coatings in such combinations that increase the performance of the
products in which they are used as well as increase breathability.
The waterproof/breathable membranes in this application may have
anti-microbial fibers and/or nonwoven fibers flocked to them to
increase performance properties. The flocked fiber layer attached
to the membrane, outer shell fabric layer or composites layers in
this invention may contain silver, corn, lyocel and/or hollow,
shaped or split polymer fibers. Nano-technology may be incorporated
in any layer in the composite products. Resin treated cotton and
synthetics materials by Nano-Tex, NanoHorrizon's E47 fabrics,
Nanomatrix fabrics by Toray and Nanosphere technology fabrics by
Schoeller can be used for selected inner lining and out shell
materials. Coating by Trann Technologies can be applied to
SPANDEX.RTM., cotton, and other fabrics. Silicone applications
allow for moisture transfer wrinkle free and fad resistant
products. Many skate protective products utilize SPANDEX.RTM. and
stretchable products. The breathable moisture transfer, open-cell
high or low density foam and nonwoven composite packages are
lightweight and easily molded to accommodate safety helmets,
protective gear, skate and technical footwear or apparel.
[0135] It should be noted that, in the case of in-line skates, the
lining system of the present invention can be applied to both shell
boot insert liners and soft boot applications. The soft boot
in-line skate mentioned earlier in the background of the invention
addressed the needs of a skater to have more flexibility and
comfort yet still maintain performance levels. This new technology
in the hockey, ice and in-line skate industry has increased
tremendously the possibilities of a lighter weight performance
product. The soft boot, in-line skate or hockey skate construction
can easily accommodate the numerous moisture transfer, breathable
composite combinations. The soft boot for hockey, in-line or ice
skate use can be constructed with the moldable exterior
Kevlar.RTM., Cordura.RTM. or the like composites in the moisture
transfer system to form tongues, side walls, toe caps and upper
applications. While the soft boot does not have a protective shell,
it can nonetheless be provided with a permanent integrated liner or
a removable liner that enjoys all of the benefits of the present
moisture transfer inner lining breathable composite systems. These
moisture transfer constructions may also be applied to alpine and
hiking boot products. Preferably, the outer shell materials of the
moisture transfer system comprising the entire soft boot
application would be comprised of a composite combination
containing a number of technical fabrics such as nylon,
Kevlar.RTM., or high abrasion Cordura.RTM. fabric, such as that
manufactured by Schoeller, Nam Liong or the like. These fabrics, as
well as the high abrasive fabrics, are encapsulated or are provided
with a waterproof/breathable membrane or coatings. A breathable,
reticulated and/or open-cell hydrophilic, anti-microbial germicidal
foam layer by Foamex or Rubberlite or a breathable, anti-microbial,
moisture transfer, nonwoven and foam blend manufactured by Foss
Manufacturing abuts the encapsulated outer fabric or breathable
membrane. The breathable, moisture transfer nonwoven including a
foam layer manufactured by Foss Manufacturing may include elastine
or SPANDEX.RTM. fibers to increase the stretchable properties. In
some options the layer of foam may be eliminated and replaced by
another nonwoven layer. The structural mesh, combined mesh and foam
composite, molded cellulose or spacer material is stitch bonded or
laminated to the 1/20-1/8 inch reticulated or open-cell hydrophilic
foam. The foam thickness can vary with the products performance
criteria. A slow recovery punctured foam or high density foam by
Rubberlite, cellulose material, spacer material or silicon gel, or
the like, are located in the heel pocket, tongue, and toe areas. An
air bladder may also be added around the ankle areas to increase
performance in some cases. The structural mesh or molded spacer
materials abut a nonwoven top sheet or a foam and nonwoven
composite that is laminated, stitched, or ultrasonically bonded to
a breathable, reticulated and/or open-cell hydrophilic 1/20-1/4
snad inch foam. The 1/8 inch foam abuts preferably a cellular
moisture transfer, breathable, elastomeric composite which is
laminated to the inner fabric. A nonwoven top sheet laminated to
1/20-1/8 inch foam may also be used in place of the moisture
transfer, breathable, elastomeric composite. Also, instead of being
removable, the liner would preferably be directly attached to the
base of the soft boot by methods well known in the art, such as
that disclosed in U.S. Pat. No. 5,437,466. Substitutions can be
made to all of the foam materials (i.e. hydrophilic open-cell,
Aquazone, Premium, VPF, etc.) just as discussed earlier, and are
not specifically repeated here. Spacer fabrics, rubber and nonwoven
materials or foam and paper composite combinations may replace any
layer in the composite systems. Semi-disposable and disposable
composite products may combine one or more fibers such as cotton,
corn, flax, hemp, lyocel, wood pulp and/or paper fibers with a foam
layer. The disclosed semi-disposable and disposable composite
materials maybe combined with a needle punch nonwoven and applied
to many end use product lines as a removable and replaceable
insert. Other aspects of the present invention can be applied to
the soft boot without any significant structural changes. The soft
boot density is increased in the footbed, toe box, and heel plate.
This added support provides protection and assists in maintaining
technical performance levels. The in-line soft boot or shell skate
breathability would be greatly enhanced with this added moisture
transfer liner system. The soft boot may also employ the nonwoven
top sheets and composites in a number of combinations with the foam
layers to increase moisture transfer. The breathable moisture
transfer system allows moisture to travel through each layer. The
performance criteria, product and selected materials determine the
rate of moisture transfer and breathability. It is preferable, but
not necessary that the outer shell materials are breathable. In
many cases a combination of exterior shell materials will allow the
moisture and heat to vent in selected areas.
[0136] Also, the soft boot outer shell may be a combination of
synthetic breathable leather (such as that available from Daewoo,
Inc. Nextec or the like), an encapsulated, waterproof film or
breathable membrane outer fabric by Gore, Schoeller, Burlington
Industries, Malden Performance Fabrics or any of the former fabrics
mentioned, or the like, as well as synthetic rubbers, PVC, TAR or
CPU, a thermoplastic composite material. Typar Nonwovens by Sontara
Technologies, Texon, or the like, may be used in combination with
the outer materials in high abrasion areas. These high abrasive
polymer materials are not known for moisture transfer or
breathability. The suggested composite combination would allow
breathable exterior shell materials such as Kelvar.RTM. and nylon
fabrics to be combined with the less breathable or non-breathable
materials in the system.
[0137] The outer shell combined materials are then laminated,
stitched, adhesively bonded or ultrasonically bonded, or the like,
to interior foam or foam and nonwoven layers. An air bladder may be
added in combination with or in place of the molded foam and
structural mesh to aid in comfort and performance. If the internal
layers of foam and nonwovens are stitch bonded, it is recommended
that the process with LYCRA.RTM., elastine, SPANDEX.RTM. thread by
the Xymid group former a Dupont.RTM. group be used or the process
developed by Tietex with nylon thread, or the like. The outer shell
fabric seams may be stitched or adhesively bonded. Alternatively,
the outer shell is a moldable composite of shell fabric foam,
needle punch thermal nonwoven with or without foam abutting inner
lining material. The exterior shell material is bonded to the
nonwoven by foam and may optionally include a mesh and/or fibers
with anti-microbial properties. The inner lining material may be
stitched, laminated or bonded with adhesives, breathable membranes
or lamination to the exterior shell composite. The exterior shell
fabric material may or may not be waterproofed.
[0138] The inner moisture transfer fabrics are any of the former
fabrics listed as suggested for the removable liner, or the like.
The foam is manufactured by Olympic Vita, Rubberlite, Dynamic foam,
Dicon, Foamex or the like, in combination with a nonwoven top sheet
as mentioned or the foam-nonwoven combination may be replaced with
a foam/top sheet composite referred to as a cellular elastomeric
composite. Presently, this invention utilizes shaped polyester
fibers (4 deep groved polyester fibers or the like and/or
polypropylene filtering material produced by Vitafibers QW 110-QW
150 quiet web or Tangerding Vliesstoffe (TH-FI 210B or FF-FI 250).
These materials may be substituted for the reticulated or open-cell
foams previously mentioned, materials 30 and 50 for example. The
composite combination can be used for apparel, medical, industrial
and protective application. Tangerding Vliesstoffe or the like may
have an anti-microbial fiber added with the phase change material
to increase the performance properties. These breathable, moisture
transfer, anti-microbial nonwoven or nonwoven and foam composite
combination may be used industrially for air or water filtering
applications or baby diapers and medical products. In fact, a large
number of the skate composites and combinations of compositions in
this invention may be used in medical and industrial
applications.
[0139] Alternatively, the elastomeric cellular composite or the
cellulose spacer material made with wood pulp and elastine fiber or
foam materials by FoxRun may be further incorporated anti-microbial
fibers. The elastomeric composite or spacer material may have a
nonwoven fiber flock on one side or both sides. The elastomeric
flocked fiber composite combination is anti-microbial, moisture
transfer and thermal regulated and may be applied to numerous
composites in this invention for helmet, protective gear, skate,
soft boot and alpine shell boots, insert liners, apparel, medical
and industrial.
[0140] In fact, a large number of the above technical composite
combinations may be used to construct the entire product line for
protective gear, sporting goods apparel, backpacks, tents, sleeping
bags, bouldering shoes, water shoes, cycling shoes, sailing and
golf apparel and footwear, as well as, apparel and footwear. In the
paddling, water sports products and sailing apparel and
accessories, the kapok fiber may be added to increase buoyancy.
[0141] FIG. 12 illustrates a snowboard or alpine insert boot liner
incorporating the moisture transfer system discussed above. The
snowboard boot may have a removable or non-removable liner and the
moisture transfer system may represent the layers of the entire
boot from the exterior shell material inward to the inner lining
fabric layer as discussed above for the soft shell or hiking boot.
Bouldering shoes, hiking shoes or cross country boots can easily
incorporate the thin, lightweight, breathable, moisture transfer,
waterproof layers to construct the entire shoe. The following
elements of the snowboard boot are shown: numeral 610 represents a
waterproof breathable synthetic leather or a leather by OutDry
(Nextec), a Kevlar.RTM. fabric (made by Schoeller, or a similar
material), Schoeller, INVISTA.RTM. & Toray or the like,
Cordura.RTM., DYNAMIC EXTREME, KEPROTEC, or DERMIZAX by Toray;
numeral 615 represents materials similar to that of numeral 610,
but can have different colors for aesthetic purposes; numeral 630
represents a Kevlar.RTM. or a technical materials made by
Schoeller, Nam Liong, a synthetic material, leather or the like,
with the heel portion being synthetic rubber, EVA, or the like,
manufactured by Daewoo; numeral 635 represents an inner moisture
transfer material covering a breathable, molded breathable foam or
breathable a spacer product numeral 640 represents a Kevlar.RTM. or
Cordura.RTM. material; numeral 650 represents some decorative
piping made of synthetic leather, stitching, polymer 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.RTM. back; and finally, numeral 675 represents an
optional sock that can be inserted into the boot with the permanent
liner or removable insert liner if desired.
[0142] The sock 675 is made up of three or four layers and is
similar to the thin race boot option. The first layer can be any of
the inner liner materials discussed above. The second layer is a
layer of moisture transfer, breathable, elastomeric composite, or a
foam and nonwoven moisture transfer composite or thermal nonwoven
composite comprised of a THERMOLITE, THINSULITE nonwoven with or
without foam and silver fibers. The third layer is a material that
absorbs and transfers moisture such as an ionized nonwoven blend or
a polyester blend manufactured by Deercreek Fabrics, Menra Mills,
or Coville fabric treated with a wicking, ionized solution or the
like.
[0143] The preferable outer shell insert sock construction may be a
three-layer composite constructed of an inner lining material, a
nonwoven composite with foam or without foam and silver fibers and
an outer shell polyester mesh waterproof with a encapsulated, film
or a finish. Optionally, a spacer fabric material may replace the
inner moisture transfer nonwoven composite layer. The inner lining
fabric or material and outer shell layer fabric or material may be
a nonwoven, knitted or a woven construction. Encapsulation
technology can also be applied to the third layer by Nextec. Sock
675 can be used for additional warmth and is removable, unlike the
shoe liner and can be inserted into the snowboard, alpine liner or
the like, for extra warmth. The insert sock liner is breathable and
preferably used in a boot where the liner is not removable or there
is no liner available. The three layers can be attached to one
another by lamination, although mechanical bonding, or stitching,
or ultrasonically bonded, can also be used. This insert sock liner
is recommended for the all-weather boot by L.L. Bean or the
like.
[0144] The alpine and snowboard race boot requires a thin moldable
liner option. The insert liner for the alpine race boot preferably
is constructed in following three options the inner lining material
abutting an open-cell foam backed with a moisture transfer nonwoven
top sheet. The third layer composite is laminated to the moisture
transfer, breathable, MVT Thermal made by Foss Manufacturing
composite and a spacer fabric material. The exterior shell fabric
is laminated to a spacer fabric material.
[0145] In the second option the inner lining material is laminated
to the moisture transfer, breathable, MVT Thermal developed by
Baychar Technologies and manufactured by Foss Manufacturing
composite and abuts the breathable moldable spacer fabric and
exterior shell material.
[0146] In the third option the inner lining material is welded to
moisture transfer, breathable, elastomeric composite, the moldable
breathable spacer fabric and exterior shell material.
[0147] Optionally, the exterior shell fabric may be a three-layer
composite constructed of foam, moisture transfer nonwoven and the
exterior shell fabric. The three-layer exterior composite may be
attached to the breathable spacer fabric and molded. In fact, any
of the combinations may be molded, adhesively bonded and welded in
this invention.
[0148] The microfiber and chemical ionized technology disclosed
above is rapidly developing and changing and has greatly increased
the potential for improved performance of such products as the
alpine boot, provided that they are properly utilized as in the
present invention. These new technical fibers, materials, foams and
moisture transfer composite combinations are part of rapidly
developing technical textiles technology industry. The present
invention employs a combination of fabric, foam, moisture transfer
nonwovens, moldable spacer materials, breathable membranes,
coating, finishes, films, structurally woven or knitted waterproof
fabrics, ionized fabrics, 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, coating and finishes are optional in alpine, hiking and
climbing shoes. The removable sock liner may be inserted into
rubber boots, all weather boots or alpine products. The discussion
above has focused upon snowboard boots, alpine boots, hiking and
climbing shoe liners. Similar applications can be made with running
shoes, helmets, protective gear or cross country boots, or in-line
skates, gloves, accessories, sleeping bags, back packs and apparel
with slight modifications.
[0149] In the snowboard boot liner, the various layers can be
combined by lamination, mechanical bonding, stitch bonding,
ultrasonic bonding or a combination of these two. The second and
third layers would include a breathable foam that contacts the
first layer and is a germicidal, reticulated foam or a hydrophilic,
open-cell foam, such as VPF or Aquazone manufactured by Foamex,
DRI-Z manufactured by Dicon with or without glycerin, Phase Change
Foam or Schoeller PCM foam or the like. Alternatively, these layers
can be a MVT Thermal made by Foss manufacturing composite. An
elastomeric cellular composite inclusive of moisture transfer,
nonwoven fibers or a open-cell foam backed by a moisture transfer,
nonwoven, apertured top sheet composed of wood pulp, polyester,
rayon, lyocel, cotton, or polypropylene, in a single process. A
foam composite may be used in combination with a thermal nonwoven
such as THERMOLITE, THINSULITE or the like.
[0150] The fourth layer is a hydrophilic, open-cell preferably, VPF
by Foamex, an open-cell, slow recovery foam by Rubberlite, or Dicon
Technologies foam, or polymer flex-guard mesh or a polymer
flex-guard mesh inclusive in an open-cell foam or a polyester
breathable spacer material (by Muller) or the like for support. In
this case, the open-cell foam, Foamex, Rubberlite or the like is
laminated to a moisture transfer nonwoven top sheet composed of
wood pulp, cotton, polyester, lyocel, blend which abuts a
waterproof/breathable membrane (fifth layer), if used. If the
flex-guard polymer mesh is used, it is included in the foam in one
process or the flex guard is followed by another layer of open-cell
foam with a moisture transfer nonwoven top sheet inclusive in the
foam or abutting the waterproof/breathable membrane or an
encapsulated or waterproof breathable coated or filmed exterior
shell fabric. If the spacer material is used, it may or may not be
molded to accommodate the foot. The moisture transfer nonwoven top
sheet may be eliminated in selected performance categories. The
breathable spacer material abuts either a waterproof breathable
membrane, an encapsulated or coated fabric. The breathable spacer
material may be combined with a THERMOLITE or the MVT Thermal
developed by Baychar technologies and manufactured by Foss
Manufacturing composite.
[0151] The Phase Change Technology by OUTLAST/INVISTA or the like
may be added to any layer in the liner system and may be combined
with encapsulated fibers and fabrics and combined with
nanotechnology. Phase Change Technology can be used in conjunction
with structurally knitted waterproof fabrics or fibers, or with the
encapsulation fabrics by Nextec, Toray or the like. Encapsulation
by Nextec combined with the Phase Change Technology or OUTLAST
Technologies/INVISTA is an enhanced option in this embodiment, but
is not essential in the products. If encapsulation is employed,
then the fourth layer preferably includes THERMOLITE with or
without split, shaped or grooved fibers or the moisture transfer,
breathable, MVT Thermal developed by Baychar Technologies and Foss
Manufacturing composite. Both THERMOLITE and the MVT nonwoven
developed by Baychar technologies and manufactured by Foss
Manufacturing or the like may include anti-microbial properties or
silver fibers. If a non-removable liner is employed instead of a
removable liner, a waterproof-breathable thin film, finishes or
coating can be used instead of encapsulation or a
waterproof/breathable membrane, nano-technology may be applied to
waterproof any selected outer shell material.
[0152] The sixth layer in this removable shell liner may be
Cordura.RTM., STARLITE, Kevlar.RTM. fabrics or the like. The
STARLITE by Faytex Corp or Faytex breathable series, Kevlar.RTM.
and Cordura.RTM. by Schoeller 6500, 14705, 13207, 13632, 65563 etc.
and Nam Liong's ARMORTEX Series, DERIZAX and ENTRANT Gil by
Toray.
[0153] The exterior shell fabric is preferably encapsulated or
waterproofed with a breathable thin film or coating. It may be
noted in this invention that there are no stated specified rates of
breathable or moisture transfer. The selected products and
performance category in the product line determines the selected
breathable and moisture transfer rates. The MVT and breathable
rates are developed by the selected fibers, foams and materials for
these technical composites product systems and are determined by
performance level and product company.
Alpine Cross Country Boots
[0154] A liner for the alpine cross country boots has a first layer
selected from a group including polypropylene, nylon blend,
polyester or polyester blends, LYCRA.RTM., elastine, SPANDEX.RTM.
or wool backed by cotton, wool, rayon, lyocel, acetate, acrylic,
polyester or a nonwoven blend. The inner lining fabric or material
may be an anti-microbial, anti-fungal INNOVA or ALPHA; sueded
polyester; polyester field sensor; looped polyester terry; Dri-line
by Milliken, Coville or Deercreek polyester blend, DRI-LEX or the
like by Faytex Corp.; polyester DRI-LEX terry by Faytex; polyester
fleeced blends or spacer fabric by Malden; and polypropylene backed
by cotton by Coville. Alternatively, the multi-layer composite may
abut the second layer.
[0155] The second layer in this embodiment may be a breathable,
open-cell foam, or a moisture transfer nonwoven composite, or a
breathable moldable spacer fabric for the outer shell material.
These materials may be individually selected or in combinations in
certain performance categories.
[0156] The breathable, germicidal, open-cell hydrophilic foam
second layer may be a open-cell, breathable foam containing Phase
Change material by Rubberlite. Foamex, Lendal or International
foam. INVISTA nonwoven and foam materials with Phase Change
Technologies or a foam by Dicon Technologies such as DRI-Z.RTM.
with or without glycerin. This foam can be provided with or without
a moisture transfer nonwoven top sheet. The moisture transfer
nonwoven top sheet can be selected from any of the materials
previously specified. Alternatively, the second layer may be an
moisture transfer, breathable, elastomeric composite or the second
layer can be a open-cell foam such as DRI-Z.RTM. or the like with a
fiber or nonwoven later integrated into the foam layer during its
construction. This moldable composite comprised of fiber and foam
is created in one process and may in some performance categories
contain a polymer mesh such as that developed by Naltex or webbed
layer. The breathable, open-cell foam with or without the polymer
mesh may alternatively, contain a nonwoven sheet constructed of the
above suggested fibers contained in the nonwoven backing to assist
in the absorption and transfer of the moisture passing through the
moisture transfer system. The moisture vapor is pulled through the
foam and nonwoven fiber layers and quickly evaporates layers. It is
not necessary that the moisture vapor travel though the outer
polymer shell systems as the majority of the moisture vapor
evaporates before the outer shell layers. Many skates have a
non-breathable exterior polymer shell material. The breathable
layers and moisture transfer system can be applied to either a
non-breathable, non-removable shell, removable liner insert, a
breathable waterproof shell skate or footwear item.
[0157] The third layer is structural support foam or a breathable,
moldable spacer material by Muller Textil. The spacer fabric is a
knitted sandwich structure with a nonwoven core. The heel and arch
may also have a slow recovery foam or spacer fabric added for
comfort. The thickness of the layer of foam or spacer fabric and
THERMOLITE may vary for performance. The third may be eliminated in
some performance cross country boot applications or be replaced by
thermal nonwoven or composite or abut a thermal nonwoven or another
foam layer.
[0158] The fourth layer is a thin layer of THERMOLITE, a hollow
core polyester fiber, containing a binder. THERMOLITE combined with
a breathable, open-cell foam with or without natural fibers such as
corn, silver wood pulp, spandex, elastine, cotton or lyocel fibers
added to absorb the moisture. The hollow polyester fibers synthetic
fibers quickly move the moisture along that is absorb by the nature
fiber from the abutting top sheet. Optionally, the fourth layer can
be a blend of moisture transfer synthetic or natural fibers blend
or the moisture transfer, absorbent nonwoven composite developed by
Baychar Technologies with or without Phase Change materials or
thermal fibers by Outlast or INVISTA.RTM. or an open-cell foam such
as Foamex, Rubberlite or the like with a moisture transfer nonwoven
top sheet made of wood pulp, lyocel, rayon, cotton, polyester,
acrylic, flax, hemp, acetate, corn or polypropylene. These nonwoven
fibers in combination or independently absorb and move moisture.
The fourth layer may be optional in some performance
categories.
[0159] The fifth layer is optionally, a breathable
waterproof/breathable membrane which may be any one of the
following: SECO at Shawmut Mills, THINTECH, THERMOLITE 2000/1300
standard, latex, breathable membranes by Harrison Technologies,
Sympatex, or ENTRANT Gil by Toray. The OUTLAST technology can be
used applied to a membrane or to a outer fabric or material that
has been treated with an encapsulated or nano-technology.
Encapsulation technology applied to the outer shell fabric is by
Nextec, Toray or the like. Alternatively, instead of the membrane,
encapsulation technology or a waterproof breathable finish or film
may be applied to the exterior shell materials of the sixth layer
and can achieve similar results. Optionally, a combination of Phase
Change Technology and nano-technology can be applied to fibers or
fabrics by Burlington Technologies or the like. If encapsulation is
employed, then the fourth layer preferably includes THERMOLITE,
moisture transfers nonwoven blend or Moisture transfer composites
(MVT Thermal) composite.
[0160] The sixth layer is one of the following fabrics. Note that
if these fabrics are encapsulated, the waterproof/breathable
membrane in the fifth layer may not be needed in this option. These
fabrics include the following: Cordura.RTM.; LYCRA.RTM., elastine,
SPANDEX.RTM. blends; STARLITE by Faytex Corp.; Kevlar.RTM. fabric
by Schoeller (14705, 6500, 13207, 13632, 65563, etc.); Nam Liong
AROMRTEX Series, INVISTA.RTM. and Toray or the like, Cordura.RTM.
2000 by INVISTA.RTM., 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, IBQ stretch Cordura.RTM. or the like; and
synthetic leathers by Daewoo, Inc., Nextec or moisture transfer
nonwovens by Freudenberg, Sisa or the like. These fabrics may be
used individually or in combination.
[0161] The seventh fabric option is a LYCRA.RTM., SPANDEX.RTM. or
elastine material covers a neoprene, moldable spacer fabric or slow
recovery foam or reticulated open-cell foam upper liner ankle
cuff.
[0162] The tongue for the alpine boot is similar to the tongue of
the in-line skate. The tongue of the cross country boot is similar
to the snowboard boot. They can be constructed of Rubberlite,
Foamex, International or the like molded foams with a moisture
transfer nonwoven 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, DRI-LEX
Aero-spacer, polyester FIELDSENSOR polyester by Toray, Freudenberg
Nonwovens with or without phase change materials, DRILINE by
Milliken, polyester spacer by Malden, polar fleece INNOVA or ALPHA
polypropylene by Coville or Deercreek Fabrics, or DRI-LEX nylon,
polyester blends sueded or fleeced or the like. The outer tongue
fabrics are high abrasive fabrics constructed of Kevlar.RTM. and
Corduras.RTM. by Schoellar or Nam Liong and DRI-LEX Aero-Spacer or
other Aero-spacer materials by Faytex, or the like, and breathable
synthetic and natural leathers by Daewoo, Nextec, or the like. All
the leather in this embodiment can be treated with OutDry by
Nextec. 3.times.Dry by Schoeller or the like.
[0163] CIBA chemical waterproof treatments or nano-technology may
be applied to any layer in this composite to enhance, soil
resistant, moisture transfer or waterproof properties.
[0164] The alpine liner can eliminate one or more layers to
accommodate race liners and cross country boot applications. The
preferable embodiment would contain a three layer composite liner.
The inner moisture transfer fabric or material, a moisture transfer
nonwoven for waterproof stain resistant exterior fabrics composite
developed by Baychar Technologies manufactured by Foss
Manufacturing and an exterior shell moisture transfer, waterproof
material. This lightweight breathable moldable composite can be
adhesively bonded.
Hiking Boots
[0165] 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 composites by Faytex; Doeskin,
BABY KID, Cambrelle by Faytex; anti-fungal, anti-microbial
polypropylene fabrics; INNOVA or ALPHA fleeced polyester and
polypropylene blends, suede surface polyester blends, COOL MAX or
nylon blends, or the like. Any combination of these moisture
transfer fabrics can also be used.
[0166] The second layer is a moisture transfer, breathable,
elastomeric composite or a hydrophilic or a breathable, open-cell
foam preferably by Foamex, International foam or Rubberlite, or
Dynamic foam or Schoeller PCM foam or Outlast coated PCM foam or a
DRI-Z foam or a breathable moisture transfer fabric or nonwoven
layer. If a foam layer is used in the second layer, a moisture
transfer absorbent nonwoven top sheet selected from previously
mentioned materials can be attached as a backing.
[0167] The third layer is a molded hydrophilic open-cell foam
backed by an aperture moisture transfer and absorbent nonwoven top
sheet composed of cotton, polyester, polypropylene, lyocel, rayon,
or wood pulp, cotton or the like. A moldable heel and ankle spacer
fabric by Muller or the like may also be used in place of the third
nonwoven layer or hydrophilic, open-cell foam. A breathable,
moldable spacer fabric or foam may be added around the toe box and
back cuff. A molded heel/ankle insert by Muller Textil is
preferably also used. The Muller Textil spacer fabric is a complex
composite with knitted top sheets on either side of the continuous
filaments sandwiched in the middle of the knitted top sheets. This
breathable, moisture transfer spacer material is moldable and
lightweight and can be used as a replacement for any nonwoven or
foam layer in this invention.
[0168] The fourth layer optionally is a waterproof/breathable
membrane which may be any one of the following: Membrane by Shawmut
Mills), THINTECH, THERMOLITE 2000/1300 standard, laytex, WILCOFLEX
DRY or the like. The Phase Change Technology or OUTLAST Technology
may also be used independently of the breathable membrane and may
also be contained in a polymer adhesive or coating to the outer
fabric or fibers or applied in a foam coated dotted matrix on the
back side of the fabric, foam or nonwoven layer. Also, this
membrane layer may be eliminated in some models depending upon the
hiker's needs. Alternatively, instead of the breathable membrane,
encapsulation of the fifth layer can be performed to achieve
similar results. If waterproof encapsulation is applied to the
outer layer, then the third layer may be an open-cell foam or a
moldable spacer fabric, a THERMOLITE, a moisture transfer nonwoven
composite or a MVT Thermal composite developed by Baychar
Technologies or a licensed representative of Baychar Technologies.
The Phase Change Technology may be applied to the moisture transfer
nonwoven, foam or fabric in this moisture liner system and may be
combined with outer shell encapsulated fibers and fabric, such as
by Nextec, or the like.
[0169] The fifth and last layer is a combination of one or more of
the following: Corduras.RTM., Supplex Nylon, STARLITE, Tudor,
Kevlar.RTM., nylon blends, polyester nylon blends, and waterproof
breathable synthetic and natural leathers. Preferably, this layer
is waterproofed by using encapsulation, waterproof finishes or
films or coatings. Waterproof treatment to the exterior shell
leathers, synthetic leathers and/or materials can be applied by
OUTDRY by Nextec, BURAPEL PLUS, HYPER D-WR or ENTRANT G2-XT,
eXY
[0170] Moisture transfer, breathable, absorbent elastomeric
composite technology may be inserted between the exterior shell
fabric and the breathable membrane, if applied, or the moisture
transfer, breathable, elastomeric composite may be a moisture
transfer nonwoven thermal blend on one side and the exterior shell
fabric on the other side. Optionally, the thermal nonwoven
composite comprised of engineered fibers with or without a foam
layer may be abutting the exterior shell material or a frothed foam
and the outer shell material. Furthermore, the breathable liner
according to the present invention could also be added to clothing
such as shirts, pants, gloves, helmets, backpacks, 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 moisture transfer, wickable inner liner,
followed by an elastomeric or an open-cell foam 1/16, 1/8 inch and
the outer shell fabric. A moisture transfer nonwoven may or may not
be laminated to the foam. Optionally, a breathable membrane abuts
the foam or moisture transfer nonwoven and is laminated to the
outer fabric. The outer fabric may be waterproofed by encapsulated,
laminated to a breathable waterproof membrane, coated with a
waterproof finish or film, structurally woven or knitted to repel
water or contain nano-technology. If encapsulation technology or a
waterproof breathable film or finish is applied to the exterior
shell fabric than the breathable membrane may not be applied.
Indeed, the amount of foam may be replaced by a nonwoven composite
blend. Presently, this liner system is combining an open-cell foam
abutting an open-cell foam and encapsulated outer shell fabric as
one embodiment. Optionally, the MVT Thermal made by Foss
Manufacturing, THERMOLITE or a nonwoven thermal or nonwoven
composite combined with foam may be used abutting the inner lining
fabric and the outer shell fabrics. The suggested moisture transfer
and absorbant nonwovens and foam composite can be mechanically
bonded.
[0171] This invention can also be used for industrial and medical
applications by using polyester spunbonded filter products by
Tangerding Vlitesstoffe, Vitafiber, or the like, combined with
alternating hydrophilic foam layers and nonwoven blends. The
nonwoven composites are constructed to filter, absorb and transfer
moisture and microscopic particles.
Other Applications
[0172] FIGS. 13-22 disclose various other embodiments of the
present invention as follows. FIGS. 13-18 show a detachable,
removable insert liner for soft shell skates and other products.
These liners are inserts and can be used in hockey skates and other
types of footwear. The same construction can be applied to a
complete boot rather than an insert. This is shown in FIG. 21. FIG.
21 is an example of a complete skate containing the same materials
as the inserts in FIGS. 13-18, and built in the same way as these
inserts. Soft shell alpine boots are illustrated in FIGS. 18 and
19.
[0173] FIGS. 13 and 13A illustrate an insert (700) for an in-line
skate, ice or hockey skate with an enlarged first portion. In FIG.
13, numeral 710 represents a composite of one layer, two layers, or
three layers. 710 shows outer shell fabric, foam, nonwoven, with no
top sheet, the top sheet is the outer shell fabric in this case.
710 can be an exterior shell fabric or material abutting a cellular
moisture transfer, breathable, elastomeric composite, or the fabric
can be backed by a flocked fiber combination abutting the foam and
followed by a nonwoven or a knit. Alternatively, the same
combination may be used without flocking. Optionally, layer 710 can
be a single layer of fabric or material, or a double layer,
including fabric or material abutting a nonwoven. Preferably, the
composite layer is a 3 layer construction of fabric, foam, and
nonwoven. Layer 720 is a spacer fabric. Optionally, layer 720 is a
combination which may include multiple layers of foam and nonwoven.
In some performance categories, 720 can simply be a foam or a
nonwoven. Layer 730 is a nonwoven or a cellular moisture transfer,
breathable, elastomeric composite or an inner lining fabric or
material such as a knit.
[0174] FIGS. 14 and 14A illustrate another embodiment of an insert
(700) for an in-line skate or a hockey skate with a second portion
enlarged. 740 illustrates a one-, two-, or three-layer composite.
The top sheet can be optionally composed of: (1) a nonwoven or a
knitted layer; (2) a nonwoven or a knit and a foam; (3) a nonwoven
or a knit with a cellular moisture transfer, breathable,
elastomeric composite; or (4) a nonwoven and a foam composite.
[0175] Layers 750, 760 and 770 together compose a spacer fabric or
a moldable foam with a mesh. Optionally, the spacer fabric or foam
with a moldable mesh may include a nonwoven thermal such as
THINSULITE or THERMOLITE with or with out silver fibers by Foss
Manufacturing or the like or a thermal composite made of nonwoven
shaped and grooved fiber blends and silver fibers. The preferable
construction replaces the 3 layers (750, 760, and 770) with a
single layered spacer fabric. In some multilayer constructions, the
specific layers could be broken down as follows: (1) layer 750 may
be a knit, woven, nonwoven construction, or foam, or an moisture
transfer, breathable, elastomeric composite; (2) layer 760 may be a
foam, nonwoven or a combination of foam and nonwoven; or (3) layer
770 may be a knit, woven, nonwoven, foam, or an moisture transfer,
breathable, elastomeric composite.
[0176] FIGS. 15 and 15A illustrate another embodiment of an insert
(700) for an in-line skate or hockey skate with a third portion
enlarged. 780 could be a combination of an outer fabric and a foam
or a combination of an outer fabric a foam and a non-woven. 782 has
many options. One combination is a foam with a mesh, a non-woven,
another foam, and another non-woven. A second combination has a
foam, a mesh, a non-woven, a second foam, and a second non-woven. A
third combination is a non-woven, a foam, a second non-woven and a
non-woven composite manufactured by Foss. Optionally, all nonwoven
layers may be a cellular moisture transfer, breathable, elastomeric
composite and may include silver fibers by Foss Manufacturing.
[0177] 784 has three options. One option is a spacer fabric. A
second option is a moldable foam. The third option is a combination
of a foam and a polymer mesh, manufactured by Naltex.
[0178] 786 has the following options. It could be an outer fabric
plus a foam or a foam and non-woven composite (Foss composite).
Another option is an outer fabric and a moisture transfer,
breathable, elastomeric composite. Finally, 786 could be a Foss
composite and a moisture transfer, breathable, elastomeric
composite together with an outer shell fabric. In some performance
products the layers of 782 are omitted. It should be noted here
that all composite materials can be backed by a flocked fiber blend
which may contain silver fibers.
[0179] FIGS. 16, 16A and 16B illustrate an insert (800) for a
soft-shell alpine boot with first and second portions enlarged. 802
illustrates a composite including an inner moisture transfer
material, a foam and a nonwoven. 802 may also be an inner moisture
transfer material, abutting a nonwoven and foam composite or a
cellular moisture transfer, breathable, elastomeric composite. 804
illustrates a composite of a nonwoven, a foam, a second nonwoven
and a second foam. Alternatively, 804 may be composed of a foam and
a nonwoven with silver fibers (this combination is an example of a
moisture transfer thermal), and in some performance categories a
cellular moisture transfer, breathable, elastomeric composite may
be combined with a moisture transfer thermal. This whole layer can
be eliminated in some performance categories. Nonwovens in this
composite may be replaced by a knitted fabric. 806 illustrates a
spacer fabric or a breathable moldable foam. The moldable foam may
include a polymer mesh, with or without silver fiber blends, or
other fiber blends including wool fibers. In one option the silvers
and natural blends abut the spacer fabrics and may be followed by a
thermal nonwoven layer. Thermal nonwovens such as THINSULITE and
THERMOLITE or the like may include the silver fibers by Foss
Manufacturing. Layer 806 is a moisture transfer thermal composite
composed of a nonwoven and foam blend. The foam with mesh can be
followed by a nonwoven or another foam. The foam nonwoven composite
may be constructed in the following ways: (1) foam-nonwoven-foam;
(2) nonwoven-foam-nonwoven; (3) nonwoven-foam-nonwoven-foam-spacer
fabric; or (4) nonwoven-foam-nonwoven-spacer fabric. All of these
combinations may include silver fibers or fiber blends and are
considered moisture transfer thermals. In some options, the
nonwoven layer may be replaced with a knitted layer, or a cellular
moisture transfer, breathable, elastomeric composite. 808
illustrates a cellular moisture transfer, breathable, elastomeric
composite or a foam and nonwoven abutting an exterior shell fabric.
The moisture transfer thermal composite may be combined with a
polymer mesh and the exterior shell fabric in layer 808.
Alternatively, 808 can be the exterior shell fabric open-cell foam
with or without silver fibers or fiber blends abutting a nonwoven,
a nonwoven thermal blend or a nonwoven and foam composite. This
exterior shell composite is moldable, transfers moisture, and
regulates temperature with fiber additions. The exterior shell
fabric may be waterproofed in the following ways: (1) with
encapsulation; (2) with breathable membrane; (3) with waterproof
breathable film or finish; or (4) with fibers treated or
constructed to repel water. A preferable three-layer construction
for golf shoes, running shoes, cross-country boots and apparel
includes a waterproof exterior shell fabric, an open-cell foam, or
a cellular moisture transfer, breathable, elastomeric composite
abutting a knitted or nonwoven inner moisture transfer material.
Optionally, the foam, nonwoven or cellular moisture transfer,
breathable, elastomeric composite may include blends containing
either silver or wool fibers, or both.
[0180] FIG. 16C also illustrates in layer 910 a spacer fabric
abutting layer 912. Optionally, 910 can be a foam with a fiber
blend and polymer mesh added. 912 is preferably a moisture transfer
thermal, composed of a foam nonwoven antimicrobial blend with
silver fibers. Alternatively, 912 can be a nonwoven thermal without
foam or a thermal nonwoven with silver fibers. 914 is a one-, two-,
or three-layer composite. It can be an outer shell fabric or
material, abutting a breathable foam followed by a nonwoven.
Alternatively, the outer shell fabric may abut a cellular moisture
transfer, breathable, elastomeric composite or thermal
nonwoven.
[0181] FIGS. 17, 17A and 17B illustrate an insert (800) for a soft
shell alpine boot with first and second portion enlarged. 810
represents an outer shell fabric, a foam and a nonwoven composite.
The 810 layer is preferably moldable antimicrobial thermal
breathable, and transfers moisture. The 810 layer can be developed
in a number of constructions. Layer 812 can be an outer shell
fabric and a breathable foam, an outer shell fabric a breathable
foam and a nonwoven, or an outer shell fabric and a cellular
moisture transfer, breathable, elastomeric composite, or outer
shell fabric and a moisture transfer thermal with or without foam.
Layer 812 is a spacer fabric, which can optionally be a breathable
foam with or without a polymer mesh and silver fibers or fiber
blends. Layer 812 can be optionally is a moisture transfer thermal
moldable nonwoven composite, and in some performance categories the
foam can be replaced with a cellular moisture transfer, breathable,
elastomeric composite included in the nonwoven layer. Layer 810 and
layer 814 are similar to each other in this three-layer
construction. Optionally, layer 814 can be a two-layer
construction. Layer 814 illustrates a composite with an outer shell
fabric and a foam, or an outer shell fabric and a nonwoven, or an
outer shell fabric and a foam, or an outer shell fabric and a
cellular moisture transfer, breathable, elastomeric composite.
Preferably layer 814 is an outer shell fabric abutting moisture
transfer thermal composite including breathable foam and silver
fibers. Layer 816 is a moisture transfer thermal nonwoven inserted
between the options in layer 814 and a spacer fabric in layer 818,
or a foam with or without a polymer mesh. Optionally, layer 816 can
be a foam nonwoven composite or a cellular moisture transfer,
breathable, elastomeric composite. This multi-layered composite
abuts an inner lining material and forms the moldable liner insert
or permanently attached liner. In some options, this liner may
incorporate 3-15 layers. The spacer fabric in layer 818 can
optionally be a foam, a nonwoven or a combination. Layer 18 may
also be a foam with a moldable polymer mesh.
[0182] FIGS. 18 and 18A illustrate a soft shell alpine boot (900)
incorporating lining materials such as those shown in FIGS. 16 and
17. In the enlarged portion of FIG. 18, 820 illustrates an inner
lining material. 822 illustrates a foam nonwoven composite and
optionally 822 may be a cellular moisture transfer, breathable,
elastomeric composite or a breathable foam. Layer 824 illustrates a
polymer mesh. The polymer mesh in 824 can be included in a foam, or
in a nonwoven, or in a foam and nonwoven composite, or
alternatively it may abut layers with any of these constructions.
One option, layer 820 abuts a cellular moisture transfer,
breathable, elastomeric composite including a polymer mesh. Layer
826 illustrates another inner lining material. 826 may
alternatively be a nonwoven and a cellular moisture transfer,
breathable, elastomeric composite or a knitted construction and a
breathable foam or a three-layer composite composed of an inner
lining material, a foam and a nonwoven or a three layer composite
comprised of a inner moisture transfer fabric, treated with a
dotted, phase change foam matrix on the side and an waterproof
exterior shell material. Preferably, the outer shell soft boot
composite is composed of an outer shell fabric, a frothed open-cell
foam in a single layer or dotted matrix, a moisture transfer
nonwoven, or nonwoven composite and an inner lining material. This
composite is moldable, transfers moisture, and is thermal and
waterproof.
[0183] FIGS. 19 and 19A illustrate a soft shell alpine boot (900)
incorporating lining materials such as those shown in FIGS. 16 and
17. In the enlarged portion of FIG. 18, 830 illustrates an inner
lining material. 832 illustrates a foam nonwoven composite and
optionally 832 may be a cellular moisture transfer, breathable,
elastomeric composite or a breathable foam. Layer 834 illustrates
another inner lining material. 834 may alternatively be a nonwoven
and a cellular moisture transfer, breathable, elastomeric composite
or a knitted construction and a breathable foam or a three-layer
composite composed of an inner lining material, a foam and a
nonwoven. Preferably, the outer shell soft boot composite is
composed of an outer shell fabric, a frothed open-cell foam or a
dotted Phase Change matrix on the back side of the exterior
moisture transfer material, a moisture transfer nonwoven, or
nonwoven composite and an inner lining material. The foamed, dotted
matrix containing phase change materials can be applied to any
layer in the three-layer composite. This composite is moldable,
transfers moisture, and is thermal and waterproof.
[0184] FIG. 20 illustrates a polymer shell for a hockey skate 960
including a moisture transfer liner.
[0185] FIG. 21 illustrates a soft shell inline skate (950)
incorporating any of the insert materials of FIGS. 13-15. The soft
shell inline skate does include some polymer shell materials
identified as 920. Similar material also forms a part of the soft
shell alpine boot of FIG. 18 although not explicitly identified. In
some options, the polymer shell material in 920 can be eliminated
from the soft alpine or skate boot, and in other options the shell
material may be increased to provide more support.
[0186] All nonwovens, foams, fabrics, materials or composites can
have fibers flocked to either one or both sides. The flocked fiber
blend may include silver fibers by Foss Manufacturing.
[0187] 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.
[0188] Any composite constructions or combination of composites in
this application may be, applied to technical apparel, casual
sportswear, protective clothing, snowboard or biking helmets,
accessories, in-line skates, ice skates, hockey skates, medical and
industrial applications.
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