U.S. patent application number 13/224811 was filed with the patent office on 2013-03-07 for direct attach waterproof footwear.
The applicant listed for this patent is Robert J. Wiener. Invention is credited to Robert J. Wiener.
Application Number | 20130055598 13/224811 |
Document ID | / |
Family ID | 46851596 |
Filed Date | 2013-03-07 |
United States Patent
Application |
20130055598 |
Kind Code |
A1 |
Wiener; Robert J. |
March 7, 2013 |
Direct Attach Waterproof Footwear
Abstract
Waterproof, breathable shoes are described. They include an
upper assembly and a sole assembly or alternatively an upper
assembly, midsole, and outsole. Each configuration includes a means
of facilitating the flow of polymer therein. The means may be an
insole, a spacer material, or an insole/spacer material
composite.
Inventors: |
Wiener; Robert J.;
(Middletown, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Wiener; Robert J. |
Middletown |
DE |
US |
|
|
Family ID: |
46851596 |
Appl. No.: |
13/224811 |
Filed: |
September 2, 2011 |
Current U.S.
Class: |
36/3R |
Current CPC
Class: |
A43B 13/38 20130101;
B29D 35/122 20130101; A43B 7/125 20130101; A43B 9/00 20130101 |
Class at
Publication: |
36/3.R |
International
Class: |
A43B 7/06 20060101
A43B007/06 |
Claims
1. Waterproof, breathable shoe comprising: an upper assembly, and a
sole assembly; wherein the upper assembly comprises upper and lower
portions, each of the upper and lower portions comprising a outer
material and a breathable layer or layers comprising at least one
waterproof functional layer; further wherein the lower portion of
the upper assembly further comprises a non-functional means of
retaining the shape of the upper assembly, the non-functional means
being connected to the breathable layer or layers comprising at
least one waterproof functional layer wherein the sole assembly
comprises an outer sole, said outer sole comprising a lower portion
of the outer material and the breathable layer or layers of the
upper interspersed therein and a means of facilitating the flow of
polymer throughout the sole assembly to adhere the sole assembly
and the lower portions of the upper assembly together to form a
waterproof seal.
2. The waterproof breathable shoe of claim 1, wherein the means of
facilitating the flow of polymer is a molded insole.
3. The waterproof breathable shoe of claim 1, wherein the means of
facilitating the flow of polymer is a spacer material.
4. The waterproof breathable shoe of claim 1, wherein the means of
facilitating the flow of polymer is a spacer material/insole
composite.
5. The waterproof breathable shoe of claim 1, wherein the means of
facilitating the flow of polymer comprises one or more openings for
facilitating the flow of adhesive material throughout the sole
assembly.
6. The waterproof breathable shoe of claim 1, wherein the
non-functional means comprise a strobel board or an elastic
material, or a textile.
7. The waterproof breathable shoe of claim 1, wherein the
non-functional means is string lasted.
8. The waterproof breathable shoe of claim 1, wherein the
breathable layer or layers further comprises one or more additional
layers adapted to form a laminate with the at least one waterproof
functional layer.
9. The waterproof breathable shoe of claim 1, wherein the
waterproof functional layer comprises polyurethane, polyester,
polyether, polyamide, polyacrylate, copolyether ester or
copolyether amides.
10. The waterproof breathable shoe of claim 1, wherein the
waterproof functional layer comprises polytetrafluoroethylene.
11. Waterproof, breathable shoe comprising: an upper assembly, a
midsole, and an outsole wherein the upper assembly comprises upper
and lower portions, each of the upper and lower portions comprising
a outer material and a breathable layer or layers comprising at
least one waterproof functional layer; further wherein the lower
portion of the upper assembly further comprises a non-functional
means of retaining the shape of the upper assembly, the
non-functional means being connected to the breathable layer or
layers comprising at least one waterproof functional layer wherein
the midsole comprises a lower portion of the breathable outer
material of the upper interspersed therein and a a means of
facilitating the flow of polymer throughout midsole to adhere the
midsole and the lower portions of the upper assembly together to
form a waterproof seal, and wherein the outsole is adapted for
attachment to the midsole
12. The waterproof breathable shoe of claim 11, wherein the means
of facilitating the flow of polymer is a molded insole.
13. The waterproof breathable shoe of claim 11, wherein the means
of facilitating the flow of polymer is a spacer material.
14. The waterproof breathable shoe of claim 11, wherein the means
of facilitating the flow of polymer is a spacer material/insole
composite.
Description
BACKGROUND
[0001] The art is replete with attempts at making waterproof,
breathable footwear. Early attempts for making such footwear
included making footwear consisting of upper materials such as
leather treated to make it water resistant and soles made of
rubber. Thus, some breathability was achieved. However, several
problems arose with this type of footwear construction. If the
upper material was to be made truly waterproof, it would lose its
ability to breath. Moreover, the connecting region between the
waterproof sole and the upper became a major source of leakage as
there was no effective way to make the connecting region
waterproof.
[0002] An alternative approach to the goal of achieving comfortable
waterproof footwear involved employing a waterproof insert or
bootie into the shoe. This method is particularly useful in machine
lasted footwear, as known in the art. This waterproof insert, if
constructed of appropriate materials had the additional advantage
of being permeable to water vapor so that there was no buildup of
water vapor within the shoe over the time when the shoe was being
worn. In the footwear art materials which are both waterproof and
water vapor permeable are commonly referred to as "functional"
materials. Exemplary of such a functional material is a
microporous, expanded polytetrafluoroethylene membrane material
available from W. L. Gore and Associates, Inc., Elkton, Md., under
the tradename GORE-TEX.RTM.. Other functional materials have also
been developed and are well known in the art.
[0003] Further approaches have included securing, by a lasting
process, a waterproof, breathable liner material to the inside of
the footwear upper and sealing the liner material to a waterproof
gasket or insole. There have been many different attempts at
providing a durable, waterproof seal or connection at the region
where the liner material is joined with the waterproof gasket or
insole. These attempts have resulted in varying degrees of
success.
[0004] One problem which often results when forming such
waterproof, breathable footwear is that the insertion of the liner
or bootie will often result in a poor fitting shoe (i.e., a smaller
fit due to the liner being inserted into the already sized shoe
upper) and/or poor attachment between the liner or bootie and the
shoe upper material, which results in, among other things, a less
than desirable appearance of the inside of the footwear (i.e., the
liner appears wrinkled or pulls away from the upper).
[0005] An additional problem is that utilization of traditional
waterproof gasket in footwear constructions is economically
inefficient because it adds an additional processing step to
achieve waterproofness.
[0006] Thus, the search continues for durably sealed, waterproof,
breathable, gasketless footwear that is both flexible in use and
economical to manufacture.
SUMMARY OF INVENTION
[0007] Waterproof, breathable shoes having an upper assembly, and a
sole assembly are described herein. The upper assembly includes
upper and lower portions, each of the upper and lower portions
having an outer material and a breathable layer or layers which
make up a bootie and that includes at least one waterproof
functional layer. The lower portion of the upper assembly further
includes a non-functional means of retaining the shape of the upper
assembly. The non-functional means is connected to the breathable
layer or layers that include at least one waterproof functional
layer.
[0008] Further the sole assembly includes an outer sole comprising
a lower portion of the outer material and the breathable layer or
layers of the upper interspersed therein. It further includes a
means of facilitating the flow of polymer throughout the sole
assembly to adhere the sole assembly and the lower portions of the
upper assembly together to form a waterproof seal.
[0009] In alternate embodiments, the means for facilitating the
flow of polymer may be a spacer material, an insole, or a spacer
material/insole composite. The non-functional means may be a
strobel board or an elastic material, or a textile, or may be
string lasted.
[0010] The breathable layer or layers may further comprise one or
more additional layers adapted to form a laminate with the
waterproof functional layer or layers.
[0011] The waterproof functional layer or layers may be composed of
polyurethane, polyester, polyether, polyamide, polyacrylate,
copolyether ester, copolyether amides, polyetetrafluoroethylene,
combinations thereof, or the like.
[0012] In an additional embodiment, a waterproof, breathable shoes
having an upper assembly, a midsole and an outsole are described
herein. The upper assembly includes upper and lower portions, each
of the upper and lower portions having an outer material and a
breathable layer or layers which make up a bootie and that includes
at least one waterproof functional layer. The lower portion of the
upper assembly further includes a non-functional means of retaining
the shape of the upper assembly. The non-functional means is
connected to the breathable layer or layers that include at least
one waterproof functional layer.
[0013] The midsole comprises a lower portion of the breathable
outer material of the upper interspersed therein and a means of
facilitating the flow of polymer throughout midsole to adhere the
midsole and the lower portions of the upper assembly together to
form a waterproof seal.
[0014] The outsole is adapted for attachment to the midsole.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1 is cross-sectional view of waterproof footwear
containing a molded insole as the means for facilitating the flow
of polymer.
[0016] FIG. 2 is cross-sectional view of waterproof footwear
containing a spacer material as the means for facilitating the flow
of polymer.
[0017] FIG. 3 is cross-sectional view of waterproof footwear
containing a spacer material/insole composite as the means for
facilitating the flow of polymer.
[0018] FIG. 4 is exploded view of waterproof footwear containing a
molded insole as the means for facilitating the flow of
polymer.
[0019] FIG. 5 is exploded view of waterproof footwear containing a
spacer material as the means for facilitating the flow of
polymer.
[0020] FIG. 6 is the exploded view of waterproof footwear
containing a spacer material/insole composite as the means for
facilitating the flow of polymer.
DETAILED DESCRIPTION
[0021] The invention relates to waterproof footwear and methods for
making the same. Unlike traditional WPB machine lasted footwear,
the disclosed inventive footwear constructions are gasketless. That
is, the inventive footwear contains a functional liner that is
gasketless or that does not have functional material across the
entire bottom of the bootie. Instead it provides space between at
least a portion of the upper assembly 10 and at least a portion of
the sole assembly 20 so that a means for facilitating the flow of
polymer 100 facilitates the flow of polymer or other adhesive
through the means in order to provide a seal between the upper
assembly and sole assembly. Additionally, the polymer or other
adhesive can be used to formulate an optional midsole 240 so that
outsole can be later attached by methods known in the art, or it
can be utilized to formulate a complete outsole as part of the sole
assembly. Because a traditional gasket or full bootie is not used,
this results in improvements in factory production including
materials, labor, energy, and inventory as well as productivity
improvements, specifically a reduction in manufacturing steps,
floor space, and total production time.
[0022] Turning to FIGS. 1-6, As a preliminary matter, the upper
assembly (whose components will be described in detail later)
includes upper 30 and lower 40 portions. Each of these portions
include at least one waterproof functional layer 70 and at least
one additional layer 60 as part of a liner 230,
[0023] Turning to FIG. 7 there is shown a liner material 230 having
an open top portion 140 and an open bottom portion 150. Also shown
are optional seams 160 where two panels of liner material may be
joined together to form the liner material into the general
corresponding shape of a shoe upper. Pieces of liner material can
be joined together by sewing, partial sewing, welding, gluing, etc.
When pieces of liner are sewn together, the seams can be made
waterproof by sealing the seams 160 with known sealing materials,
such as GORE-SEAM..RTM. tape (available from W. L. Gore and
Associates, Inc.). Other sealants may be applied to the seams to
render them waterproof if they are not inherently waterproof due to
welding or gluing. The liner material 230 includes at least one
layer of material which is waterproof and water vapor permeable
(i.e., a functional material), such as a breathable polymeric
membrane, known as a waterproof functional layer 70. As used
herein, "water vapor permeable" and "breathable" are used
interchangeably and mean that the functional layer has a water
vapor coefficient Ret of less than 200 m.sup.2 Pa W.sup.sup.-1. The
water vapor permeability is tested by the Hohenstein skin model.
This method is described in DIN EN 31092 (02/94) or ISO 11092
(19/33). Breathable polymeric membranes may be breathable by virtue
of pores in the membrane or through a solution diffusion mechanism.
Breathable polymeric membranes may be selected from polyurethane,
polyester, polyether, polyamide, polyacrylate, copolyether ester
and copolyether amides. In an aspect of the invention the
waterproof, water vapor permeable membrane is a membrane of
microporous polytetrafluoroethylene. In a further aspect of the
invention, the microporous polytetrafluoroethylene membrane is a
membrane of expanded polytetrafluoroethylene as taught in U.S. Pat.
Nos. 3,953,566 and 4,187,390, to Gore. Such membranes of expanded
polytetrafluoroethylene are commercially available from W. L. Gore
and Associates, Inc., Elkton, Md., under the tradename
GORE-TEX..RTM. fabric. The subject matter of both of these U.S.
patents is incorporated herein by reference.
[0024] The liner material will contain at least the above described
functional material 70 and at least one other material 60 laminated
thereto. In this regard, the liner can include the functional
material and a textile material (desirably breathable) laminated or
otherwise joined to at least one side, and often times joined to
both sides thereof. Lamination is generally carried out with the
use of a discontinuous pattern of suitable adhesive. Thus, water
vapor permeability is not significantly effected. At least one
other material can be a textile fabric. Textile fabrics can be
woven, knit, mesh, nonwoven, felt constructions, etc. Textiles can
be produced from natural fibers such as cotton, or from synthetic
fibers such as polyesters, polyamides, polypropylenes, polyolefins,
or blends thereof. In an aspect of the invention a textile fabric
is laminated to the side of the functional material which will be
in contact with the outer material of the upper 50. In a further
aspect of the invention a textile fabric is laminated to the side
of the functional material which will face the inside of the
footwear. In a still further aspect of the invention, textile
fabric is laminated to both sides of the functional material, thus
providing a three layer liner material. Suitable outer material of
the upper includes leather, cordura, nylon, or the like.
[0025] FIG. 7 shows a means for retaining the shape 80 of the upper
assembly 10. This means is generally in the shape of the bottom of
a foot and it is attached to the waterproof breathable functional
layers by any suitable method known in the art, including, for
example, stitching. The means for retaining the shape of the upper
assembly can be any suitable material which is capable of being
secured to waterproof breathable functional layers at the open
bottom portion 150 and is compression resistant enough to maintain
the shape of the upper assembly to form a bootie. The means for
retaining the shape of the upper assembly can include, for example,
a woven or nonwoven material, and for example, could be a strobel
board, an elastic material, or a textile. For example, it may be
formed from polyester, nylon, polyacrylic, polyolefin,
polyurethane, polyvinyl, cotton, acetate, rayon, olefin, acrylic,
wool, spandex, metallic, etc. For reasons which will become
apparent, it is not desirable for the means for retaining the shape
of the assembly to be waterproof or even water resistant. The means
for retaining the shape of the upper assembly can be secured to the
bottom portion of the breathable layers by any suitable means. For
example, means for retaining the shape of the upper assembly can be
secured to the bottom portion of the liner material 230 by
stitching, partial stitching, stapling, welding, ultra sonic
welding, etc. Upon securing means for retaining the shape of the
upper assembly to the bottom portion of liner material 230, a
bootie is obtained which is formed to be capable of accepting a
wearer's foot.
[0026] Alternatively, the means for retaining the shape 80 of the
upper assembly 10 could include a string lasted liner. That is, it
could be composed of strips of material holding together the upper
assembly without need for additional material.
[0027] Once the bootie is formed, a lasting process is carried out.
Specifically, a shoe last, as known in the art, is inserted into
the bootie at the open top portion 140 to form the bootie to the
exact shape of the shoe last.
[0028] Typically, at this point, in prior art lasting processes
when the shoe last is inserted into the bootie, a waterproof
gasketing material is attached to the bottom surface portion of the
bootie as part of a sole assembly.
[0029] It has been unexpectedly discovered, however that the
attachment of a waterproof gasket material is not necessary.
[0030] In this regard, a means for facilitating the flow of polymer
100 throughout the sole assembly to adhere the sole assembly 20 and
the lower portions of the upper assembly 40 together to form
waterproof seal is placed at the bottom of the bootie for
subsequent attachment. In one embodiment the means may be a spacer
material, for example, a spacer mesh 110 cut into substantially the
same shape as the bottom of the last. In another embodiment, the
means may be an spacer material/insole board composite 130
substantially the same shape as the bottom of the last (i.e. the
bottom of a foot). Any other suitable means may be utilized as long
as it is sufficiently compression resistant to retain flow channels
during an injection process and sufficiently stiff and bending to
facilitate lasting of the upper. In another embodiment, the means
may be a molded insole board 120 by itself. In all embodiments, the
spacer material, insole board and/or the spacer material/insole
board composite may have one or more opening contained therein to
facilitate the flow of adhesive material throughout the sole
assembly to create a waterproof seal. The openings may be holes,
channels, or the like.
[0031] Turning to FIG. 7, there is shown a perspective view of the
bootie 170. As can be seen in FIGS. 3 and 6, a spacer
material/insole board composite is attached and is adhered to the
bottom surface portion of the bootie. In one embodiment the spacer
material is located on top of the insole board and directly in
communication with the bottom of the bootie. In another embodiment
the order is reversed. In yet other embodiments, as discussed
above, a molded insole board or spacer material by itself may be
attached to the bottom portion of the bootie. Regardless of
construction or arrangement, the spacer material and insole board
may be made of any suitable material with sufficient rigidity.
Non-limiting examples include polymeric and fabric materials. The
means for facilitating the flow of polymer 100 can be adhered to
the bottom surface portion of the bootie using any suitable
adhesive material. Non-limiting examples of suitable adhesive
materials include polyurethane and PVC, but any expandable and
foamable substance sufficient for forming a seal may be utilized
bootie.
[0032] Regardless of the type of adhesive used, the adhesive must
by flowable to an extent that flow through the openings in means
for facilitating the flow of polymer 100 to at least substantially
fill those openings with polymer and adhere together the sole
assembly and the lower portions of the upper assembly.
[0033] Thereafter, the upper assembly 10 is pulled down, cemented
(or otherwise attached to the bottom of the means for facilitating
the flow of polymer 100) and folded over to fix the shape of the
shoe upper to the last. The spacer material is positioned to keep
the insole out of complete contact with bottom of the bootie so
that the adhesive is able to completely seal the bottom of the
bootie once injected into the openings.
[0034] Molding compounds, as known in the art, are then applied
through the openings utilizing convention methods known in the art,
such as, for example injection molding, pour molding, etc.
[0035] Conventional steps can then be performed to attach a
suitable outer sole material or outer sole/midsole to the bottom
surface of the footwear, if required.
[0036] For completeness, FIGS. 1-3 are cross-sectional views of the
footwear according to the invention wherein conventional outer sole
is indicated by 220. Outer sole 220 can be any suitable material
such as, for example, polyurethane, natural rubber, synthetic
rubbers, leather, artificial leather, polyvinyl chloride, ethylene
vinyl acetate, etc., and combinations thereof.
[0037] Conventional methods include injection or pouring of
polymeric material utilizing conventional injection molding to form
an outersole or a midsole. Alternatively, an outersole may be
cemented or otherwise attached (stitching, partial stitching,
stapling, welding, etc) to the bottom of the footwear construction
following injection or pouring of polymeric materials.
[0038] What is meant by "waterproof footwear" is determined as
follows. The footwear is placed on top of a piece of blotter paper.
The inside of the footwear is filled with room temperature water to
a height of about 30 mm below the top line of the functional
material (measured from the insole at the heel area of the
footwear). The water is allowed to stand in the footwear for at
least two hours. At the end of the two hour period the blotter
paper and footwear upper are examined to determine if water has
reached the blotter paper or the outside of the upper. If no water
has reached the blotter paper or the outside of the upper, then the
footwear is waterproof.
[0039] As used herein the "waterproof, water vapor permeable
functional layer" and the "waterproof gasket material" are
"waterproof" if, when combined to form the footwear according to
the invention, they result in the footwear being "waterproof" as
defined above.
[0040] While particular embodiments of the present invention have
been illustrated and described herein, the present invention should
not be limited to such illustrations and descriptions. It should be
apparent that changes and modifications may be incorporated and
embodied as part of the present invention within the scope of the
following claims.
* * * * *