U.S. patent application number 14/020970 was filed with the patent office on 2014-05-01 for softboots and waterproof/breathable moisture transfer composite and liner for in-line skates, ice-skates, hockey skates, snowboard boots, alpine boots, hiking boots and the like.
This patent application is currently assigned to SOLID WATER HOLDINGS. The applicant listed for this patent is BAYCHAR. Invention is credited to BAYCHAR.
Application Number | 20140120310 14/020970 |
Document ID | / |
Family ID | 46300703 |
Filed Date | 2014-05-01 |
United States Patent
Application |
20140120310 |
Kind Code |
A1 |
BAYCHAR; |
May 1, 2014 |
SOFTBOOTS AND WATERPROOF/BREATHABLE MOISTURE TRANSFER COMPOSITE 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 includes 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;; (Eastport,
ME) |
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Applicant: |
Name |
City |
State |
Country |
Type |
BAYCHAR; |
Eastport |
ME |
US |
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|
Assignee: |
SOLID WATER HOLDINGS
Eastport
ME
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Family ID: |
46300703 |
Appl. No.: |
14/020970 |
Filed: |
September 9, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11526594 |
Sep 26, 2006 |
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14020970 |
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10757454 |
Jan 15, 2004 |
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11526594 |
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10600711 |
Jun 23, 2003 |
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10757454 |
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60440034 |
Jan 15, 2003 |
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Current U.S.
Class: |
428/138 |
Current CPC
Class: |
A43B 5/0405 20130101;
B32B 2307/724 20130101; B32B 2307/7265 20130101; B32B 27/065
20130101; A43B 1/0045 20130101; B32B 2305/38 20130101; A43B 7/125
20130101; A43B 23/07 20130101; A43B 3/0084 20130101; B32B 5/32
20130101; B32B 2307/7145 20130101; Y10T 428/24331 20150115; B32B
5/22 20130101; B32B 5/18 20130101; B32B 5/245 20130101 |
Class at
Publication: |
428/138 |
International
Class: |
A43B 23/07 20060101
A43B023/07 |
Claims
1. A composite soft-shell, removable alpine or snowboard boot liner
product comprising: a first layer comprised of breathable, moisture
transferring, lining material including shaped, multi-grooved,
channeled and wool fibers; a second layer comprised of a
breathable, moisture transferring and absorbent, open-cell,
anti-microbial, punctured or perforated foam material backed by a
breathable, moisture transferring, nonwoven material containing
shaped, multi-grooved and channeled fibers; a third layer comprised
of a breathable, moldable spacer material; a fourth layer comprised
of a water resistant, exterior, synthetic, stretchable, soft-shell
material.
2. A composite soft-shell, removable alpine or snowboard boot liner
product according to claim 1, wherein at least one or more of the
layers or seams thereof are attached by adhesive bonding.
3. A composite soft-shell, removable alpine or snowboard boot liner
product according to claim 1, wherein the spacer material is a
moldable three-dimensional knitted construction.
4. A composite soft-shell, removable alpine or snowboard boot liner
product according to claim 1, wherein the moldable spacer fabric is
an anti-microbial, punctured or perforated, open-cell foam
layer.
5. A composite soft-shell, removable alpine or snowboard boot liner
product according to claim 4, is attached to a water resistant,
exterior, synthetic, elastomeric, soft-shell material.
6. A composite soft-shell, removable alpine or snowboard boot liner
according to claim 1, wherein the third layer is backed by a
breathable, absorbent, moisture transferring nonwoven material.
7. A composite soft-shell, removable alpine or snowboard boot liner
according to claim 1, wherein the moisture transfer mechanically
bonded nonwoven is material is comprised of shaped, and channeled
fiber, and silver fibers.
8. A composite soft-shell, removable alpine or snowboard boot liner
product according to claim 6, wherein the third layer is a
punctured foam.
9. A composite soft-shell, removable alpine or snowboard boot liner
product according to claim 1, wherein the first layer is a
breathable spacer material.
10. A composite soft-shell, removable alpine or snowboard boot
liner according to claim 1, wherein the first layer is comprised of
two materials, the breathable spacer material placed an the upper
portion of an inside of the liner closest to an individual and
attached to a moisture transfer fabric located in a lower portion
of the inside of the liner.
11. A composite soft-shell, removable alpine or snowboard boot
liner product according to claim 10, wherein the breathable, spacer
material in the first layer closest to the individual in the tongue
portion of the liner is backed by a moisture transfer nonwoven and
a punctured or perforated, breathable, anti-microbial foam and a
stretchable, exterior soft-shell material.
12. A composite soft-shell, removable alpine or snowboard boot
liner product according to claim 11, wherein the open cell,
punctured or perforated, breathable, anti-microbial foam is backed
by a spacer material and the exterior soft-shell stretchable
material.
13. A composite soft-shell, removable, alpine or snowboard boot
liner product according to claim 1, wherein at least one layer is
treated or contains phase change technology or nanotechnology.
14. A composite soft-shell, removable alpine or snowboard boot
liner product according to claim 1, wherein the breathable,
moisture transferring, lining material or water resistant,
exterior, synthetic, stretchable, soft-shell material layer
contains shaped, hollow, channeled, multi-grooved, and wool fibers.
Description
CROSS-REFERENCE
[0001] This is a continuation application of U.S. application Ser.
No. 11/526,594, filed Sep. 26, 2006, which is a continuation of
U.S. application Ser. No. 10/757,454, filed Jan. 15, 2004, which
claims priority of 60/440,034, filed Jan. 15, 2003. The entire
disclosures of these applications are hereby incorporated by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates to composite materials,
removable insert liners and completed product constructions with an
non-removable liner used in a variety of application. 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, transfer 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 microsheres or the like containing
air, polymers or liquid fibers that aids in cool or thermal
regulating temperatures during performance and are capable of
absorbing an electrical charge. The microsphere encapsulating the
air, polymer or electrically sensitive to thermal absorbing
material may be constructed of a 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.
[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 and soft boot liners. In prior removable liner
design, the conventional liner is often constructed with rigid,
non-breathable outer materials such as vinyl's, 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 act 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 if 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
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. 19 and 19A 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.
[0030] FIG. 22 illustrates a cross-section of a deep groove
fiber.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] 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.
[0032] Where possible, tradenames of specific products have been
used to assist in the understanding of the invention. The lining
system according to the present invention can be easily adapted to
accommodate further developments currently envisioned are set forth
below.
[0033] 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 ultra sonically 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 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.
[0034] 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 variable.
Depending on the application, some of the foam materials may not be
the 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, VFI by Foamex, Comfortemp by Frisby, or
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 the 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
coatings 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 or a
combination thereof. This top sheet is designed to absorb and move
moisture. The fibers have inherent moisture transfer and absorb
properties and can be treated with a number of MVT surfactants or
wicking solution such as Intera Technology, Ultraphil,
Nano-Technology or the like. 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 layers, fiber, fabric foam layers or
combinations in this applications. 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 scrums 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 a nonwoven
wet-laid, spunbond or needle punch product may be inclusive in the
foam. The nonwoven fibers in this application are extremely
important and they selected for the abilities as stated previously
to move 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-Deep Groove polyester fiber
(see FIG. 22, for example) or a variation of the shaped polyester
fiber preferably, manufactured by 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 quick to the exterior
surface. The shaped fabrics maybe combined with an active carbon
compound such as that by Craghoppers or silca gel to which increase
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 the polyester such as corn,
acrylic, acetate an the like be included or in any layer in
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
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 elastomeric
composite maybe mechanically or ultrasonically bonded to the inner
lining material abutting the foam, nonwoven or thermal nonwoven.
The elastomeric composite contains synthetic and natural fibers and
foam. These fibers may be treated with wetting solutions and/or
hydrophilic foam such Cofoam as that by Hydrophilix Inc. US
application 09-823-129 The elastomeric may be applied to the
thermal nonwoven on either side or be mechanically or
ultrasonically bonded to the thermal nonwoven. The elastomeric
composite may be attacked or included in any layer in the moisture
transfer system or may be any layer in the moisture transfer system
excluding the exterior shell fabric.
[0035] The Cofoam or the like may be used as the selected foam in
the 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 combination with the
thermal blend by Foss Manufacturing Dupont thermal nonwoven such as
Thermolite, Ultrathin or with 3MM thermal nonwovens such as
Thinsulite, nonwoven by Millennium or the like.
[0036] The nonwoven top sheet may be a dry-laid, wet laid, melt
blown, spun bond or a needle punch product. The select fibers,
fiber construction and treatment of the nonwoven top sheet is 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.
[0037] The selected non-woven top sheets are manufactured by DuPont
(Sonatra Technology non-woven), Alhstrom Nonwovens, Dexter
Synthetics, Freudenburg Nonwovens, Veritex, Nordlys, or the like.
All nonwoven fibers in this application possess either active or
passive moisture transfer abilities or both. The nonwoven may have
polymer or silca microspheres or encapsulated PCM technology added
with various fibers.
[0038] The preferably construction s optional to cooling and/or
heating properties. The Outlast melt spun fiber may be an option in
this layer or in thermal nonwoven layer. In some options the
nonwoven fibers in the top sheet may be wrapped by another fiber or
coated with a hydrophilic foam. The foam and fiber composite,
nonwoven, fabric or the 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 to
the back of the inner lining fabric or material or to the abutting
nonwoven. In fact the Cofoam or the like may be substituted for any
foam layer in this application creating extreme 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 outshell fabric for use in several of the defined
categories discussed in this application.
[0039] 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 a 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 Foss Composite
is constructed of a number of layers and fibers such lyocel, PVA,
silver polyester or a blend needled together with or without foam.
Alternatively, The Foss composite may be constructed with a
nonwoven thermal by Dupont such as Ultralite, Themolite or the like
or the Foss composite may have a 3 mm nonwoven included such as
Thinsulite 100, 200, 300 or the like. These composites transfer
moisture and are thermal regulate the product by increasing or
decreasing the fiber contain or treated fibers. Of course Dupont,
3MM and Foss nonwovens may be used in place of the Foss composite
in any layer between the inner material and out shell fabric.
[0040] The selected nonwoven 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 elastomeric
composite, breathable membrane, thermal or thermal composite.
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 optional may be flocked to both sides of the
nonwoven, breathable membrane, breathable adhesive or open cell
foam. The thermal nonwoven such as that by Dupont or 3MM optionally
may be attacked to the foam inclusive of the fibers or polymer mesh
or both.
[0041] The aperture nonwoven alternatively may be mechanically
bonded to the foam layer 20, 30, 50 on one or both sides.
Optionally, the apertured foam composite combination may be
combined with the thermal nonwoven, nonwoven composite or flocked
composite blend. 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, Foamex foams distributed by
Rogers Corporation or the like.
[0042] The foam or foam and nonwoven laminated or welded
combinations in layer 20 or 30 as previously suggested maybe
optionally replaced by a needle punched nonwoven with or without
foam preferably the Foss composite or by the elastomeric composite
having a foam inclosing a non-woven fiber formed in a single
process.
[0043] 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 either be used 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 technically engineering of several fibers
constructions and combinations is employed in this application. A
flocked fiber blends made be added to the back of the inner lining
or shell fabric material.
[0044] The multi-faceted shaped polymer based synthetic and natural
fiber blends lend endless possibilities in construct to the first
layer. These new shaped fibers increase moisture transfer, cooling
and heating applications and increase performance levels.
[0045] 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
compositions and construction may vary with the products and
performance needs.
[0046] 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-teared construction flocked or needled
together. The first layer may alternative flock the fibers from the
nonwoven in to the back fabric or nonwoven inner lining material or
the foam or foam and nonwoven blend may be flocked or needled to
the back side of the inner lining material. This multi-teared
construction absorbs and transfer moisture and may be treated with
a cooling microshpere or chemical option. The inner lining material
contain an active carbon compound to increase the moisture transfer
as well as shaped fibers. The following inner moisture transfer
liner materials may also be replaced by new moisture transfer
fabrics with similar characteristics as the technology on the
market develops for this invention.
[0047] The first fabric is an anti-microbial, anti-fungal
polypropylene (also referred to as polyolefin) lycra blend (2%)
with INNOVA fiber, or the like. INNOVA is a continuous filament
fiber (manufactured by Coville, Deercreek fabrics.)
[0048] 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.
[0049] The third fabric is an anti-microbial, anti-fungal
polypropylene/cotton blend with ALPHA fiber, or the like (such as
that manufactured by Intex Fabric, Inc.)
[0050] The fourth fabric is a field sensor 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, distributed by Teijin Shojin
can be employed or the like.
[0051] The fifth fabric is a Technofine polyester shaped fiber by
Gelanots
[0052] The sixth fabric is 3.times. Dry process fabrics or by
Schoeller
[0053] 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.
[0054] The eighth fabric or nonwoven is made from corn fibers or a
blend of corn fibers with one or more of the following fibers,
lyocell, acretate, PVA and polyester.
[0055] The ninth fabric is polyester fabric with an active carbon
compound bonded to the polyester by a fabric Craghoppers
[0056] The tenth fabric group by Nano-Technology called Nano-Dry
Fabrics
[0057] The eleventh fabric materials is a synthetic leathers
preferably by Nextec of Italy, SISA or Clarino.
[0058] The twelfth fabric Technofine polyesters by Gelanots
[0059] The thirteenth fabric is a Dri-release fabrics by Optimer
Performance fibers
[0060] The fourteenth fabric is Dri-line and Sphere Technology
fabrics by NIKE
[0061] The fifteenth fabric is Polyguard guard by KOSA
[0062] The sixteenth fabric group is Dry-tech Comfort System
fabrics by Westcot
[0063] The seventeenth fabric group is a the Thermal Pro Fabrics by
Malden
[0064] The eighteenth fabric group is the Gore Windstopper N2S
[0065] The nineteenth group Polartec powerdry
[0066] The twentieth fabric is a fabric called Aquafil Dryarn by
rhovyl in France and Italy.
[0067] The twenty-first fabric Sterling Performance fabric
[0068] The twenty-second fabric Dryline by Milliken
[0069] The twenty-third fabrics are Corn fibers and fabrics by
Draper Knitting
[0070] The twenty-fourth fabric is Acrillian or Duraspun by
Monsanto
[0071] The twenty-fifth fabric is a hydrophilic, anti-microbial
Dri-Lex Baby Kid or perforated material (such as that manufactured
by Faytex Corp.).
[0072] The twenty-sixth fabric is a polyester looped Terry (such as
that manufactured by Fronfli Spundale Mills, Inc.).
[0073] The twenty-seventh fabric is a sueded/sanded polyester
microfiber material (such as that distributed by Yagi & Co.,
Inc. and Teijin Shojin, Inc., Millken or Malden Mills).
[0074] The twenty-eighth fabric is an anti-microbial, anti-fungal
Polar Tec Series 2000, which is a wickable, moisture transfer
fiber, containing lycra, polypropylene, or the like.
[0075] The thirtieth fabric group are Sensitive Fabrics
[0076] The thirty-first fabric are polyester fabrics by Coville
[0077] The thirty-second nonwoven fabric is Evolon nonwoven by
Freudenburg.
[0078] The thirty-third nonwoven wool blend by Foss
Manufacturing
[0079] 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.
[0080] All of these fabrics have good moisture transfer
characteristics which prevent damage to a skater'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.
[0081] This application constructs the following inner lining
composite constructions
As stated previously all inner lining materials and fabrics are
laminated, needled, stitched, ultrasonically bonded or mechanically
bonded to the abutting material, nonwoven or foam. The inner lining
materials or fabrics may be selected from the previously list
[0082] The first is a inner lining fabric or material abutting an
open cell, hydrophilic foam laminated or needled to a nonwoven
material.
[0083] The second a inner lining fabric or material abutting a 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.
[0084] The third is a inner lining material or fabric with an
elastomeric cellular composite such as that referenced in the U.S.
Pat. No. 6,074,966 mechanically or ultrasonically bonded to the
inner lining material.
[0085] The fourth is a 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.
[0086] 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), Lyocel or
acetate, corn, woodpulp cellulose and silver fibers.
[0087] The sixth is a inner lining fabric or material with the foam
and nonwoven fibers flocked into the back surface.
[0088] The seventh is an inner lining fabric or material abutting a
foam. The foam is inclusive of a nonwoven layer or fibers.
[0089] The eighth is a 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 a extremely thin increment
to accommodate the comfort needs of the user.
[0090] All of the above composite options are presumed breathable
and transfer moisture. The inner lining composite abuts another
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 insert
between the exterior shell fabric and the nonwoven, spacer product,
cellulose material, polymer mesh or foam layer.
[0091] In one option a combination of 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 suggested for
use in the ice and hockey skates, protective gear, helmets and
accessories such as gloves.
[0092] The moisture transfer characteristics of the inner liner
composite causes moisture vapors to be passed from a skater'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. The spacer fabric
and thermal nonwoven are optional as well in layer 30 and are use
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.
[0093] In another liner option consists of an exterior shell
fabric, a frothed open cell foam or free rise foam abutting a
nonwoven or nonwoven thermal layer preferably by Foss
Manufacturing, Dupont, 3MM or the like and the inner lining
material. The foam 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, Frisby, Freudenburg
or Wisconsin Global may be used abutting the exterior shell fabric
material
[0094] As discussed above, first foam material 20 may be a cellular
elastomeric composite comprised of a layer of germicidal
anti-microbial open cell hydrophilic polyurethane foam such as
Foamex foams (VPF, Aquazone), Dicon foams or the like and a
non-woven top sheet. All of the foam material discussed herein are
preferably polyurethane, although not specifically mentioned each
time. The inclusive top sheet is preferably composed of wood pulp,
rayon, corn, cotton, lyocel, PVA, silver fiber, polypropylene,
polyester, or a combination thereof.
[0095] Alternatively, foam material 20 can be a foam that is
separate from the non-woven top sheet and is attached to the
non-woven top sheet by lamination, stitch bonding, or the like. The
non-woven top sheet (when used) abuts the next layer of 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
germicidal, anti-microbial, reticulated and/or open cell
hydrophilic 1/8/1/4'' 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
backed with a non-woven top sheet as mentioned above. In fact, any
of the foam materials discussed herein can be backed by such a
non-woven top sheet, but the non-woven top sheet is not absolutely
necessary. Also, many of the foam materials are interchangeable
depending upon specific needs of the skater. The non woven
apertured top sheet is comprised of cotton, woodpulp, lyocel,
silver fiber, PVA, polypropylene or polyester or a combination
thereof,
[0096] The previous fibers may be flocked into the back of the foam
layer 20, 30, or 50. A nonwoven top sheet layer, elastomeric
composite or thermal nonwoven composite may be combined with the
foam and flocked fibers or foam and flocked fibers and inner lining
material.
[0097] One preferable embodiment for a hockey skate moisture
transfer liner combines the inner lining material laminated to a
foam with flocked fiber backing the inner lining or foam and a
spacer fabric or polymer mesh and the exterior shell fabric.
[0098] As shown in FIG. 2, a third foam material 50, which 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 outside and 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. The spacer fabrics 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. All the spacer
fabrics are engineered with fibers that increase moisture transfer.
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 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 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 PCM'S. 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 allows for a comfortable stride. With this
added comfort, the aggressive or recreational skier can achieve a
higher level of continued performance.
[0099] 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 skate 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.
[0100] A nonwoven thermal may be a Thinsulite, 3MM thermal
nonwoven, Themolite, Dupont thermal nonwoven, Ssoftherm, or a Foss
composite with or without foam. A shaped polyester, or synthetic
fiber may be combined with a thermal nonwoven with or without foam.
Alternatively, the nonwoven fibers suggested previously may be
combined with the thermal or foam. The foam may be combined with
the fibers, a polymer mesh or a combination in a number of
performance categories. Optional the foam combined with the fiber,
mesh or a combination may has fibers flocked to either side or both
in some applications.
[0101] A moldable foam, spacer material, or gel or the like may
also be used in place of this flexguard and foam combination or an
air bladder. The moldable foam may or may not be a slow recovery
foam by Rogers 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, Comfortemp, 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.
[0102] 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
flocked to the any fabric, nonwoven, foam, breathable membrane or
spacer material in this liner system. The 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
polymer shell or a combination. An example of a combined fabric and
polymer shell is the Rossignol soft alpine boot or the K2 in-line
skate.
[0103] The suggested nonwoven top sheet fibers maybe flocked into
the foam, combined with the thermal, inner lining material,
elastomeric composite, breathable membrane or spacer fabric. The
nonwoven top sheet may be mechanically bonded to the thermal
nonwoven, foam or thermal composite on one side or both to provide
an increase rate of moisture transfer.
[0104] 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 eliminates the need for a waterproof/breathable membrane in
most categories. However, the a 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 maybe 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 use 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, 593680 applications and the U.S. Pat. Nos. 4,666,765,
5,004,643, 5,418,015, 5,209,965. 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.
[0105] The moisture vapor continues from the second foam material
30 through the meshor spacer if applied 30, and on through the
third exterior foam material 50 or outer shell material. If the
spacer fabrics or thermal nonwovens are used then the outer layer
of foam material 50 may be eliminated in certain performance
conditions. The moisture vapors are then passed through
waterproof/breathable membrane 60 or the 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.
[0106] Those under the tradenames Aquador, Entrant Dermizax,
Witcoflex, Harrison Technologies membranes, eEvent, Super Dry Film,
Windstopper membrane, eEvent, 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, PTFE by Tetratec are currently being considered.
However, the membranes currently being considered is 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 disclosed in
this application. Outlast fibers which regulates temperature may be
combined in some options in the nonwoven Dupont products or other
nonwoven blends or foam in this application. If the preceding foam
layers are Comfortemp or have PCM Technology applied to the foam,
then the Outlast fibers or membrane is 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 contained in a membrane, a spun melt fiber
or a coating and is manufactured by Gateway Technologies. Frisby
Technologies which is a thermabsorb micro-encapsulation technology
can adjust to temperature changes and is added to foam. PCM
Technology can be added to any fiber, fabric, foam, foam composite,
thermal, breathable membrane or flocked fiber blend in this
application.
[0107] 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 Frisby.
For example, U.S. Pat. Nos. 4,756,958 and 5,366,801 are directed to
fibers and fabrics with reversible enhanced thermal properties,
respectively. The disclosures of these two patents are hereby
incorporated by reference. Other patents assigned to Triangle
Research & Development Corp., that are related by subject
matter and have overlapping inventorship, include U.S. Pat. Nos.
5,415,222; 5,290,904; and 5,224,356. These patents are also hereby
incorporated by reference.
[0108] 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.
[0109] Also shown in FIG. 4 is a protective rim or cuff 80,
preferably made of neoprene covered by lycra. 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 DuPont, for example.
[0110] 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 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 of
encapsulated fibers layer is closes to the fabric surface, the
fabric is very waterproof and less breathable. If the layer of
encapsulated fibers are in the middle of the outer shell fabric,
then the fabric is equally waterproofed and breathable.
[0111] The outer layer of fabric 70 is a combination of extremely
durable, lightweight materials, Kevlar/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 and nylon Fabrics by Nam Liong, nylon
supplex (such as that manufactured by Travis Textiles, Inc. or
Blank Textiles, Inc.), nylon Cordora (manufactured by Schoeller,
Inc.), other Cordoras (manufactured by Schoeller or DuPont), 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, DuPont, 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
DuPont, or nonwoven by Freudenburg for example.
[0112] 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 need a moisture
transfer liner that can remove large amounts of moisture
continuously from the foot. These skaters 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.
[0113] 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.
[0114] 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.
[0115] The polyester field sensor fabric or intera treated
polyesters, polyester blends or the like works well with those
individuals who prefer sports or recreational skating. This liner
absorbs moisture immediately and is recommended for the soft boot
inner liner.
[0116] Finally, polyester microfiber fabric is advantageous in that
it is coot to the touch, smooth and wickable. A wetting agent
treatment enhances wickability.
[0117] As a result of using this lining system, the skater
continues to have a cooler, drier foot. The lightweight Kevlar,
Starlite, and Cordura, 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.
[0118] FIGS. 5(a) and 5(b) illustrate a sole portion 200 of a
footpad covered with one of the selected fabrics such as cambrelle
Dri-Lex nylon, evolon by Freudenburg, 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 sole insert footbed 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 Saran@Climate 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 reticulated and/or slow recovery
moldable foam or a cellulose material. This cushion protector
allows circulation in the heel. The anti-microbial silver fibers,
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 a
comfortable stride.
[0119] 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 nonwoven, polypropylene, polyester or
lycra 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 foam 320, which is
preferably a 1/4 inch anti-microbial reticulated and/or slow
recovery punctured foam. A hydrophilic open cell or reticulated
perforated foam 330 abuts a structural support foam 320. The
hydrophilic open cell or the slow recovery perforated foams 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 can be used.
[0120] The nonwoven material such as Cambrelle Dri-Lex, Nextec
synthetic leathers, Evolon a spun lace moisture management products
by Freudenburg can product strength and moisture transfer
properties to the tongue. It should be understood that these
nonwoven materials can always be substituted for the aero-spacer
Dri-lex, even if not specifically mentioned in other parts of this
disclosure. This material 340, is wrapped around the outer edge of
the tongue to allow moisture vapors traveling from the upper foot
area to escape through moisture transfer material 340 to the outer
surface of the tongue 300. Material 340 also aids in providing a
softer edged tongue. Finally, and 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 nylons, Kevlar, 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.
[0121] As shown in FIG. 6, polyurethane, Kevlar 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 lycra and nylon thread such as those used by the
DuPont Xymid Group or Tietex 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.
[0122] In-line 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 they meet 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 to develop. The optional anti-microbial
fiber blends and ionized fibers and fabric discourage bacteria and
fungus growth.
[0123] 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, 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 skate 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 by Toray, DuPont, or Schoeller (Keprotec or Schoeller
Spirit) or Texon, Starlite, Cordura, or the like. Finally, outer
shell fabric 70 is the same as that shown in FIG. 4, and can be any
of the fabrics listed previously in connection with outer shell
fabric 70. The nylon pull tab 90 allows the skater to easily slip
into the liner.
[0124] 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
cellulose material can be substituted 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 be 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 by FoxRun can be used
as material 510. 520 represents the combination of the flexible
mesh (in the case 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.
[0125] 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 optionally a foam and
nonwoven fiber blend may be used abutting the mesh or spacer
material in the top box and heel.
Abrasive grip fabric 100 is also shown. Texon Aquiline or a Nam
liong nylon or kelvar product may be used.
[0126] The 6500 high abrasive fabrics manufactured by Schoeller,
inc., Nam Liong kelvar 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 and Cordura Starlite fabrics provide
comfort and durability to the liners and are extremely strong and
resistant to abrasion and allow for breathability and
performance.
[0127] 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 fabrics, foam layers,
nonwovens, spacer fabrics, breathable membranes, polymer mesh and
cellulose materials, flocked fibers and foams technology,
encapsulated 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.
[0128] 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
boots and soft boots. 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 has
numerous combination of the moisture transfer composites prior. The
liner of the soft boot can be adapted to this new moisture transfer
system. While the soft boot does not have a protective shell, nor a
removable liner it can nonetheless be provided with a liner that
enjoys all of the benefits of the liner according to the present
invention. Preferably, the outer layer of the moisture transfer
system for the soft boot application would be a Starlite Dri-lex
nylon, Kevlar, or high abrasion Cordura 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 reticulated
and/or open cell hydrophilic anti-microbial germicidal 1/8 inch
foam or the anti-microbial nonwoven and foam blend manufactured by
Foss Manufactured abuts the encapsulated outer fabric or breathable
membrane. The structural mesh, combined mesh and foam composite,
molded cellulose or spacer material is stitch bonded or laminated
to the 1/8 reticulated or open cell hydrophilic foam. A slow
recovery punctured foam, 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 reticulated and/or open cell hydrophilic 1/8'' inch
foam. The 1/8'' foam abuts preferably a cellular elastomeric
composite which is laminated to the inner fabric. A nonwoven top
sheet laminated to 1/8'' foam may also be used in place of the
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.
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 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.
[0129] 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 DuPont, Schoeller, Burlington,
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.
[0130] The outer shell combined materials are then laminated,
stitched 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 thread by the Xymid group of DuPont 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.
[0131] 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, Dicon, Foamex or the
like, in combination with a nonwoven topsheet 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 is considering the use of a breathable
polyester, shaped polyester (4 deep groove 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 an 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. This combination may be
used industrial for air or water filtering applications. In fact, a
large number of the skate composites and combinations of
compositions in this invention may be used in medical and
industrial applications.
[0132] Alternatively, the elastomeric cellular composite or the
cellulose spacer material by FoxRun may have anti-microbial and/or
nonwoven flocked to one side or both sides. The elastomeric flocked
composite combinations may be use in numerous combinations for
skate, soft boot and alpine shell boots and insert liners, apparel,
medical and industrial applications.
[0133] In fact, a large numerous of the above composite
combinations may be used for protective gear, sporting goods
apparel, backpacks, tents, sleeping bags, bouldering shoes, sailing
and golf apparel and footwear, as well as, apparel and footwear. In
the padding and sailing apparel and accessories the kapok fiber may
be added to increase buoyancy.
[0134] FIG. 12 illustrates a snowboard or alpine insert boot liner
incorporating the lining system discussed above. The snowboard boot
may have a removable or non-removable liner as discussed above for
the alpine boot. 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 fabric (made by
Schoeller, or a similar material), Schoeller, DuPont & Toray or
the like, Cordura, 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 or a material 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 or Cordura 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 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.
[0135] The sock 675 is made up of three or four layers and 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 elastomeric composite, foam composite or nonwoven composite,
thermal nonwoven composite, Themolite, Thinsulite, Gore nonwoven
with or without foam or silver fibers. The third layer is a
material that absorbs and transfers moisture such as a ionized
nonwoven blend, polyester blend manufactured by Deercreek fabrics,
Menra Mills, NAM LIONG fabric treated with a wicking solution or
the like. This layer is optional. 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. The inner lining fabric and
outer shell layer material may be a nonwoven, knitted mesh or a
woven construction. Encapsulation technology can also be applied to
the third layer by Nectex. Sock 675 can be used for additional
warmth and is removable, unlike the shoe liner and can be insert
into the snowboard, alpine liner or the like, for extra warmth. The
insert sock liner is breathable and preferable 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.
[0136] 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; Inner lining material
abutting an open cell foam backed with a moisture transfer nonwoven
top sheet. The three layer composite is laminated to the Foss
thermal composite and a spacer fabric material The exterior shell
fabric is laminated to the a spacer fabric material.
[0137] In the second option the inner lining material is laminated
to the Foss thermal composite and abuts the breathable moldable
spacer fabric and exterior shell material.
[0138] In the third option the inner lining material is welded to
elastomeric composite, the moldable breathable spacer fabric and
exterior shell material.
[0139] 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
attacked to the breathable spacer fabric and molded. In fact, any
of the combinations may be molded and welded in this
inventions.
[0140] 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 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 insert into rubber
boots and 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.
[0141] 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 foam that contacts the first layer and is a
germicidal, reticulated foam or a hydrophilic, open-cell foam, such
as DuPont and VPF manufactured by Foamex, DRI-Z manufactured by
Dicon with or without glycerin, COMFORTEMP by Frisby and Schoeller
or the like. Alternatively, these layers can be a Foss thermal
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.
[0142] The fourth layer is a hydrophilic, open cell preferably,
(DuPont or VPF), a slow recovery foam, or Dicon Technologies foam,
or polymer flex-guard mesh or a polymer flex-guard mesh inclusive
in a open cell foam or a polyester breathable spacer material (by
Muller) or the like for support. In this case, the open cell foam,
DuPont 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 include in the foam in one
process or the flex guard is followed by another layer of open cell
(DuPont) 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 to 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 combined with a THERMOLITE or the Foss thermal
composite.
[0143] The Phase Change Technology by OUTLAST, Frisby may be added
to any layer in the liner system and may be combined with
encapsulated fibers and fabrics. 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 OUTLAST
Technologies is an enhance option in this embodiment, but is not
essential in the products. If encapsulation is employed, then the
fourth layer preferably includes THERMOLITE or the Foss thermal
composite. 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.
[0144] The sixth layer in this removable shell liner may be
Cordura, STARLITE, KEVLAR fabrics or the like. The STARLITE by
Faytex Corp or Faytex breathable series, Kevlar and Cordura's by
Schoeller 6500, 14705, 13207, 13632, 65563 etc. and NAM LIONG's
ARMORTEX Series, DERIZAX and ENTRANT Gil by Toray.
[0145] The exterior shell fabric is and preferably encapsulated or
waterproofed with a breathable thin film or coating.
Alpine Cross Country Boots
[0146] 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 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 polyesters;
polyester field sensor; looped polyester terry; Dri-line by
Milliken, DRI-LEX DOESKIN or BABY KID 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 three layer composite by Faytex, Dicon
or the like may abut the second layer.
[0147] The second layer in this embodiment may be a open cell foam,
or a moisture transfer nonwoven composite, or a breathable moldable
spacer fabric or the outer shell material. These material may be
individually selected or in combinations in certain performance
categories.
[0148] The second layer is a germicidal, open cell hydrophilic
foam. It may be COMFORTEMP by Frisby or DuPont with Phase Change
Technologies or a foam by Dicon Technologies 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 elastomeric
composite or the second layer can be a open cell foam such as DRI-Z
or DuPont or the like with a fiber integrated into the foam during
it's construction. This composite 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 a webbing. The
open cell foam with or without the polymer mesh may alternatively,
contain a fibers nonwoven sheet constructed of the above suggested
fibers contained in the nonwoven backing. The assist in the
absorption and transfer of the moisture passing through the
moisture transfer system.
[0149] The third layer is a structural support foam or a breathable
moldable spacer material by Muller Textil. 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.
[0150] The fourth layer is a thin layer of THERMOLITE, a hollow
core polyester fibers, THERMOLITE combined with a with a open cell
foam with or with out nature fibers such as corn fibers added.
Optionally, the third layer can be a blend of moisture transfer
synthetic or nature fibers blend or the THERMALFOSS nonwoven
composite with or with out DuPont thermal fibers or an open cell
foam such as DuPont or the like with a moisture transfer nonwoven
top sheet made of wood pulp, lyocel, rayon, cotton, polyester,
acrylic, acetate, corn or polypropylene. These nonwoven fibers in
combinations or independently absorb and move moisture. The fourth
layer may be optional in some performance categories.
[0151] 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, laytex, breathable membranes by Harrison Technologies,
Sympatex, or ENTRANT Gil by Toray The OUTLAST Membrane can be used
by itself, with another membrane or with encapsulation technology
on the outer shell fabric, such as 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
encapsulation fibers or fabrics by Nextec or Toray. If
encapsulation is employed, then the fourth layer preferably
includes THERMOLITE, a moisture transfer nonwoven blend or
THERMALFOSS composite.
[0152] 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 combination. These
fabrics include the following: Cordura; LYCRA blends; STARLITE by
Faytex Corp.; KEVLAR fabric by Schoeller (14705, 6500, 13207,
13632, 65563, etc.); NAM LIONG, AROMRTEX Series, DuPont and Toray
or the like, Cordura 2000 by DuPont, Dermizax and ENTRANT Gil by
Toray, 3 or 4 ply Supplex; Mojave and Tudor nylon and polyester
blends by Travis; 6 ply Maxus nylon blends or the like; and
synthetic leathers by Daewoo, Inc., Nextec or moisture transfer
nonwovens by Freudenberg, Sisa or the like. These fabrics may be
used individually or in combination.
[0153] The seventh layer is a LYCRA covered neoprene, moldable
spacer fabric or slow recovery foam or reticulated open cell foam
ankle cuff.
[0154] 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 DuPont 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, DRILINE by Milliken, polyester spacer
by Malden, polar fleece INNOVA or ALPHA polypropylene by Coville or
Deercreek fabrics, or DRI-LEX DOESKIN nylon, polyester blends
sueded or fleeced or the like. The outer tongue fabrics are high
abrasive fabrics constructed of KEVLAR and Corduras by Schoellar's
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.
[0155] Hiking Boots
[0156] 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, sueded polyester blends, COOL MAX or nylon
blends, or the like. Any combination of these moisture transfer
fabrics can also be used.
[0157] The second layer is a cellular elastomeric composite or
hydrophilic open cell foam preferably DuPont, COMFORTEMP by
Frisby/Schoeller or DRI-Z by Dicon. The OUTLAST membrane is an
option in this layer. If a foam is used, a moisture transfer
nonwoven top sheet selected from previously mentioned materials can
be attached as a backing.
[0158] The third layer is a molded hydrophilic open cell foam
preferably DuPont backed by an aperture 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 layer of
hydrophilic 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.
[0159] The fourth layer optionally is a waterproof/breathable
membrane which may be any one of the following: OUTLAST membrane by
Gateway Technologies combined with Seco-Tex, TX1540 (distributed by
Shawmut Mills), THINTECH, THERMOLITE 2000/1300 standard, Laytex,
WILCOFLEX DRY or the like. The OUTLAST Technology may also be used
independently of the breathable membrane and may also be coated to
the outer fabric or fibers. 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
encapsulation is employed, then the third layer may be an open cell
foam or a moldable spacer fabric, a THERMOLITE, a moisture transfer
nonwoven composite or a THERMALFOSS composite. The Phase Change
Technology may be applied to the moisture transfer nonwoven, foam
or fabric in this moisture liner system and may be combination with
outer shell encapsulated fibers and fabric, such as by Nextec, or
the like.
[0160] The fifth and last layer is a combination of one or more of
the following: Corduras, Supplex Nylon, STARLITE, Tudor, KEVLAR,
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, DURAPEL PLUS, HYPER D-WR or ENTRANT G2-XT.
[0161] Elastomeric composite technology may be insert between the
exterior shell fabric and the breathable membrane if applied or the
elastomeric composite may about a moisture transfer nonwoven
thermal blend one side and the exterior shell fabric on the other
side. Optionally, the thermal nonwoven composite may be abutting
the exterior 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 wickable inner liner, followed by an elastomeric
or an open cell foam 1/16, 1/8 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, or structurally woven or knitted to repel water. 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 a open cell foam abutting a open cell foam and
encapsulated outer shell fabric as one embodiment Optionally, the
FossThermal, THERMOLITE or a nonwoven thermal or nonwoven composite
combined with foam may be used abutting the inner lining fabric and
the outer shell fabrics.
[0162] This invention can also be used for industrial and medical
applications by using polyester spun bonded 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
[0163] 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.
[0164] FIGS. 13 and 13A illustrate an insert (700) for an in-line
skate or hockey skate with a first portion enlarged. 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
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 be simply a foam or a nonwoven. Layer 730 is a
nonwoven, or a cellular elastomeric composite or an inner lining
fabric or material such as a knit.
[0165] 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 elastomeric composite; 4) a nonwoven and a foam
composite.
[0166] Layer 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
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 elastomeric composite;
2) layer 760 may be a foam, nonwoven or a combination of foam and
nonwoven; 3) layer 770 may be a knit, woven, nonwoven, foam, or an
elastomeric composite.
[0167] 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 elastomeric composite, and may include
silver fibers by Foss Manufacturing.
[0168] 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.
[0169] 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 an elastomeric composite.
Finally, 786 could be a Foss composite and an 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.
[0170] 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 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
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 he 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; 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 elastomeric composite.
808 illustrates a cellular 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; 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 elastomeric composite abutting a knitted or
nonwoven inner moisture transfer material. Optionally the foam,
nonwoven or cellular elastomeric composite may include blends
containing either silver or wool fibers, or both.
[0171] 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
elastomeric composite or thermal nonwoven.
[0172] 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
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 be a moisture transfer thermal moldable nonwoven
composite, and in some performance categories the foam can be
replaced with a cellular 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 elastomeric composite. Preferably layer 814
is an outer shell fabric and a 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 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.
[0173] 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 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 elastomeric composite including a polymer mesh. Layer 826
illustrates another inner lining material. 826 may alternatively be
a nonwoven and a cellular 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, a moisture transfer
nonwoven, or nonwoven composite and an inner lining material. This
composite is moldable, transfers moisture, and is thermal and
waterproof.
[0174] 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 elastomeric composite or a
breathable foam. Layer 834 illustrates another inner lining
material. 834 may alternatively be a nonwoven and a cellular
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 pouter shell soft
boot composite is composed of an outer shell fabric, a frothed open
cell foam, a moisture transfer nonwoven, or nonwoven composite and
an inner lining material. This composite is moldable, transfers
moisture, and is thermal and waterproof.
[0175] FIG. 20 illustrates a polymer shell for a hockey skate 960
including a moisture transfer liner.
[0176] 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.
[0177] 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 Co.
[0178] 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.
[0179] 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
may have industrial applications.
* * * * *