U.S. patent application number 14/057266 was filed with the patent office on 2015-01-29 for tapeless waterproof footwear.
The applicant listed for this patent is Starensier, Inc.. Invention is credited to Henry Feng, Josh VanDernoot, Frank Xu.
Application Number | 20150027001 14/057266 |
Document ID | / |
Family ID | 52389238 |
Filed Date | 2015-01-29 |
United States Patent
Application |
20150027001 |
Kind Code |
A1 |
VanDernoot; Josh ; et
al. |
January 29, 2015 |
TAPELESS WATERPROOF FOOTWEAR
Abstract
Described herein are devices and techniques for solving the
problems associated with the assembly of standard waterproof
footwear such as the increased labor and cost of purchasing a
taping machine and individually taping each seam of a waterproof
article of footwear. Waterproof footwear described herein is made
by laminating a waterproof membrane over substantially the entire
exterior surface, including the seams, of a footwear liner, thereby
producing a tapeless waterproof footwear article.
Inventors: |
VanDernoot; Josh; (Weston,
MA) ; Xu; Frank; (Guangdong, CN) ; Feng;
Henry; (Guangdong Province, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Starensier, Inc. |
Byfield |
MA |
US |
|
|
Family ID: |
52389238 |
Appl. No.: |
14/057266 |
Filed: |
October 18, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13949540 |
Jul 24, 2013 |
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14057266 |
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Current U.S.
Class: |
36/87 ; 12/107R;
12/129.4; 12/142R; 36/83; 36/84 |
Current CPC
Class: |
A43B 7/125 20130101 |
Class at
Publication: |
36/87 ; 36/83;
36/84; 12/129.4; 12/107.R; 12/142.R |
International
Class: |
A43B 7/12 20060101
A43B007/12; A43B 13/04 20060101 A43B013/04 |
Claims
1. A tapeless waterproof footwear article comprising: a footwear
liner comprising an exterior surface and at least one seam, wherein
the footwear liner is substantially free of any waterproof
membrane; and one or more layers of waterproof membrane laminated
with substantially the entire exterior surface of the footwear
liner and associated seams, wherein none of the one or more layers
of waterproof membrane are seam-specific.
2. The tapeless waterproof footwear article of claim 1, wherein the
footwear liner is constructed from one or more textile layers.
3. The tapeless waterproof footwear article of claim 1, wherein the
one or more textile layers are constructed from at least one of a
woven textile, non-woven textile, tricot, knit textile, polyester,
nylon, polypropylene, cotton, wool, or leather.
4. The tapeless waterproof footwear article of claim 1, wherein the
at least one seam is positioned so that the footwear liner lies
flat when empty.
5. The tapeless waterproof footwear article of claim 1, wherein the
at least one seam is positioned so that the footwear liner retains
a three-dimensional shape when empty.
6. The tapeless waterproof footwear article of claim 1, wherein the
footwear liner further comprises a substantially foot-shaped
base.
7. The tapeless waterproof footwear article of claim 6, wherein the
substantially foot-shaped base further comprises at least one of a
Strobel board, a cushioning layer, or a footbed.
8. The tapeless waterproof footwear article of claim 1, wherein the
at least one seam is at least one of sewn, stitched,
needle-punched, welded, and/or glued.
9. The tapeless waterproof footwear article of claim 1, wherein the
one or more layers of waterproof membrane are constructed from at
least one of fluoropolymers, polyurethanes, polyesters, polyethers,
polyamides, polyacrylates, coplyether esters, copolyether amides,
Teflon, microporous polytetrafluoroethylene (PTFE), expanded PTFE,
the membrane known under the trademark "GORE-TEX", or the membrane
known under the trademark "SYMPATEX."
10. A system for producing tapeless waterproof footwear comprising:
a closeable press including a first heatable plate and a second
heatable plate, wherein the second heatable plate is substantially
parallel to the first heatable plate in a closed position of the
press; and a pressurizing mechanism for closing the closeable press
to apply pressure externally of a waterproof membrane, wherein
applying pressure externally of the waterproof membrane laminates
the waterproof membrane with substantially an entire exterior
surface of a footwear liner and at least one seam of the footwear
liner.
11. The system of claim 10, wherein the pressurizing mechanism is
at least one of an electric drive, a hydraulic drive, a hydraulic
piston drive, a winch, a lever, or a clamp.
12. A system for producing tapeless waterproof footwear comprising:
a footwear last; a closeable mold including at least two heatable
shells, the at least two heatable shells being shaped to receive
the footwear last, wherein closing the closeable mold causes the at
least two shells to close about the footwear last and apply
pressure externally of a waterproof membrane, wherein applying
pressure externally of the waterproof membrane laminates the
waterproof membrane with substantially an entire exterior surface
of a footwear liner and at least one seam of the footwear
liner.
13. A method for producing tapeless waterproof footwear comprising:
providing a footwear liner comprising an exterior surface and at
least one seam, wherein the footwear liner is substantially free of
any waterproof membrane; providing one or more layers of waterproof
membrane; and laminating substantially the entire exterior surface
of the footwear liner and associated seams with the one or more
layers of waterproof membrane.
14. The method of claim 13, further comprising fitting the footwear
liner around a footwear last.
15. The method of claim 13, further comprising positioning the one
or more layers of waterproof membrane in at least two heatable
shells of a closeable mold.
16. The method of claim 15, further comprising closing the
closeable mold to compress a footwear last having the footwear
liner fitted thereon between the at least two heatable shells.
17. The method of claim 13, further comprising positioning the one
or more layers of waterproof membrane on at least one heatable
plate of a closeable press, wherein the footwear liner is
positioned between at least two of the one or more layers of
waterproof membrane.
18. The method of claim 17, further comprising closing the
closeable press to compress the footwear liner positioned between
the at least two of the one or more layers of waterproof membrane
between the at least one heatable plate and at least one additional
heatable plate.
19. The method of claim 13, wherein the step of laminating is
performed using at least one of an epoxy, heat-activated adhesives,
water-based adhesives, ethylene vinyl acetate (EVA)-based
adhesives, polyurethane-based adhesives, solvent-based glue, flame
lamination, or heat-pressing.
Description
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates generally to waterproof
footwear and more particularly to a method for producing
waterproof, breathable footwear without using waterproof tape to
seal seams.
[0003] 2. Discussion of Background Information
[0004] Waterproof boots and shoes are typically made from a
layered, waterproof textile. The waterproof textile is typically
produced in sheets or rolls comprising a non-waterproof textile
(e.g., polyester) laminated or glued to a waterproof layer (e.g.,
the membrane known under the trademark "GORE-TEX"). The layered,
waterproof textile is typically cut and sewn, glued, etc. together
along the seams into the shape of a shoe or bootie (i.e., forming
the upper and possibly forming the sock liner, insole and/or
midsole as well). In this construction, the seams are not
waterproof and each seam must be subsequently sealed using a
seam-specific sealing step in which a waterproof tape is applied
over the seams. This is a time-consuming, labor-intensive process,
which requires expensive equipment and adds substantially to the
cost of production.
SUMMARY OF THE INVENTION
[0005] It would be desirable in shoe production applications to
produce waterproof shoes without the need for a seam-specific
waterproofing step. Because conventional seam-specific
waterproofing requires the application of a waterproof "tape," the
term "tapeless" is used throughout this application to capture the
concept of waterproofing without the need for a seam-specific
waterproofing step in the production process. The tapeless
waterproof footwear can be assembled with substantially less labor
cost and time than the state of the art construction described
above.
[0006] Described herein are devices and techniques for solving the
problems, such as high costs and intensive labor, associated with
seam-specific treatment of a waterproof layer. The tapeless
waterproof footwear described herein is made by laminating a
waterproof membrane over the exterior surface, including the seams,
of a footwear liner. The footwear liner may, for example, be
constructed from one or more lining materials. The lining materials
may, in various embodiments, be substantially free of waterproof
membrane prior to lamination.
[0007] In one embodiment, the invention relates to a tapeless
waterproof footwear article comprising a footwear liner comprising
an exterior surface and at least one seam, wherein the footwear
liner is substantially free of any waterproof membrane, and one or
more layers of waterproof membrane laminated with substantially the
entire exterior surface of the footwear liner and associated seams,
wherein none of the one or more layers of waterproof membrane are
seam-specific.
[0008] In another embodiment, the invention relates to the tapeless
waterproof footwear article of paragraph [0005], wherein the
footwear liner is constructed from one or more textile layers.
[0009] In another embodiment, the invention relates to the tapeless
waterproof footwear article of paragraph [0005], wherein the one or
more textile layers are constructed from at least one of a woven
textile, non-woven textile, tricot, knit textile, polyester, nylon,
polypropylene, cotton, wool, or leather.
[0010] In another embodiment, the invention relates to the tapeless
waterproof footwear article of paragraph [0005], wherein the at
least one seam is positioned so that the footwear liner lies flat
when empty.
[0011] In another embodiment, the invention relates to the tapeless
waterproof footwear article of paragraph [0005], wherein the at
least one seam is positioned so that the footwear liner retains a
three-dimensional shape when empty.
[0012] In another embodiment, the invention relates to the tapeless
waterproof footwear article of paragraph [0005], wherein the
footwear liner further comprises a substantially foot-shaped
base.
[0013] In another embodiment, the invention relates to the tapeless
waterproof footwear article of paragraph [0010], wherein the
substantially foot-shaped base further comprises at least one of a
Strobel board, a cushioning layer, or a footbed.
[0014] In another embodiment, the invention relates to the tapeless
waterproof footwear article of paragraph [0005], wherein the at
least one seam is at least one of sewn, stitched, needle-punched,
welded, and/or glued.
[0015] In another embodiment, the invention relates to the tapeless
waterproof footwear article of paragraph [0005], wherein the one or
more layers of waterproof membrane are constructed from at least
one of fluoropolymers, polyurethanes, polyesters, polyethers,
polyamides, polyacrylates, coplyether esters, copolyether amides,
Teflon, microporous polytetrafluoroethylene (PTFE), expanded PTFE,
the membrane known under the trademark "GORE-TEX", or the membrane
known under the trademark "SYMPATEX."
[0016] In another embodiment, the invention relates to a system for
producing tapeless waterproof footwear comprising a closeable press
including a first heatable plate and a second heatable plate,
wherein the second heatable plate is substantially parallel to the
first heatable plate in a closed position of the press, and a
pressurizing mechanism for closing the closeable press to apply
pressure externally of a waterproof membrane, wherein applying
pressure externally of the waterproof membrane laminates the
waterproof membrane with substantially an entire exterior surface
of a footwear liner and at least one seam of the footwear
liner.
[0017] In another embodiment, the invention relates to the system
of paragraph [0014], wherein the pressurizing mechanism is at least
one of an electric drive, a hydraulic drive, a hydraulic piston
drive, a winch, a lever, or a clamp.
[0018] In another embodiment, the invention relates to a system for
producing tapeless waterproof footwear comprising a footwear last,
a closeable mold including at least two heatable shells, the at
least two heatable shells being shaped to receive the footwear
last, wherein closing the closeable mold causes the at least two
shells to close about the footwear last and apply pressure
externally of a waterproof membrane, wherein applying pressure
externally of the waterproof membrane laminates the waterproof
membrane with substantially an entire exterior surface of a
footwear liner and at least one seam of the footwear liner.
[0019] In another embodiment, the invention relates to a method for
producing tapeless waterproof footwear comprising providing a
footwear liner comprising an exterior surface and at least one
seam, wherein the footwear liner is substantially free of any
waterproof membrane, providing one or more layers of waterproof
membrane, and laminating substantially the entire exterior surface
of the footwear liner and associated seams with the one or more
layers of waterproof membrane.
[0020] In another embodiment, the invention relates to the method
of paragraph [0017], further comprising fitting the footwear liner
around a footwear last.
[0021] In another embodiment, the invention relates to the method
of paragraph [0017], further comprising positioning the one or more
layers of waterproof membrane in at least two heatable shells of a
closeable mold.
[0022] In another embodiment, the invention relates to the method
of paragraph [0019], further comprising closing the closeable mold
to compress a footwear last having the footwear liner fitted
thereon between the at least two heatable shells.
[0023] In another embodiment, the invention relates to the method
of paragraph [0017], further comprising positioning the one or more
layers of waterproof membrane on at least one heatable plate of a
closeable press, wherein the footwear liner is positioned between
at least two of the one or more layers of waterproof membrane.
[0024] In another embodiment, the invention relates to the method
of paragraph [0021], further comprising closing the closeable press
to compress the footwear liner positioned between the at least two
of the one or more layers of waterproof membrane between the at
least one heatable plate and at least one additional heatable
plate.
[0025] In another embodiment, the invention relates to the method
of paragraph [0017], wherein the step of laminating is performed
using at least one of an epoxy, heat-activated adhesives,
water-based adhesives, ethylene vinyl acetate (EVA)-based
adhesives, polyurethane-based adhesives, solvent-based glue, flame
lamination, or heat-pressing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] One will better understand these and other features,
aspects, and advantages of the present invention following a review
of the description, appended claims, and accompanying drawings:
[0027] FIG. 1A is an exploded view of various components of an
article of tapeless waterproof footwear constructed in accordance
with various embodiments having a flat seam structure.
[0028] FIG. 1B is a side view of an article of tapeless waterproof
footwear constructed in accordance with various embodiments having
a flat seam structure.
[0029] FIG. 1C is a cross-sectional view of an article of tapeless
waterproof footwear constructed in accordance with various
embodiments having a flat seam structure.
[0030] FIGS. 2A-2B are isometric views of a system for producing an
article of tapeless waterproof footwear having a flat seam
structure in accordance with various embodiments.
[0031] FIG. 3A is an isometric top view of an article of tapeless
waterproof footwear constructed in accordance with various
embodiments having a three-dimensional seam structure.
[0032] FIG. 3B is an isometric bottom view of an article of
tapeless waterproof footwear constructed in accordance with various
embodiments having a three-dimensional seam structure.
[0033] FIGS. 4A-4B are diagrams of a system for producing an
article of tapeless waterproof footwear having a three dimensional
seam structure in accordance with various embodiments.
[0034] FIG. 5 is a flow chart of a method for making an article of
tapeless waterproof footwear in accordance with various
embodiments.
DETAILED DESCRIPTION
[0035] The devices and techniques described herein solve the
problems associated with standard waterproof footwear assembly such
as the increased labor and cost of purchasing a taping machine and
individually taping each seam of a waterproof article of footwear.
The tapeless waterproof footwear described herein is made by
laminating a waterproof membrane over the exterior surface,
including the seams, of a footwear liner. The footwear liner may,
for example, be constructed from one or more lining materials. The
lining materials, in various embodiments, are substantially free of
waterproof membrane prior to lamination.
[0036] Referring now to FIGS. 1A-1C, various embodiments of a
tapeless waterproof footwear article 100 may include at least a
footwear liner 101 having lining materials 104 and one or more
seams 103, and at least one layer of waterproof membrane 105
laminated over substantially the entire exterior surface 107 of the
footwear liner 101, including the one or more seams 103, thereby
providing tapeless waterproofing of both the lining materials 104
and the one or more seams 103 of the footwear liner 101.
[0037] The footwear liner 101 as shown in FIGS. 1A-1C is
constructed from one or more lining materials 104 and, as a whole,
is non-waterproof. In various embodiments, the lining materials 104
are substantially free of any waterproof membrane 105. In various
embodiments, the lining material(s) 104 can each include a single
layer or multiple layers of one or more textiles. The one or more
textiles can be, for example, any textile suitable for providing a
bootie, footbed, and/or sock liner in a shoe. In various
embodiments such textiles can include any suitable textile material
(e.g., any woven textile, any non-woven textile, any tricot, any
knit textile, polyester, polypropylene, nylon, cotton, wool,
leather, and/or any other suitable material).
[0038] While the lining material(s) 104 are generally
non-waterproof, the footwear liner, in various embodiments, may
include cushioning and/or stiffening elements which are
incidentally waterproof, thus adding local areas of waterproof
properties. In such embodiments, the footwear liner 101 as a whole
still remains non-waterproof Due to cost and performance
considerations (e.g., breathability), it can be, in various
embodiments, advantageous for the lining materials 104 to be
substantially free of any waterproof membrane 105. However, it will
be apparent in view of this disclosure that a textile having a
waterproof membrane can be used to construct the footwear liner
101, in accordance with various embodiments. In such embodiments
the presence of the one or more seams 103 still renders the
footwear liner 101 as a whole non-waterproof Therefore, in such
embodiments, at least one additional layer of waterproof membrane
105 is laminated over substantially the entire exterior surface 107
of the footwear liner 101.
[0039] The one or more seams 103 can, in various embodiments, be
sewn, stitched, needle-punched, welded, and/or glued. It will be
apparent in view of this disclosure that, while a single seam 103
is shown in FIGS. 1A-1C for clarity, any number of seams 103 can be
used in accordance with various embodiments (e.g., seams required
to assemble reinforcing elements, cushioning elements, toe caps,
vamps, and quarter portions). As shown in FIGS. 1A-1C, the one or
more seams 103 include a single stitched seam arranged such that
the footwear liner 101 lies flat when empty (e.g., when no foot or
last has been inserted into the footwear liner 101). This flat
structure of the one or more seams 103 advantageously allows
lamination of the waterproof membrane 105 using relatively
simplistic, inexpensive equipment as described below with reference
to FIGS. 2A-2B below. However, a flat seam structure of the
footwear liner 101 can, in various embodiments, limit the
manufacturer's ability to provide an accurate foot-shape of the
footwear liner, thereby decreasing the quality of the fit.
Accordingly, for various embodiments where the importance of
improved fit outweighs the associated increase in equipment cost
and complexity, a three-dimensional seam structure can be used as
described in further detail below with reference to FIGS.
3A-4D.
[0040] The waterproof membrane 105, in various embodiments may
include any waterproof material (e.g., rubber, plastic, polymer,
etc.). In various embodiments the waterproof membrane 105 is
constructed from one or more waterproof, water vapor permeable
functional layers, such as a breathable polymeric membrane. As used
herein, the terms "water vapor permeable" and "breathable" are used
interchangeably and mean that the waterproof membrane 105 has a
water vapor permeability coefficient Ret of less than 200 m.sup.2
Pa W.sup.-1. The water vapor permeability is tested by the
Hohenstein skin model. This test method is described in DIN EN
31092 (02/94) or ISO 11092 (19/33). Breathable polymeric membranes
may be breathable by virtue of pores in the breathable polymeric
membrane or through a solution diffusion mechanism. Breathable
polymeric membranes include, for example but not limited to,
fluoropolymers, polyurethanes, polyesters, polyethers, polyamides,
polyacrylates, coplyether esters and copolyether amides, Teflon,
polyester, microporous polytetrafluoroethylene (PTFE) such as
expanded PTFE, and/or any commercially available membrane which is
waterproof and vapor permeable, such as the membrane known under
the trademark "GORE-TEX" or "SYMPATEX."
[0041] During construction of the tapeless waterproof footwear
article 100, the waterproof membrane 105 is applied about the
exterior surface 107 of the footwear liner, including the one or
more seams 103 and the lining materials 104. The waterproof
membrane is then laminated over substantially the entire exterior
surface 107 of the footwear liner 101, including the one or more
seams 103, thereby providing tapeless waterproofing of both the
lining materials 104 and the one or more seams 103 of the footwear
liner 101. Lamination of the waterproof membrane over substantially
the entire exterior surface 107 can be performed according to any
method of lamination, including for example, using epoxies,
heat-activated adhesives, water-based adhesives, ethylene vinyl
acetate (EVA)-based adhesives, polyurethane-based adhesives,
solvent-based glue, flame lamination, heat-pressing, and/or any
other suitable method.
[0042] As shown in FIGS. 2A-2B, a system 200 for producing an
article of tapeless waterproof footwear 100 having a flat seam
structure includes, in various embodiments, a heat press 201 having
a first plate 203a, a second plate 203b, and a pressurizing
mechanism 207. As shown in FIG. 2A, in various embodiments, the
footwear liner 101 is sandwiched between two layers of waterproof
membrane 105 and positioned on the first plate 203a. The waterproof
membrane 105 is heated and, as shown in FIG. 2B, the second plate
203b is driven by the pressurizing mechanism to exert pressure
against the waterproof membrane 105 and the footwear liner 101,
thereby laminating the waterproof membrane 105 to the footwear
liner 101 to produce a tapeless waterproof footwear article 100
(e.g., as shown in FIG. 1B).
[0043] Heat press 201, in accordance with various embodiments, may
be any suitable press, including for example, a steam fabric press,
a dry heat press, a small format heat press, a large format heat
press, or any other suitable device. The first plate 203a and the
second plate 203b of the heat press 201 may be completely flat or
may have one or more slight depressions for accommodating the
thickness of the tapeless waterproof footwear article 100. The
first and second plates 203a, 203b can be constructed from any
suitable material, including for example, metal (e.g., iron, steel,
titanium, aluminum), coated metal (e.g., powder coating, ceramic
coating, and/or Teflon coating), wood (e.g., bamboo, oak, butcher
block), ceramic, plastic (e.g., polyvinylchloride), composites
(e.g., carbon fiber) and/or any other suitable material. Heat can
be introduced to the waterproof membrane 105 by for example but not
limited to, directly heating the first and second plates 203a, 203b
(e.g., via an electrical heating element or an external heat
source), introducing steam and/or heated air through the first
plate 203a and/or the second plate 203b, combinations of direct
heating and steam/hot air introduction, and/or any other suitable
method of introducing heat to the waterproof membrane 105
[0044] Pressurizing mechanism 207 is operable to drive the first
and second plates 203a, 203b together so as to apply pressure to
the waterproof membrane 105 and the footwear liner 101. The
pressurizing mechanism 207 can be, for example but not limited to,
a manual lever, a hydraulic piston (e.g., as shown in FIGS. 2A-2B),
an electrical motor, and/or any other suitable mechanism.
[0045] Referring now to FIGS. 3A-3B, various embodiments of a
tapeless waterproof footwear article 300 may include at least a
footwear liner 301 having upper lining materials 304a, lower lining
materials 304b, and one or more seams 303, and at least one layer
of waterproof membrane 305 laminated over substantially the entire
exterior surface 407 of the footwear liner 301, including the one
or more seams 303, thereby providing tapeless waterproofing of the
upper and lower lining materials 304a, 304b and the one or more
seams 303 of the footwear liner 301.
[0046] The footwear liner 301 as shown in FIGS. 3A-3B is
constructed from one or more upper lining materials 304a and one or
more lower lining materials 304b and, as a whole, is non-waterproof
In various embodiments, the upper lining materials 304a are
substantially free of any waterproof membrane 305. In various
embodiments, the upper lining material(s) 304a can be, for example
but not limited to, lining materials 104 as described above with
reference to FIGS. 1A-1C. In addition, upper lining materials 304a
may include various reinforcing or other add-on materials, such as
for example, cushioning materials (e.g., polyester needle-punch,
recycled fiber, viscose fibers, ethylene vinyl acetate (EVA),
rubber, neoprene, polyurethane, gel, combinations thereof, and/or
any other suitable material) or reinforcing/stiffening materials
(e.g., any non-woven, stitch-bounded, fibrous material, polyester,
polypropylene, cotton, nylon, wool, viscose fibers, leather,
polyvinylchloride, wood, metal, carbon fiber, combinations thereof,
and/or any other suitable material).
[0047] FIGS. 3A-3B illustrate, in accordance with various
embodiments, upper lining materials 304a comprising a single piece
of upper lining material 304a on each side of an upper portion of
the tapeless waterproof footwear article 300. However, it will be
apparent in view of this disclosure that a plurality of pieces of
upper lining materials 304a can be used (e.g., to improve fit,
install reinforcement elements, provide a toe cap, provide a vamp,
provide a quarter portion, or to serve any other purpose associated
with upper lining materials 304a).
[0048] In various embodiments, the lower lining materials 304b are
substantially free of any waterproof membrane 305. In various
embodiments, the lower lining material(s) 304b can be, for example
but not limited to, upper lining materials 304a described above
and/or lining materials 104 as described above with reference to
FIGS. 1A-1C. In addition, in various embodiments, lower lining
materials 304b may include various materials suitable for use in a
midsole and/or insole, such as for example, cushioning materials
(e.g., polyester needle-punch, recycled fiber, viscose fibers,
ethylene vinyl acetate (EVA), rubber, neoprene, polyurethane, gel,
combinations thereof, and/or any other suitable material), Strobel
board materials (e.g., any non-woven, stitch-bounded, fibrous
material, polyester, polypropylene, cotton, nylon, wool, viscose
fibers, leather, combinations thereof, and/or any other suitable
material), and/or footbed (also referred to as a sock liner)
materials (e.g., any textile material previously recited herein
with reference to upper lining materials 304a and lining materials
104).
[0049] As illustrated by FIGS. 3A-3B, the upper lining materials
304a are attached to lower lining materials 304b along one or more
seams 303 to form a generally non-waterproof footwear liner 301. It
will be apparent in view of this disclosure that, in various
embodiments, footwear liner 301 may include cushioning and/or
stiffening elements which are incidentally waterproof, thus adding
local areas of waterproof properties. In such embodiments, the
footwear liner 301 as a whole still remains non-waterproof Due to
cost and performance considerations (e.g., breathability), it can
be, in various embodiments, advantageous for the upper and lower
lining materials 304a, 304b to be substantially free of any
waterproof membrane 305. However, it will be apparent in view of
this disclosure that a textile having a waterproof membrane can be
used to construct the footwear liner 301 in accordance with various
embodiments. In such embodiments the presence of the one or more
seams 303 still renders the footwear liner 301 as a whole
non-waterproof Therefore, in such embodiments, at least one
additional layer of waterproof membrane 305 is laminated over
substantially the entire exterior surface 307 of the footwear liner
301.
[0050] The one or more seams 303 can, in various embodiments, be
sewn, stitched, needle-punched, welded, and/or glued. It will be
apparent in view of this disclosure that, while three seams 303 are
shown in FIGS. 3A-3B (i.e., Strobel seam 303a, front seam 303b, and
heel seam 303c), any number of seams 303 can be used in accordance
with various embodiments (e.g., seams required to assemble
reinforcing elements, cushioning elements, toe caps, vamps, and/or
quarter portions). As shown in FIGS. 3A-3B, the one or more seams
303 are arranged such that the footwear liner 301 retains a
three-dimensional shape when empty (e.g., when no foot or last has
been inserted into the footwear liner 301). This three-dimensional
structure of the one or more seams 303 advantageously allows for a
broad variety of configurations and a highly adjustable fit.
However, lamination of the waterproof membrane 305 for a
three-dimensional footwear liner 301 requires more complex and
expensive equipment (e.g., as described below with reference to
FIGS. 4A-4B) when compared with the relatively simplistic,
inexpensive equipment described above with reference to FIGS.
2A-2B.
[0051] The waterproof membrane 305, in various embodiments may
include any waterproof material (e.g., rubber, plastic, polymer,
etc.). The waterproof membrane can be, for example but not limited
to, waterproof membrane 105 as described above with reference to
FIGS. 1A-1C.
[0052] During construction of the tapeless waterproof footwear
article 300, the waterproof membrane 305 is applied about the
exterior surface 307 of the footwear liner 301, including the one
or more seams 303, the upper lining materials 304a, and the lower
lining materials 304b. The waterproof membrane 305 is then
laminated over substantially the entire exterior surface 307 of the
footwear liner 301, including the one or more seams 303, thereby
providing tapeless waterproofing of the upper lining materials
304a, the lower lining materials 304b, and the one or more seams
303 of the footwear liner 301. Lamination of the waterproof
membrane over substantially the entire exterior surface 307 can be
performed according to any method of lamination, including for
example but not limited to, adhesives, heat-activated adhesives,
flame lamination, heat-pressing, vacuum-molding, and/or any other
suitable method.
[0053] As shown in FIGS. 4A-4B, a system 400 for producing an
article of tapeless waterproof footwear 300 having a
three-dimensional seam structure includes, in various embodiments,
a last 401, a mold 402 having a first shell 403a, a second shell
403b. In various embodiments, at least one of the first shell 403a
and the second shell 403b. As shown in FIGS. 4A-4C, in various
embodiments, the footwear liner 301 is fitted onto last 401. The
waterproof membrane 305 is then positioned in the first shell 403a
and the second shell 403b such that hangers 407 hold the waterproof
membrane in place. The waterproof membrane is then heated and the
first and second shells 403a, 403b are closed about the last 401 to
exert pressure against the waterproof membrane 305 and the footwear
liner 301, thereby laminating the waterproof membrane 305 to the
footwear liner 301 to produce a tapeless waterproof footwear
article 300.
[0054] Last 401 can be foot-shaped (as is typical in the footwear
industry), or any other suitable shape (e.g., egg-shaped, a
rectangular prism, circular). Last 401 can be constructed of, for
example but not limited to, any metal, any wood, any plastic, any
composite, and/or any other suitable material.
[0055] Mold 402, in accordance with various embodiments, may be
shaped and sized so as to receive the last 401, thereby encasing
and applying pressure to substantially the entire exterior surface
307 of the footwear liner 301. The mold 402 can be sized to fit the
last 401 exactly or may be sized to provide a designed clearance
from the last so as to accommodate the thickness of the footwear
liner 301 and/or waterproof membrane 305. The first shell 403a and
the second shell 403b of the mold 402 can be constructed from any
suitable material, including for example, metal, coated metal,
wood, ceramic, plastic, composites, and/or any other suitable
material. Heat can be introduced to the waterproof membrane 305 by
for example but not limited to, directly heating the first and
second shells 403a, 403b (e.g., via an electrical heating element
or external heat source), introducing steam and/or heated air
through the first shell 403a and/or the second shell 403b,
combinations of direct heating and steam/hot air introduction,
and/or any other suitable method of introducing heat to the
waterproof membrane 305. In various embodiments, the first and
second shells 403a, 403b are heated via an electrical heating
element to a temperature of between 120.degree. C.-130.degree. C.
However, it will be apparent in view of this disclosure that any
temperature can be used in accordance with various embodiments.
[0056] While depicted in FIGS. 4A-4B as having two shells (i.e.,
first shell 403a and second shell 403b), it will be apparent in
view of this disclosure that mold 402 may include any number of
shells and/or shell pieces. For example, in various embodiments,
mold 402 can be a three-piece mold having a bottom shell and two
upper/side shells. In other embodiments, mold 402 may have any
number of additional shells as appropriate for laminating the
waterproof membrane.
[0057] Hangers 407 hold the waterproof membrane 305 in and/or on
each of the first shell 403a and the second shell 403b. Suitable
hangers include, for example but not limited to, hooks, hook and
loop fasteners, tack strips, clips, clamps, adhesive strips, and/or
any other suitable mechanism for removably retaining the waterproof
membrane 305 on each of the first and second shells 403a and
403b.
[0058] FIG. 5 illustrates a method 500 for making an article of
tapeless waterproof footwear in accordance with various embodiments
of the present disclosure comprising the steps of providing a
footwear liner comprising an exterior surface and a seam 501,
providing one or more layers of waterproof membrane 503, and
laminating substantially the entire exterior surface of the
footwear liner and associated seams with the one or more layers of
waterproof membrane 505.
[0059] In various embodiments the steps of providing a footwear
liner comprising an exterior surface and a seam 501 and providing
one or more layers of waterproof membrane 503 may include, but are
not limited to, providing a footwear liner 101, 301 and one or more
layers of a waterproof membrane 105, 305 as described above with
reference to FIGS. 1A-1B and 3A-3B.
[0060] The step of laminating substantially the entire exterior
surface of the footwear liner and associated seams with the one or
more layers of waterproof membrane 505 may, in various embodiments
include laminating waterproof membrane 105, 305 externally of
substantially the exterior surface 107, 307 and one or more seams
103, 303 of the footwear liner 101, 301 as described above with
reference to FIGS. 1A-1B and 3A-3B. The step of laminating 505 can
be performed using, for example but not limited to, an epoxy,
heat-activated adhesives, water-based adhesives, ethylene vinyl
acetate (EVA)-based adhesives, polyurethane-based adhesives,
solvent-based glue, flame lamination, heat-pressing, and/or any
combination thereof
[0061] Accordingly, a tapeless waterproof footwear article 100, 300
is provided, the use of which reduces the time, labor, and cost
associated with taped waterproof footwear construction. It will be
apparent in view of this disclosure that any tapeless waterproof
footwear article described herein can be constructed as a
standalone bootie or be incorporated into an article of consumer
footwear (e.g., work boots, hiking boots, athletic shoes, dress
shoes, high-heeled shoes, hiking socks, and/or any other type of
footwear).
[0062] Furthermore, although the tapeless waterproof footwear
article 100, 300 is described throughout with reference to
application in a footwear product, other applications of the
present invention are contemplated, particularly applications
requiring reduced-cost flexible waterproof products. Such
applications may include, for example, construction of various
athletic devices and/or articles of clothing.
[0063] It is noted that the foregoing examples have been provided
merely for the purpose of explanation and are in no way to be
construed as limiting of the present invention. While the present
invention has been described with reference to an exemplary
embodiment, it is understood that the words, which have been used
herein, are words of description and illustration, rather than
words of limitation. Changes may be made, within the purview of the
appended claims, as presently stated and as amended, without
departing from the scope and spirit of the present invention in its
aspects. Although the present invention has been described herein
with reference to particular means, materials and embodiments, the
present invention is not intended to be limited to the particulars
disclosed herein; rather, the present invention extends to all
functionally equivalent structures, methods and uses, such as are
within the scope of the appended claims.
* * * * *